Electronics & High Tech – Telecomms Equipment Manufacturer
Lean Manufacturing
Business Challenge
To become the “industry benchmark” for manufacturing excellence in telecommunications equipment
Background
Our client, a leading manufacturer of telecommunications equipment for both military and civil markets, was faced with a number of operational challenges including the need to significantly reduce costs and production lead times whilst improving both product quality and delivery performance
Approach
- A short initial phase comprised visits to all manufacturing facilities and the development of a set of performance benchmarks , improvement targets and a comprehensive implementation plan.
- The second phase developed a “factory within a factory” based on lean principles at the main production site, and was used to rapidly showcase the new ways of working and the associated benefits.
- The new manufacturing architecture was then rolled out to all sites
Key Achievements & Value Delivered
- 80% reduction in inventory
- 50% reduction in manufacturing lead time
- 100% increase in manufacturing throughput efficiency
- Company-wide savings estimated at over £20m in inventory reductions alone