Layouts & Space Utilisation
Trio Skips and Hooks Ltd.
Trio Design and Engineering employs 110 people at its headquarters in Gloucester. Opportunities were identified to improve process flow, workplace layout and general organisation, as well as materials management.
Stanley Security Systems
Blick Communications Ltd is one of Europe's leading manufacturers, and pioneers, of new technology in radio-based products and services. The South West MAS were invited to work with the Blick team to introduce a new way of working for the company. They wanted to move from large batch manufacture with long lead times to small batch short lead time (just in time) manufacturing. The aim was to reduce inventory and to become more responsive to customer demands.
Clifton Canvas Developments Ltd.
Clifton Canvas Developments employs 28 staff at its only design and manufacturing facility in Bristol. They manufacture technically sewn products for the front line military and emergency services. South West MAS asked to improve the effectiveness and productivity of manufacturing operations through the application of lean manufacturing techniques.
Rittal C S M Ltd
Rittal-CSM is the largest manufacturer of industrial and data communication enclosures worldwide. A team of three people attended the SWMAS Six-Sigma Greenbelt Programme.
XYZ Machine Tools
XYZ Machine Tools operate through a UK network of five strategically located showroom and training centres supported with nationwide teams of service, programming & technical engineers. nitial scope was to identify and implement improvements to the loading and prioritisation of machine builds on the shop-floor. Improvements in lead time of machine build through the factory and increased on-time deliveries to customers. Develop production management skills and metrics associated with production progress.
Turnstyle Designs
Since 1992, Turnstyle Designs has been creating architectural hardware that is unique in both design and construction, whilst gaining a reputation for producing some of the world's most innovative and inspiring architectural hardware. The initial manufacturing review focused on where the company was at at the moment and where Steve wanted to get to. Steve was confident that sales were available to double the turnover as long as production could match this increased demand.
Dartmoor Kitchen
Based in Clyst St Mary, Devon, and with a turnover of £450,000, Dartmoor Kitchen is spearheaded by owner and head chef, Tom Cull. The food manufacturer wanted to boost pie production from 300 to 3,000 per week, utilising its new manufacturing facility in a more efficient way.
The empty box company
Since its formation in 1988, The Empty Box Company, has been designing and making handmade Wedding Dress Boxes in the UK. The brief was clear James and Giselle had decided that their business in Surrey, needed to expand, and so started a project to create an additional facility in Devon.
Biotrack
All radio tags are customised for individual projects with over 25 years experience of radio tag manufacture and research to rely on. The company had already identified an opportunity to introduce lean manufacturing principles into the production area and had planned to improve layout. Prior to making the layout changes they wanted to review the processes that they were using to ensure the maximum benefit from the layout changes.
Nelson Stokes Ltd
Nelson Stokes Ltd was established in Camelford, North Cornwall in 1976 by its current Managing Director Mr Harold Stokes. During this period the facility has provided the automotive world with an array of brake hoses and assemblies, master cylinders, calliper repair kits, hydraulic brake seals and dust covers inline with industry compliance standards SAE J1401 and FS 106 specifications.
Caterlink Ltd
Call Caterlink commenced operation on their Bodmin, Cornwall site in 1993 selling waffle cones. Today the business is one of the leading suppliers of ice cream ingredients and related products within the UK.
Chough Bakery
The Chough Bakery, in the heart of Padstow, North Cornwall, has experienced considerable growth in business during the past few years. Owners Rob and Elaine Ead have developed considerable market share within the food and drink sector of the county. Because of growing demand, the decision was made to move the production side of the business to a purpose built industrial unit on the outskirts of town.
Infoteam International Services Limited
Infoteam International Services Limited was established in 1997, and provides a technology repair service - configuring, maintaining and extending the life-cycle of electronic equipment. Like many other companies, Infoteam has the desire to expand and grow its presence in a competitive market. In striving to achieve these goals the need to embrace statistical process controls into its operation is the most logical step in its future development.
Cheltenham Tool Co Ltd
Cheltenham Tool Company manufactures precision formed, sheet metal components for the aerospace, defence industries, automotive and industrial metal forming. Key Achievements: * Reduction in leadtime to process CMM parts from 17 working days to 8 days, a reduction of 53%. * Reduction in subcontract costs and increased capacity going forward. * Freeing up quality team (time) to look at continuous improvement projects/lean initiatives
Francis & Lewis International
Francis and Lewis International (FLI) fabricate telecoms, radar and meteorology towers in a variety of innovative and attractive designs for the major mobile phone companies, Networkrail and other customers. Key Achievements: * The value stream mapping exercise helped the local area management to review their operations with fresh insight from the lean perspective. In the first area alone the exercise saved 15% of the cost. * The OEE measurement exercise showed that the lost time due to stoppages twice what the management had originally thought, and prompted a saving of 40 hours per week. * Customer service levels have improved markedly since the programme began. * The 5 S/Workplace organisation initiative helped change behaviours within the workforce, improved discipline to the new reduced stock levels implemented during the Lean initiative and has helped improve visibility of work-in-progress in all areas.
Helander Precision Engineering Ltd
Helander Precision Engineering Ltd produce high quality, precision engineered parts from specialist alloys for a variety of customers in relatively small batches. Key Achievements: * Based on the initial action plan the next time the componet was run it showed a saving of 35%. * The time generated by reducing set up time can be directly translated into increased sales for the business, and increases the labour and overhead recovery against the installed capacity. * The company managers have decided to roll-out the methodology internally using their newly trained team, a team who now have an excellent example of the SMED tools and techniques in practice.
Invertec Ltd
Invertec manufactures bespoke lighting for public transport, inverters and other lighting products. Key Achievements: * Significant improvement of shop floor space utilisation * 50% reduction in kitting time * 20% reduction in the movement of materials and people
Severn Glocon Group
Severn Glocon have been designing & manufacturing Control Valves & Actuators for approximately 40 years. Key Achievements: * Stock reduction * Productivity * Floor space utilisation = sales turnover in area / area in square metres
SPP Pumps Ltd
SPP specialises in the design, manufacture and supply of split case, end suction and vertical turbine pumps for applications such as water supply, sewage and storm water handling HVAC, irrigation drainage and well pumping across the globe. Key Achievements: * Initial results confirm that the productivity has almost doubled in the area and significant inroads into an order backlog have improved cash flow and customer satisfaction. * Middle & top management effectiveness and efficiency has been improved by the visual planning and performance boards which reduce the time taken to understand the current position within assembly and machining areas and to allow rapid prioritisation of corrective actions. * Shopfloor & planning staff are delighted with the new systems as it makes their job so much easier and has given them the opportunity to learn new skills and make a personal contribution to the design of their working environment.
William Haley Engineering
Established manufacturing business designing, manufacturing and erecting bespoke steel framed buildings. Although the manufacturing processes are very slick and lean, the manufacturing process was deemed as the weak area of the company. Results :- Output increased by 27% Tonnes per employee increased by 10 % Non conformances reduced by 42 % Major reduction in absenteeism
