' Champions' a boost for cosmetics business; WALES TRAINING AWARD.

THE fortunesof astruggling South Wales cosmeticsfactory havebeen transformed through the remarkable efforts of its workforce and its tailor-made 'toolbox'.

The COSI Group has secured a bright future for its 600 people after innovative methods were used to turn the firm back from the brink of ruin to become a market leader.

The Maesteg factory adopted ground-breaking Lean Manufacturing techniques to see it switch a pounds 2m loss in 1992into apounds 5m profit this year.

COSI Group Chief Executive BobbyTolan decided totake the 'leanleap' todriveupqualitydelivery productivity and eliminatewaste. The COSI Group,aleading providerof outsourced manufacturing and product developmenttothe beauty and healthindustries, delivered impressiveresults bycreating 70 ' Lean Champions'.

The champions,who havebeen trained in the principles of Lean Manufacturing in a programme part-funded bythe Welsh development Agency, have had a stunning effect on the fortunes of the factory.

Championsweretrained using atailor-made COSI Lean'toolbox'consisting of four-hourinteractiveworkshops,seven classroom sessions and particularlessonsand work-based projects. The workofone Champion-leadproject resulted in the companysaving pounds 205,000. COSI trainers werementored by DrNickRich,of Cardiff University.Hesaid:"The business isa good example of whatatruelearning organisation canachieveand how'good products and good people' combine tocreateaworld class business." The innovativeprogramme led to increased productivity,improved quality and safety forthe business whichnumbers Proctor& Gamble,Caissonsand Unileveron its clientlist