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Podcast: An Award-Winning Journey of Improvement

About this Podcast Episode: An Award-Winning Journey of Improvement with Paul Hayward at CooperVision

This isn’t just a conversation;  it’s a masterclass in building a culture of Continuous Improvement. Join us as we delve into the remarkable transformation at leading contact lens manufacturer CooperVision, and how Senior CI Engineer Paul Hayward led his team to success at the BQF UK Excellence Awards as they took home the prestigious Excellence in CI Culture award.

We begin at the start of their journey, as Paul talks candidly about the challenge of producing a staggering 12 million batches of one unit, in their made-to-order department every month. This put pressure on lead times, whist needing to maintain quality and reliability, all in a highly regulated environment. Skip forward three years, and the initial targets have been exceeded 7-fold. Quick to credit the dedication and hard work of the entire team, Paul explains that from the boardroom to the shop floor, the mantra has been to “work smarter, not harder”.

It’s about empowering people to challenge the status quo and creating a culture where problem-solving at every level becomes an opportunity for progress and innovation.

And their journey is far from over; with a “Trident Wall” to keep the fire for improvement burning bright, the culture of improvement at CooperVision is thriving. This is a powerful example for organisations everywhere, showing that with the right mindset and commitment, a culture of Continuous Improvement can lead to exceptional results.

"Teams across all shift patterns had carried on doing it because it wasn't me pushing it; they've actually seen a value in it."

Team Success at the BQF Awards

A celebration of collective effort, winning the Excellence in CI Culture award serves as a reminder that when a team comes together with a shared vision and commitment, excellence is not just an aspiration; it’s an inevitable outcome.

The Key to Successful Problem-Solving

A fundamental truth in leadership and problem-solving: involving people in finding solutions isn’t just a nice-to-have, it’s a must-have for successful implementation. The commitment, creativity, and collaboration that come from this inclusive approach are invaluable.

Balancing Regulations and Process Redesign

Innovation and compliance are not mutually exclusive. Paul shares how rethinking the ‘set in stone’ mentality allowed the team to implement common-sense improvements.

Watch the Vodcast

Join PMI’s Susannah Clarke in the studio with Paul Hayward of CooperVision, as they talk all about An Award-Winning Journey of Improvement.  You’ll hear them discuss:

  • The challenges faced by the organisation
  • Implementation of problem-solving and lean manufacturing concepts
  • Adhering to regulatory requirements while challenging existing processes
  • Engagement and empowerment of employees
  • Impact of continuous improvement on company performance
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