The Cardiff University Innovation Prize 2005 for outstanding innovation in practice is awarded to Creative Outsourcing Solutions International (COSi), a manufacturer of cosmetic products based in Maesteg.
The business was acquired from Revlon in 2002 at a time when it was in danger of closure. At that time, a collaboration with Dr Nick Rich of Cardiff Business School was formed through which the business has been turned around to become an international benchmark for the industry.
The original collaboration focused on the design of production systems and the introduction of best practices throughout the business. Since that time, the collaboration has involved almost all staff and processes at Maesteg. The pioneering introduction of lean systems in a non-traditional industry has had a remarkable effect on all aspects of business performance, from profitability to customer service levels. COSi ,which employs 750 staff, now has 16 customers compared with the original 2, has won numerous awards and competes on a global basis in what is an extremely competitive sector.
The adoption of lean methodology, through its collaboration with the renowned Research Centre at Cardiff university, in particular, Dr Nich Rich, has resulted in major developments. Dr Nick Rich says “The close liaison between the Cardiff University Centre and COSi has fostered a relationship of mutual trust which has allowed COSi to embrace the lean manufacturing methodology and achieve significant improvements by utilising these proven techniques. So much so that lean is now a way of life at COSi and has been incorporated into COSi’s global expansion strategy”
Lean programmes have been operational within the two U.K. COSi facilities for the last two years and has fostered a culture of waste elimination and continuous development. The drive for improvement has brought dramatic results;enhanced quality, reduced waste, a production increase of 30% and a 50% reduction in inventory. The foundation of COSi’s progam is CANDO, COSi’s version of the 5S’s which promotes a clean, well organised and visual factory. Andy Mortimer, head of operations at Maesteg, says “ The success of CANDO is entirely down to the involvement and empowerment of all teams, which design and implement their own CANDO improvements. This award recognises the enthusiasm, commitment and hard work from all Maesteg employees”
With lean operational in both of it’s two U.K. facilities COSi is now embracing the next stage, the introduction of 80 Lean Champions, which has also led to the introduction of customer focus and safety champions, all re-inforcing the culture of continuous improvement within the business.
Further Information:
COSi
Innovative Manufacturing Research Centre
Edwards Geldard
MEM Group