CASE STUDY: ON-SiTE COACHiNG FOR PRODUCTiViTY iMPROVEMENT AT ELECTRONiCS MANUFACTURER2019-07-16T14:34:02+00:00

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

Company X

Company X 2

WordPress Video Lightbox Plugin