CASE STUDY: ON-SiTE COACHiNG FOR PRODUCTiViTY iMPROVEMENT AT ELECTRONiCS MANUFACTURER
OBJECTiVES
Company X* is a high volume, low-cost SME, that to meet the needs of their customers in an increasingly competitive market, must improve their quality and delivery performance, whilst reducing cost. A six-week intensive project was identified to create a model work area that would demonstrate increased output of 50%, increased quality performance to 98% right first time, and reduces inventory by 60%. The project is to be delivered collaboratively with the team at Company X to ensure maximum transfer of knowledge and skills for future improvement projects.
WHAT WE DiD
Through six weeks of daily on-site coaching, we:
- Re-designed the work area
- Created product families for more effective planning
- Identified process constraints and implemented actions to remove
- Implemented Kanban material system for right-sized inventory, delivered line-side
- Implemented a visual management system and coached new working for team leaders
- Implemented TPM (total productive maintenance) on key equipment
- Moved from paper to electronic work instructions
- Implemented new controls and attitude to safe working
THE RESULTS
- Output increased by 100%
- 25% of the workforce in the area redeployed
- Quality increased to 95% right first time
- Inventory reduced by 75%
- Overall floor space reduced by 50%
- Other cost savings totally £22k
Using the above improvements to deliver additional sales meant an overall net benefit of the project of £2.5 million.
*Company name changed for confidentiality purposes