Using Lean to streamline operations, increase clarity & reduce costs
CASE STUDY - Manufacturing
Owner / CEO: “…..Lean is a way of thinking and of continuously questioning what we do and if there is a better way to do it. Our job as the owners of the business is to create an environment where every member of staff is encouraged to take ownership of their area, to share their ideas for improvement and to solve the problems that affect them, as close to base as possible….”
A quote from the owners
The Situation
Door manufacturing business, with an overall goal to increase production 3- fold using the same equipment & staff.
Where faced with the situation their current setup was fragmented and required streamlining machinery and processes.
Following a successful Lean Plus, the business enrolled in an OPEX programme to achieve their goal, encompassing Training . Digital and Automation.
The Objectives & Challenges
The Actions
• Introduce a lean philosophy, eliminating waste, adding value as a team, starting from the bottom up.
• Create a manufacturing environment that will increase productivity, increase process efficiencies, and reduce the direct labour as a % of output.
• Design an automated layout to meet customer fulfilment and scale effectively
• Develop our own inhouse to embed the principles of lean
Implement an ERP System
Training plan was developed with a full suite of both lean & Digital Modules giving the business the skills the team required to upskill and deliver on its goals.
Key people within the business were identified to lead the project and make it sustainable within the business
Develop an integrated system to drive efficiencies and measure productivity throughout the business
The Outcomes
• At the time of writing the Capacity has doubled , with further improvements to come.
• Lead times have reduced from 12 weeks to 3 weeks.
• On time delivery has improved from 50% to 80%
• Technology integration has allowed processing time to reduce by 75%
• Tiered Meetings introduced to give structure & communication
• Downtime reduction of 23%
• Turnover Growth up 32%
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