Spitfire supports booming Irish furniture manufacturer meet ambitious waste and efficiency targets

Irish Furniture Manufacturer

The Spitfire team has successfully delivered its latest brief from a renowned Irish furniture manufacturer. With orders flooding in and the plant booming, space was at a premium and efficiency more important than ever - Spitfire was called in to support the firm meet its objectives of reducing waste and improving efficiency.

Spitfire's expert consultants worked in collaboration with the manufacturer to design and implement a Lean Transformation Programme, delivered over a 12 month period. Deploying a combination of trainer led experiential learning sessions and shop floor coaching activities, the Spitfire team worked closely with both senior management and key team members.

After observing the busy factory at work, the training sessions were designed to target inefficiencies and leverage opportunities for improvement. By identifying value and non-value efforts, experiential learning and shop floor coaching worked in harmony to bring the manufacturer closer to their waste reduction and optimal efficiency goal.

The adoption of a 'Lean Thinking' approach to all processes provided a critical advantage to the client, with waste reduction generating notable savings and efficiencies. What's more, the manufacturer is now better placed to capitalise on its influx of new business wins, putting it in a very strong position in a competitive sector.

Following the initial phase of work with the Spitfire team, the manufacturer reported that all staff had engaged with the programme and it had the metrics in place to measure success moving forwards.

The general manager commented, "We are convinced that taking part in the Lean Transformation project with Spitfire has been the right approach at this stage in our business. Many benefits have already been experienced, and Spitfire have been extremely professional every step of the way and flexible in their approach."

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Testimonials
  • "We were very impressed by the quality of the delivered solution, as well as of professionalism of the consultants, their understanding of our complex internal processes and their commitment to quality and respect of deadlines."

    Global Train Manufacturer
  • "With Spitfire's support we have been able to identify impressive savings and with the tools and coaching they provided we will be able to identify even greater savings. The Spitfire team were impressive from the start, quickly becoming part of the team and working in a structured way."

    Material Planning - Ordering Officer Aerospace Company (UK)
  • "At the end of the project we made quite a few changes to our existing systems. The best outcome is the change to the way we now think within the department whenever we are reviewing even the simplest of procedures, we find ourselves applying the 'lean' way of thinking and continue to make improvements."

    Cytology Manager NHS – Primary Care Trust Hospital
  • "A  number of excellent pieces of work all delivered with professionalism and a good level of outside best practice knowledge shared and transferred. Good cross-functional connections made with the team at all levels and are very well respected and trusted in the organisation…"

    Market-leading provider of steam systems and services
  • "This Programme has revolutionised the way my team delivers its projects. It has enabled personal ownership and commitment from everyone involved. The teams are empowered to remove waste from their own processes and deliver real improvements in a matter of weeks, rather than months."

    Graeme Shaw | Business Process Improvement Leader Global Metro
  • "The Spitfire consultants were very knowledgeable and able to relate complicated techniques to us in language we understood. Their experience and expertise gave us a great leap in understanding."

    BT Manager Leading Energy Saving Group
  • "The real power of the programme is the empowerment and tangible cultural change it delivers in a short time scale. It releases momentum from every level and silo of the organisation, generating immediate impact and identification and eradication of waste. This is worthy of immediate wider application."

    Independent Investment Programme Advisory Group to the Mayor of London
  • "After many months of analysis, planning and effort we have, for the first time, achieved all of our Operational Performance Indicators for defects. This is a great achievement and has been delivered at the same time as working to drastically cut the number of outstanding defects, which have reduced from over 2,000 to about 150 today."

    Highways & Transport Manager Local authority (UK)
  • "An excellent piece of work delivered by knowledgeable and experienced logistics experts. Spitfire's packaging design concepts and Lean Logistics approach not only tackle space constraint issues, they also improve ergonomic handling and part quality. The designs ensure reduced handling of sub-assembled material & parts, and reduce costs."

    Plant Manager, Bremen Major Aircraft Manufacturer
  • "The turnaround of the fleet has been incredible! Spitfire Consultancy have been instrumental in making this happen. We now have the tools and the knowledge to maintain control and continue to meet our future performance challenges."

    Fleet Manager Asset Maintenance Company
  • "A great result, this supplier was one of our biggest concerns in terms of parts supply for the new model and now we're getting parts ahead of the model launch, a very positive outcome, well done…."

    Quality Director Leading Prestigious Car Manufacturer
  • "Spitfire have delivered a strategy that is clear and follows all Lean principles to ensure parts are available when required, all without impacting on production. Stakeholders involved have been impressed by Spitfire's knowledge and approach."

    Head of Supply Chain Logistics Major Aircraft OEM
  • "During development of the project, we recognised the immediate potential and in a joint activity with the original project team, installed the Body Shop Training Centre into a brand new manufacturing plant being built in the U.S.A. to assist us with the very difficult task of new plant hire and skill-up."

    Global Lean Centre Manager Global Vehicle Manufacturer
  • "A stellar performance from a rotating team of consultants achieved all I could have hoped for. A great programme which should be wider applied in my organisation."

    Head of Delivery Global Metro
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