“I joined Ford MRF as the manager in late 2016. At the time we were totally reliant on agency engineering support. Maintenance was reactive and the plant would be run until it failed; it was all about breakdown management. By 2018 this was becoming an expensive approach and we were looking at ways to cope with how the poor availability impacted processing our material, for example by putting on extra shifts, rather than attacking the root of the problem which was the poor availability! We were attacking the symptoms and not the cause.
Chris Sweetland was part of a team that came to Ford in 2019 to introduce the concept of WorkSmart. We were the trial site, so both sides were learning. However, it became readily apparent that what was being shared with us would, if delivered and followed, bring massive benefits to the site. Working as one team was a key ingredient as were the visual boards which quickly imparted the current situation: H&S, production, planned maintenance, red tags, 24-hour tasks.
Following the WorkSmart processes and ethics has seen Ford’s year on year availability increase from 88.7% in 2018 to 92.6% in 2024. 100% shifts are not unusual. This has enabled us to reduce weekend running with a consequent reduction in operating costs and allow more opportunities for maintenance – which themselves go around to underpinning the next jump in availability.
Chris is now the Managing Director of MMS and continues to deliver top quality support as his recent WorkSmart “Refresh” at Ford has demonstrated. A preeminent individual, who is also the most enthusiastic person I’ve met, he is highly recommended if you wish to see similar improvements in your plant operations. WorkSmart truly works and the concepts are not difficult or complicated.”
Russ Tuppen – General Manager