Sample summaries of client projects
Introduction of concept of Lean and building of Lean Awareness with management and key operations staff. This was achieved through “Lean Awareness” training and Lean Waste Walks. Focused project on “Quick Changeover” (SMED) methodology yielded a 20% reduction in the average changeover times.
Achieved 15% labour cost reduction through lean programme.
Drove culture change from a reactive to proactive type of thinking, where people speak with facts and figures rather than estimates and opinions. To effect this, a suite of targeted KPIs were devised and deployed. Deployment of Lean System and tools achieved, a productivity gain of 17% (11% OEE increase). This combined with various other productivity improvements delivered a 15% year on year boost to profit margins
Reduced “Batch Release Days” by 50% by deploying lean tools and techniques in the laboratory.
Achieved a 50% reduction in throughput days, 20% capacity increase and 20% efficiency improvements across Production, Packaging and Laboratories operations for a world leader in the pharmaceutical industry.
Working with the Design, Purchasing and Manufacturing groups achieved 25% reduction in manufacturing costs through a re-design for manufacturing programme.
Configured and installed automatic replenishment of components with electronic kanbans from point of use on production line via blue tooth and GSM to supplier. Project included VMI up to point of consumption on production line.
Provided classroom training and “On the Job” training for deployment of FMEA. Delivered 50% PPM reduction through FMEA programme
Provision of in-depth analysis and evaluations of manufacturing operations of various acquisition targets. This included generation detailed Cash Flow Change based on planned changes in the fundamental operations of the business.
Working with numerous design and manufacturing sites to achieve uniform design, material selection and process utilisation standards facilitating a two-week turn on concept to pre-series production samples of electronic components.
Assessment of current operations, development of improvement plan and implementation of plan to achieve 10% improvement in O.E.E. in a six month time frame.
Benchmarking and Analysis of plastics manufacturing capabilities and costs in Italy versus Eastern Europe and China Italy.