Driving Through Efficiency Improvements
Wilcox Commercial Vehicles Ltd is one of the UK’s leading manufacturers and premier aluminium body builders in the field of commercial vehicles, covering a range of different rigid/trailer designs to effectively cater for almost any kind of load transporting requirement. Wilcox requested MAS assistance to improve its operational efficiency in an effort to reduce production costs.
Wilcox Commercial Vehicles Ltd
Key Achievements
- Stock turns improved by 50%
- Value add per person improved by 13%
- Implemented 5S practices and established benchmark standards in manufacturing cells
- Improved visual communication
- Established operational KPIs to improve performance
The project objective was defined as: “ To identify and implement improvements in either the information or product flow processes that will result in a productivity improvement of 10% and a corresponding increase in sales revenue.”
Working with a multi-functional project team that was introduced to LEAN manufacturing and the variety of tools available, a Value Stream Mapping workshop was carried out that utilised LEAN learning as the team plotted its current state process, identified potential opportunities for improvement and any non-value adding activities that could be either reduced or eliminated.
The active participation of all team members generated healthy discussion and ideas which led to a better understanding of each area’s specific issues and constraints resulting in identification of agreed solutions.
A 5S initiative was also carried out in a nominated build cell and fitting cell to establish benchmarks for effective working environments. The company was very positive in its acceptance of the improvements identified and quickly moved to implement the actions.
The outcome of the five day exercise is that the new process improved value add per person by 13%, improved stock turns by 50%, established benchmarks for optimum working conditions and established a workforce that understands LEAN and is capable of implementing these practices across the rest of the business.
