Lean Manufacturing Case Study

The assignment was to train the management team in preparation for a company restructuring; introduce lean manufacturing processes and layout a new factory in line with lean principles. The assignment was review all practices and procedures from design, planning and control, stock management, capacity planning, purchasing. Re-design and implement the processes and measure success. The restructuring was a significant culture change and this was addressed using training workshops.

What have we done with the company?

An initial mapping and diagnostic phase identified the key processes, their strengths and weaknesses and priorities for action and change, with an assessment on risk and benefit.
Implementation of the findings included some of the activities below: -

• Process mapping of the production and information flow
• 5S of the area and implementation of standards
• Use of TPM on key machines
• Spaghetti charting the flow of materials and people
• Stock profiling
• Production planning

An approved DTI Business Finance Workshop was used to demonstrate the principles of financially lean manufacture. An approved DTI Sales Workshop was customised to impart customer relationship skills required by the senior management in their new roles.

Outcomes

• Reduction of fire fighting
• Improved morale
• Equipment efficiency increased by >20%
• Failure to meet delivery times improved by >20%
• Defect rate improved by >10%
• Turnover increased by >20%

Competencies Demonstrated

• Business Process Re-engineering
• Change Management
• Lean Manufacturing
• Value chain analysis and mapping
• Sales & Operations Planning
• Training
• Sales channel Management
• Negotiating