Transportation – Rail Refurbishment Company
Performance Transformation
Business Challenge
Significantly accelerate production ramp-up whilst reducing product cost.
Background
- Our client had secured a substantial contract to refurbish 100 train sets for the Victoria, Northern and Piccadilly lines.
- Set #1 had taken four times the contracted man-hours and 8 months to complete. Performance for sets #2 and #3 was forecast to be no better.


Approach
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Our approach comprised three distinct, complementary strands:
- “Produceability Studies” : focused on Design for Manufacture & Installation.
- Production Scheduling & Execution: established a one week takt time, with eight production stages.
- Lean Techniques: included lineside visual controls, lineside material supply and daily production meetings.
Key Achievements & Value Delivered
- Target man-hours were achieved by set #9, delivering one train set per week.
- The lead-time from train set arrival at site to customer delivery was reduced from 8 months to 8 weeks.