| Client
:- |
Manufacturer
of Pipes, Sutton Coldfield, England |
| Situation
:- |
Part of a larger
group, the Company was partway through an internal improvement programme
but had lost direction. To ensure momentum the Company needed direction
and a quick boost to rejuvenate the programme.
|
| Objective
:- |
Revise
the overall programme to ensure alignment to customers. Choose a high
impact area and make dramatic improvements with an internal team to show
the way forward. |
|
| Proposal
:- |
Focus on waste as
the main driver and aligning tool which fitted hand in hand with the
initial scope of the internal initiative. Benchmark all the areas and
highlight areas of weakness that could then be used to determine the
focus area.
Establish process
and working methods to achieve the desired outcomes.
|
| Approach
:- |
HOSCA
benchmarked the Company against current best practice. A cross-functional
team was established to review and revise the layout and working methods
in a core part of the factory; focusing on those areas of weakness identified
by the benchmarking exercise. |
|
| Outcome
:- |
The
teams spent 5 days reviewing and measuring various aspects of the operation
including: |
| |
- TAKT time
- Process flows
- Line Balance and Total
Loss for the selected area
- Ergonomics
- Operator flexibility
|
| |
The
recommendations were accepted totally and implemented over a period of
60-days. |
|
| Benefits
:- |
| Dock
to Dock time |
reduced
by 12%
|
| Work
in Progress |
reduced
by 27%
|
| Space
utilised |
reduced
by 18%
|
| N°
of operators |
reduced
from 23 to 12
|
| Parts
per labour hour |
increased
by 30%
|
| Distance
part travels |
reduced
from 35m to 12m
|
| Changeover
time |
reduced
from 20 minutes to 5 minutes
|
|
|
