Spitfire's expertise in the manufacturing sector has been called upon to support one of the country's leading water pump manufacturing experts in their mission to reach new levels of growth. Working with both domestic and commercial clients, the renowned water pump manufacturer and distributor had been enjoying rapid gains, but felt that internal limitations could prevent them from achieving greater successes.
With the existing UK manufacturing facility not only starting to reach capacity in terms of physical space but also in levels of productivity, the Spitfire team were tasked with generating and implementing a strategic and proactive plan to negate some of the potential obstacles identified. These challenges included a breach of facility capacity, on-time delivery and distribution, and rising labour costs which could prove to be unsustainable in the long term.
Following an assessment of existing processes, the Spitfire team designed a 3-phase approach to maximise workplace efficiency and reduce the risk of growth-preventing obstacles. Under phase 1, the team was introduced to the foundation of lean transformation, while phase 2 focused on the design and implementation of an improvements plan. Phase 3 saw the Spitfire team test the new processes and systems to ensure the plan would drive new growth.
The plan was delivered by adopting Spitfire's proven Lean Manufacturing Strategy, engaging advanced learning techniques to demonstrate the most effective and efficient management tools for the firm's senior leaders. Through the creation of a supportive and organised working environment, Spitfire provided managers with the knowledge, power, and confidence to not only implement change within the facility, but also to embrace this change, too.
As a result of the implementation of new workplace practices and a lean transformation, the manufacturer reported an 11% time reduction in the work content cycle, a 20% increase in daily production, and a 30% reduction in required space, effectively handling the capacity concerns that had been weighing heavily on the company. The company continued to see successes even after Spitfire's departure, with a 75% - 80% overall efficiency, and a step closer to future growth goals.
"The Spitfire team is professional and more importantly friendly and approachable which has made the team more comfortable with change. Results were delivered in a professional manner" says the manufacturing facility's Technical Director.
"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