Ahead of a period of significant investment, the Spitfire team supported this international manufacturer to create a lean production facility

lean production facility technology

The Spitfire team recently completed a challenging business transformation project after being appointed by an international manufacturer to drive the creation of a lean production facility prior to a substantial investment in new technologies.

Before the large capital investment in cutting edge new machinery and technology, our client needed to demonstrate both to key clients and the board the future direction of the company. The mandate was clear; to implement a gold standard machining cell in a newly designed and created lean production facility. This modern facility needed to include certain elements to allow our client to fully leverage the benefits of this methodology:

• Optimised layout

• One piece flow replacing the previous batch production process

• Electronic visual management - including TAKT adherence monitoring and an Andon system, enabling real time view of performance and adherence to output requirements

• Connected communications using Industry 4.0 principles

This brief was made even more interesting by the addition of some of the very latest manufacturing technology including robotics, WorkPartner jig and electrode robotic loading.

Our approach

The Spitfire team began with a detailed analysis calculating the required volume to be produced in the new cell without lapsing into weekend overtime. In order to optimise productivity, we created standardised work combination charts and designed and implemented a single piece flow cell.

The outcome

• The new lean machining cell requires 45% fewer processes than its inefficient predecessor

• Lead time was reduced by more than 98%

• Annual capacity was increased by more than 145%

• The distance moved through processes was cut by 81%

• The required headcount shrunk by more than 43%

Our client reported a host of benefits and noticeable changes commenting, "Spitfire has made a significant change with the drive and tools they bring. The site team has benefitted having them as part of the project".

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