Dealing with product complexity and increased demand

The Problem

Last year our client moved to new premises which doubled the size of their previous manufacturing site. This move allowed them to manufacture additional product ranges, increasing production volume and the variety of products. This increased the complexity of planning, scheduling, parts ordering processes and placed more emphasis on managing available space.
  • Client : Private
  • Business Area : Manufacturing

How we helped

We helped our client design a programme involving all business functions, to map out value streams and identify improvement areas, from customer enquiry, to product delivery processes. This approach also incorporated team members from across the group’s international sites, ensuring a cross functional approach from all stakeholders. Kaizen rapid improvement events used the mapping outputs to identify, manage, and implement improvement projects thus creating a sustainable approach to the company’s continuous improvement activities.


The benefits realised by our client from their investment in this programme include:
28% reduction in lead time resulting in increased capacity
Improved flow of product through the factory through a 10% reduction in incomplete kits issued to the shop floor
Improved availability of parts and components, reducing stock outs by 50%
Improved inventory management reducing excess stock by £400k
Greater flexibility of staff by multiskilling
Increased cooperation between business functions
95% reduction in admin time spent processing orders, and generating Engineering drawings

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