From strategy to execution: junior consultant to work at BMI Netherlands

BMI Netherlands is currently deploying a young professional from Symbol to conduct a PFMEA. In conversation with Ron Blokland, Plant Manager at BMI Monier location Woerden, and young professional Mathijs Rietveld.

“Our roof tile factory in Woerden is an artisanal working environment where many people have worked for many years,” says Ron. “How they do that work was, until recently, mainly based on experience – our production process had never been put on paper. I wanted to change this, because if there is nothing on paper it is difficult to start a discussion with each other. In addition, it poses a risk when people leave. Moreover, we have been transforming into a process technology factory rather than an experience factory for a number of years now and an important ERP migration is on the way. Reason enough to map out our production process from beginning to end. And for that I engaged Symbol.”

“I really like the combination of strategy and execution.”

“I am a Black Belt Lean Six Sigma practitioner and know how to use process data for improvement projects, but I simply did not have the time for an assignment of this size. And the people in the factory are obviously good at their jobs, but not at putting down on paper exactly what they do and why. That’s why I approached Symbol,” Ron continues. “What I like about Symbol is that they are dyed-in-the-wool and therefore come up with a solution from a different perspective – a solution you wouldn’t have thought of so quickly yourself. For example, they suggested I do a Process FMEA (PFMEA). That seemed a bit over the top to me at first, but the methodology just turned out to fit perfectly. Creating a Process FMEA examines the consequences and impact of potential failure of a product or process. Thus, preventive or detective measures can be taken at an early stage to avoid failure or take the appropriate action. Then they were also able to pair me with a motivated young professional to perform that PFMEA. That combination of strategy and execution is very pleasing.”

Product from clay to roof tile tracked

The young professional now employed at BMI Netherlands is Mathijs Rietveld. “Wearing a safety cap and vest and safety shoes, I followed the product from clay to roof tile. By having people talk about their work, ask questions and watch along, I recorded every step of the production process. What happens when, by whom and why? I then turned this into a process flow: a schematic representation of all the processes in the factory – the perfect input for the PFMEA. With a PFMEA you prevent product or process problems by making risk analyses of all steps in the process. So I look at all the steps to see what can go wrong, how big this risk is and what needs to be done to mitigate it.”

Support from senior consultants

Mathijs says he has a very independent role at BMI Netherlands. “In previous assignments I worked mostly in project teams – now I can walk my own path and be my own project manager. Also, here they are open to my ideas and suggestions – I even presented to the MT. I like noticing that my input as a young professional is appreciated.” Ron is therefore very satisfied with Mathijs, and with the young professional program in general: “My experiences have been very good. Mathijs independently conducts interviews with our people in the plant, but also brings the knowledge and expertise to guide the process and make the actual PFMEA. And what I also like is that he is well supported by senior consultants from Symbol. Such a senior person takes a fresh look and gives targeted advice based on years of experience. That back-up is a good addition for Mathijs as well as for us.”

Clear agreements on paper

Meanwhile, Mathijs’ assignment is almost over. Ron says: “The next step is to write out procedures that we can use during the onboarding of new employees. Thanks to the PFMEA, we can put clear agreements on paper for all the steps in our production process, on the basis of which we can train and ultimately assess people. I think this will bring about a change in mentality on the shop floor, but that we will also see this reflected in a reduced number of complaints. After all, you can only improve if agreements are established and secured.”

Also interested in being a young professional?

Does your organization, like BMI Netherlands, need temporary extra support in achieving specific goals? Then read all about working with a young professional at Symbol or contact us directly.