This guide delves into model area deployment, a targeted strategy for driving change within organisations by beginning with manageable pilots, evaluating solutions, and expanding proven successes.
A model area—also known as a model line, cell, or zone—provides a focused, hands-on testing environment where organisations can address operational challenges on a smaller scale.
Whether your goal is to streamline processes, reduce costs, or create a more sustainable improvement culture, following best practices in planning and deploying model areas is essential for achieving long-term success.
Why It Matters in 2024
Recent data highlights the challenges facing the UK manufacturing sector. In November 2024, the UK’s Manufacturing Purchasing Managers’ Index (PMI) fell to 48.0, the sharpest contraction in nine months. This decline is driven by reduced orders, ongoing supply chain disruptions, and rising costs.
Efficiency Under Pressure: UK Productivity Down
Additionally, the Office for National Statistics reported a 1.8% decrease in output per hour worked in Q3 2024 compared to the same quarter in 2023, indicating a decline in labour productivity.
UK Manufacturing Hits Nine-Month Low
These figures underscore the urgent need for strategies like model area deployment to boost productivity and operational efficiency in an increasingly challenging economic landscape.
What is a Model Area Deployment?
A model area deployment involves selecting a specific line, cell, or area within your organisation to pilot new processes or methodologies.
This approach allows businesses to:
- Customise solutions to their unique operational needs.
- Build evidence-based buy-in by showcasing measurable outcomes.
- Develop internal capabilities through hands-on experience and training.
By narrowing the scope of deployment, organisations can focus resources and expertise on targeted improvements. This creates a practical, cost-effective way to trial new approaches while minimising the risks associated with larger-scale rollouts.
Planning Model Area Deployment
- Defining Clear Objectives
Define the specific outcomes you aim to achieve before beginning the deployment. Whether it’s reducing downtime, cutting maintenance costs, or improving quality, clear objectives provide direction and measurable criteria for success.
- Engage Leadership and Workforce Early
To set a strong foundation, involve both leadership and employees in the planning phase. Explain the purpose and expected outcomes, ensuring alignment between organisational goals and workforce engagement. Early buy-in helps to mitigate resistance during deployment.
- Prioritise the Right Area
Identify a line, cell, or area with significant potential for improvement. This should address a critical operational challenge, such as frequent downtime or high maintenance costs. Choosing the right focus area is vital for creating a meaningful impact.
- Allocate Resources Effectively
Ensure the required tools, budget, and expertise are available for deployment. Planning resource allocation upfront prevents delays and ensures smooth execution during the implementation phase.
- Tailor the Approach
Customise the deployment strategy based on your organisation’s unique goals and challenges. Flexibility during planning ensures the solutions are both relevant and scalable.
- Establish Metrics for Success
Identify KPIs to track progress and measure ROI. Common metrics might include downtime reduction, cost savings, or quality improvements. Having clear benchmarks in place ensures the results are quantifiable and actionable.
Planning Model Area Deployment
Deploying Model Area Deployment
- Focus on Action and Results
While analysis and preparation are essential, implementation drives change. Quickly and iteratively apply solutions, making adjustments based on feedback. This keeps the deployment on track and builds momentum through visible wins.
- Engage the Workforce During Execution
During the deployment, collaborate closely with employees on the ground. Provide hands-on training and regular updates to maintain engagement and ensure alignment between goals and actions.
- Tackle Root Causes
Address underlying issues rather than surface symptoms. Tools like value stream mapping and root cause analysis can help identify and resolve inefficiencies, waste, or bottlenecks.
- Measure ROI Along the Way
Track operational and financial metrics consistently during deployment. For example, monitor downtime, maintenance costs, and throughput improvements to validate the impact of changes.
- Build Long-Term Capability
Use the deployment as an opportunity to upskill your team. By empowering employees to sustain and expand improvements, you reduce dependence on external consultants and ensure long-term results.
- Adapt as Needed
Monitor the effectiveness of solutions and be prepared to refine them. Deployment often uncovers new insights, so maintaining flexibility ensures the process remains effective and responsive to on-the-ground realities.
Real-World Example: Achieving 500% MTBF Increase & 88% Fewer Breakdowns with Model Area Deployment
Challenge:
The GKN Western Approach site, known for its advanced aerospace technologies, faced frequent equipment breakdowns and deterioration, particularly during the global pandemic. To protect critical assets and improve reliability, the team selected their NDT rig as the pilot machine for a model area deployment.
Implementation:
The model approach alternated between classroom-based learning and practical application on the shop floor. Employees were trained to identify and address issues, implementing Total Productive Maintenance (TPM) principles to improve basic conditions and performance.
This practical approach allowed them to:
- Identify key pain points.
- Apply targeted Total Productive Maintenance (TPM) methods.
- Verify results after implementation.
Results:
- 500% increase in meantime between failures.
- 88% reduction in breakdowns.
- Zero breakdowns due to lack of basic conditions since the pilot programme’s completion.
The team also trained 11 practitioners, who are now capable of delivering TPM training across other sites, achieving self-sufficiency, and creating a valuable resource for the organisation.
The Benefits of Model Area Deployment
Model area deployment creates a scalable framework for continuous improvement. Benefits include:
- Targeted Impact: Focuses on high-priority areas to deliver quick wins.
- Sustainability: Builds internal capability and reduces dependency on external consultants.
- Scalability: Demonstrates success in pilots, creating momentum for organisation-wide adoption.
- Culture Shift: Encourages collaboration, ownership, and a mindset of continuous improvement.
Conclusion
Model area deployment turns strategy into action, delivering measurable outcomes like a 500% increase in MTBF and 88% fewer breakdowns, as demonstrated in real-world applications.
This structured and results-oriented approach focuses on addressing operational challenges while laying the groundwork for long-term resilience and efficiency.
With UK productivity dropping 1.8% YoY in Q3 2024, the demand for practical and scalable solutions has never been greater. The question is:
What steps will your organisation take to convert operational challenges into measurable success?
