Case Studies
Follow the link to read the full case study details:
CUSTOMER SERVICE
- Improved Customer Service for a Market Leader
- Creating Airline Customer Service Excellence
- Improving Global Customer Relationships and Clarifying NPD Focus
DISTRIBUTION MODELLING & THIRD PARTY SOURCING
- Outsourced Distribution in the Chemical Industry
- Fast Savings for Fast Food Firm
- Hi Tech, Low Volume Sourcing from China
- Delivering a smart Logistics Solution for the NHS
E-SUPPLY CHAIN
- E-Fulfillment into a Pan European Automotive Manufacturer
- Factory Relocation to the Far East
- European Inventory Optimisation
- Lean and Mean in a Traditional Environment
- Creating Consistency for a Building Products Company
- Performance Improvement for a Global FMCG Business
- Reducing the Risks for an Insurance Company
- Creating the Standard for a Pop Star
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STRATEGY
- Cross Industry Benchmarking for a Leading Retailer
- Operational Turnaround at a Major Brewery
- Business Recovery in Food Services
FAR EAST OUTSOURCING
INVENTORY
LEAN MANUFACTURING
PROJECT MANAGEMENT
Lean and Mean in a Traditional Environment
The client
Major manufacturer of commercial lighting
Premium products with high design content
Sales and profit growth in a static market
The challenge
Improve customer service by operational agility
Automate highly skilled " spinning " operation
Reduce operational costs by reducing third party supplier dependence
The solution
Our client's products are assembled around a spun aluminium disk, provided by a wide range of small local sub-contractors. It was decided to create 3 major manufacturing cells, integrating a range of bespoke machines and applying lean manufacturing techniques to bring this process in-house.
The provision of manufacturing and project management expertise to create cells that were schedule using Kanban pull from final assembly, operated using single piece flow and were made flexible by the application of SMED set up techniques.
Developing and modelling a range of cell options and factory layouts. Once thoroughly tested, a single solution was agreed and an internal project team created. The project was managed and the team facilitated during the planning and implementation of this major project so that a new operational process was achieved without any breakdown in supply.
This complex project was delivered on time, within the original budget and provided a range of outstanding benefits.
Benefits at a glance
- Set up reduced from hours to minutes
- Supply lead times reduced by 75%
- Batch sizes reduced by 80%
- Exposure to key sub-contractors removed
- Process absorbed from sub-contract without additional on-cost
