Value Stream Mapping
Gibbs Engineering
Gibbs Engineering of Bridgwater was established in 1975. The company manages complete projects using specifications or their own design and draughting facilities. The company has expanded considerably in recent times and wanted to review its operating methods to ensure that they were the most effective for translating client requirements into reality.
Naim Audio
Naim Audio, based in Salisbury, are renowned for the design and manufacture of a premium range hi-fi and AV equipment. South West MAS were able to help train and introduce manufacturing best practice into the company from the shop floor upwards.
Trumac Group Ltd.
Designers and manufacturers of high specification refrigerated units that are subsequently retro fitted to vehicles. MAS asked to help reduce lead-time and improve on-time delivery. Also, increase capacity without increase in labour by reducing non value added activities.
Romarsh Ltd.
Designers and manufacturers of industrial electrical transformers and inductors. MAS asked to reduce manufacturing lead-time and improve on-time delivery.
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.
Thorn Secure Science International
Designers, Manufacturers and licensed suppliers of Security/Recognition systems and patented watermarked magnetic tape. South West MAS requested to investigate established watermarked magnetic tape process to: Reduce end of line rejection rate currently >10% Increase productivity, reduce lead-time and improve Housekeeping
DEZAC Group Ltd.
DEZAC manufacture health and beauty products through retail outlets such as Boots, Argos and TV shopping channels to name but a few. Main Processes: Plastic moulding of components, Assembly, Warehousing and distribution South West MAS support requested for a programme of change to introduce: Better utilisation of space, Increased output, Improving material flow and development of team leaders.
Knorr Bremse
Part of a global group and formerly Bendix, the company manufactures commercial vehicle braking systems. SWMAS were asked to improve the productivity of the wedge brake cell.
Teledyne Geophysical Instruments
At the Gloucester site the Teledyne team specialise in the repair and upgrading of seismic arrays. After meeting with the team at Teledyne Instruments it was agreed that an opportunity for improvement for the business would be in the area of process flow and workplace organisation
City Engineering Bristol Ltd.
A Bristol stainless steel and aluminium company is on track to save £50,000 in just a few months thanks to the South West Manufacturing Advisory Service's Advanced Engineering Skills Programme.
Kaba (UK) Ltd
Kaba is a world leader in the application of Total Access for integrated security solutions. Having worked on several Kaba Group projects embracing some lean thinking the vision of Kaba (UK) management team and in particular, Alan Stevenson, the Technical Director, was to fully incorporate and develop a lean operation for the UK organisation.
Lowley Engineering
Lowley Engineering is a member of the Cornwall Aerospace Defence Initiative collaboration, known as CADI. Formed in 2005 the group consists of a variety of Cornish companies whose aim, via a cluster of approx fifteen, is to access new markets and improve competitiveness within the aerospace and defence industries of the South West and beyond.
Gibbs Engineering
Gibbs Engineering of Bridgwater was established in 1975. The company manages complete projects using specifications or their own design and draughting facilities. The company has expanded considerably in recent times and wanted to review its operating methods to ensure that they were the most effective for translating client requirements into reality.
Becatech Ltd
Becatech design, manufacture and supply specialist security solutions. The business has experienced significant growth over recent years, which has lead to an increase in manufacturing output. The need to improve material management, operating procedures, manufacturing measures and quality processes was identified as an area of key importance.
Corin Group Plc
Hip/Knee replacement and surgical instrumentation products. Key Achievements * Implemented new cellualr layout reducing leadtime by 22 weeks * 80% delivery on time. * Increased productivity flow * Increased shop floor communcation. * Use of PDCA as continuous improvemnt process * Increased confidence to lead CI and implementation.
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.
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
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
Deso Engineering
DESO Engineering manufactures a wide range of moulded tanks and its key markets are the oil and fuel storage sectors. A series of workshops were delivered to all DESO employees. These were followed by one to one sessions with the lean champion.
Eco Composting Ltd
ECO owns and operates the UK's leading purpose-built site for organics recycling and is leading in the way it manufactures a range of products from a number of sustainable source of green waste.
