Client
:- |
UK
Manufacturer of Telecoms racking equipment. |
Situation
:- |
Part
of an international Group Producing products for customers within UK &
Europe |
Objective
:- |
Meet
ever increasing customer demands whilst reducing response time and costs. |
|
Proposal
:- |
Select
and train an improvement team on Lean Manufacturing techniques. Then work
with Improvement Team to analyse production of a group of products, before
designing and implementing their 1st production cell. |
Approach
:- |
Trained
Improvement Team on all aspects of Lean Manufacturing using HOSCAR situation
to test competence, before supporting the team in the detailed analysis
of current production methods. Eliminated waste and all non-value adding
activities to deliver a concept cell delivering massive performance improvements. |
|
Results
:- |
Performance
at start of study :- |
|
- Output = 2,000,000
panel per year
- headcount
required = 90
- Inventory
& W.I.P. = 8 weeks
- Quality performance
> 5% scrap
|
|
Improvements
Delivered :- |
|
- Output increased to 2,300,000 p.a.
- headcount reduced to 25
- Inventory & W.I.P. to 5 days
- Quality performance < 1% scrap
- Material control entirely "Pull"
|
|
Further
:- |
Delivering
a comprehensive package of Team Leader Training whilst original Improvement
Team continued unaided to roll out cell manufacture to other key areas.
|
|