FLAGSHIP SYSTEM

Operational Excellence

A comprehensive operational excellence system built around one culture, one purpose, stable processes, engaged people and superior results.

THE SYSTEM

Operational Excellence: 9 Comprehensive Pillars

EXPERIENCE

Operational excellence as a practical operating system.

Operational excellence is central to Jaco’s work and forms a key focus of his doctoral research: how organisations can translate capability, systems, leadership discipline, data and emerging technologies into meaningful operational and business value.

Rather than treating operational excellence as a standalone improvement initiative, Varion approaches it as an integrated operating system - connecting leadership, culture, strategy, asset management and disciplined execution into a practical framework for sustained performance.

Leadership, Culture and Strategy Deployment

  • Developing organisational identity – Who are we? What is our purpose and values? How do we align and leverage?
  • Operational excellence & Asset Management maturity assessments and strategy development.
  • Change management processes
  • Leadership coaching
  • Organisational development
01

Safety, quality & customer value

  • Formalised SHE and Quality risk assessment & mitigation. RA, BLRA, FMEA’s and Control Plans
  • Service Level Agreements
  • 1st level leadership development as drivers of SHE/Quality
  • 5S as a core to discipline
  • Quality-at-source systems, SPC, Andon charting
02

Process stability

  • Asset Management (ISO55000) maturity assessment
  • Risk management (ISO31000) maturity assessment
  • Standardised work & FMEA and Control Plan
  • Process Mapping, Value Stream Mapping
  • Statistical Process Control, PCV’s, CIV’s, COV’s and process capability tracking CPk’s.
03

Standard work

  • Define the best-known way of working – The Standard
  • Make standards clear, visible and understood
  • Train and confirm consistent application
  • Make deviations immediately visible
  • Establish leadership discipline to act on deviations
  • Use deviations to drive coaching and improvement
04

Visual management & transparency

  • Mission directed work teams – Shopfloor, middle and senior management. Pragmatic real-life approach
  • Track what matters most
  • How are we doing at a glance
  • VPA, SPC
  • Escalation processes
05

Daily management system

  • KPI / OEE / VPA tracking and visual performance management
  • Action tracking and close-out discipline
  • GEMBA where value is created / Visible Leadership
  • Nemawashi commitment to key deliverables
  • A3 / One-Page CI Planning
06

Structured problem solving

  • Critical thinking
  • SWOT analysis
  • Porter’s Five Forces
  • Scenario planning
  • Strategic option analysis
  • DMAIC, mind mapping ....
07

Waste elimination & flow

  • Waste walks
  • Value-stream mapping
  • Bottleneck identification
  • Throughput improvement
  • Variation identification and improvement in flow
08

People involvement & capability

  • Skill, capability, attitude and accountability
  • RACI design
  • Performance management routines
  • Coaching for performance
  • Succession planning
  • Empowered team structures
09

Continuous Improvement

  • Building a culture of curiosity and learning
  • Kaizen events and rapid improvement workshops
  • Ideas funnel/hopper and prioritisation
  • Continuous improvement strategy and roadmap
  • Building a culture that values shop floor innovation
  • Innovation workshops
One system One culture One purpose Stable processes Engaged people Superior results

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