Master Class Case Study : Wild Precision


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The Company
Wild Manufacturing is a long-established, privately owned component manufacturer of high-volume precision pressings. It operates on an international basis, with the majority of its sales based on special parts for the automotive sector in the UK, mainland Europe and the US.

The Issue

The Press Shop at Wild Manufacturing produces high-precision components. These are pressed in batches, and the pressing tools are set up specifically for each batch in the Tool Room.

'A previous MasterClass had successfully solved our biggest problems in the Press-Room.' reported Stephen Bates, Managing Director of Wild. 'We decided to take a second MasterClass to tackle the most important remaining issue; the set-up of tools in the Tool Room.'

The Solution
'The initial analysis revealed that although tools were invariably ready on time, quality varied from tool to tool,' observed Stephen Bates. 'We discovered that this came down directly to the experience of the toolmaker. The answer was to establish standards and procedures to ensure that tools were set up to a consistently high level.'

So the MasterClass reorganised the working method of setting up tools. Standard procedures for servicing, combined with checklists, were introduced. 'This helped to create a consistent level of tool service from the toolmakers,' said Stephen Bates. Procedures were also established for standard tool settings; these along with longer-term tool modifications, eliminated the problems of variability in the
setting process.

Equally importantly, the organisation of the working environment was improved. This meant ensuring that the working area contained
only the necessary tools for the job.

The tools were placed on shadow boards so that they could easily be found and replaced. 'Missing tools would stand out quickly,' Stephen Bates pointed out. All this has improved the underlying culture in the Tool Room, where the staff are more aware of the significance of their work and the need for quality. 'They understand that the Press Shop is their customer, that quality matters,' observed Stephen Bates.

Benefits
The life of the tool that the MasterClass worked on was improved by 500%, and quality consciousness has increased in and beyond the Tool Room.

'The MasterClass has built us a very strong team in both the Tool Room and the Press Shop. Communications between the two are much better and they are working together very constructively. We've been able to carry these improvements forward. Some of the changes are quite subtle, but there are a lot of gradual improvements week-by-week.'


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