Case Study
Business Process Improvement Case Study
Situation
Our client is a specialist supplier of handmade components to the worldwide semiconductor industry who were experiencing problems meeting the demand for their products, as quality criteria were tightened to meet the requirements of their customers next generation of chips.
The market required the company to meet stringent delivery, quality and price targets. To achieve these objectives the company needed to turnaround customer service and financial results in the short-term and implement a longer-term strategy to improve internal performance, particularly in the areas of productivity, rework, and scrap and develop a highly skilled and motivated workforce.
Solution
An initial diagnostic exercise identified the key areas for improvement and an improvement roadmap was designed to address short-term improvements in customer satisfaction and financial results and longer term development of the operations and workforce, this was implemented in phases over a 24month period.
In the first phase we focused on installing the basics foundations of Lean through 5S and Visual management while introducing a streamline production planning process to focus on eliminating customer delivery issues.
Scrap and rework reduction were supported by the introduction of a Structured Problem Solving process with trained facilitators to lead the teams through the process. Further improvement was achieved through the use of Failure Mode Effect Analysis (FMEA) specifically to support new product introduction and then training on Statistical Process Control (SPC) was delivered to Engineers and Team Leaders, complying with customer requirements, enabling further reduction of scrap and rework levels
The team leaders were supported to introduce a coaching style of management, which was designed to support continuous improvement efforts.
Business Process Improvement integrated corrective and preventative actions such as problem solving, FMEA, and SPC, into a streamlined reporting and improvement structure
Benefits
The company increased turnover by 25% during the period, increasing delivery schedule achievement to greater than 95% scrap and rework was reduced from 25% to less than 2%.
There has been a dramatic improvement in the engagement of staff in improvement activities, and the workforce has grown by 10% over this period.
The improvements have allowed the company to win increased market share from current customers and expanded their market penetration. They have become the recognised centre of excellence in their group and have recently began transferring the systems introduced to their worldwide sister plants.
"We have worked with Pragmatique for 5 years now and have found them to be reliable, trustworthy and very capable of providing good improvements. They have provided sustained support and guidance to improve our facility, to help us achieve both our short and long term goals. I have no problems in recommending them to provide a superb service." - David Bellamy, Senior Manufacturing Engineer
Contact us at enquire@pragmatique.co.uk to find out more.
Our client is a specialist supplier of handmade components to the worldwide semiconductor industry who were experiencing problems meeting the demand for their products, as quality criteria were tightened to meet the requirements of their customers next generation of chips.
The market required the company to meet stringent delivery, quality and price targets. To achieve these objectives the company needed to turnaround customer service and financial results in the short-term and implement a longer-term strategy to improve internal performance, particularly in the areas of productivity, rework, and scrap and develop a highly skilled and motivated workforce.
Solution
An initial diagnostic exercise identified the key areas for improvement and an improvement roadmap was designed to address short-term improvements in customer satisfaction and financial results and longer term development of the operations and workforce, this was implemented in phases over a 24month period.
In the first phase we focused on installing the basics foundations of Lean through 5S and Visual management while introducing a streamline production planning process to focus on eliminating customer delivery issues.
Scrap and rework reduction were supported by the introduction of a Structured Problem Solving process with trained facilitators to lead the teams through the process. Further improvement was achieved through the use of Failure Mode Effect Analysis (FMEA) specifically to support new product introduction and then training on Statistical Process Control (SPC) was delivered to Engineers and Team Leaders, complying with customer requirements, enabling further reduction of scrap and rework levels
The team leaders were supported to introduce a coaching style of management, which was designed to support continuous improvement efforts.
Business Process Improvement integrated corrective and preventative actions such as problem solving, FMEA, and SPC, into a streamlined reporting and improvement structure
Benefits
The company increased turnover by 25% during the period, increasing delivery schedule achievement to greater than 95% scrap and rework was reduced from 25% to less than 2%.
There has been a dramatic improvement in the engagement of staff in improvement activities, and the workforce has grown by 10% over this period.
The improvements have allowed the company to win increased market share from current customers and expanded their market penetration. They have become the recognised centre of excellence in their group and have recently began transferring the systems introduced to their worldwide sister plants.
"We have worked with Pragmatique for 5 years now and have found them to be reliable, trustworthy and very capable of providing good improvements. They have provided sustained support and guidance to improve our facility, to help us achieve both our short and long term goals. I have no problems in recommending them to provide a superb service." - David Bellamy, Senior Manufacturing Engineer
Contact us at enquire@pragmatique.co.uk to find out more.