Maxpower Automotive Ltd.
A case study in delivering National Supply Chain Process Improvement
"Because of commitments to other programmes at the time, we had to carefully consider whether to support this initiative, but chose to go ahead because of the reputation of Industry Forum. Now that we can see the great results, we are committed to rolling out the tools and techniques across the rest of the business" Richard Higginson - Company Spokesman
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The Customer
The Host
Perkins is a leading supplier of diesel and gas engines
in the 4-2000 kW (5-2600 hp) market.
Perkins diesel engine solutions are supplied to more
than 1,000 leading manufacturers in industrial,
construction, agricultural, materials handling, marine
and electrical power generation markets.
Participating Supplier
Maxpower manufactures a diverse range of tube
manipulations and pipe assemblies, primarily for major
automotive
customers. The company employs 138
people and has an annual turnover of £5.5M
The Customer's need
The Host
Maxpower to improve Delivery Schedule
Achievement to better than 95%, through Set Up
reduction, and improvement in Overall Equipment
Effectiveness and People Productivity.
The Supplier
Improve current throughput in the cell from 32
pipes/hour to 45 pipes/hour.
To reduce the pipe bending cycle time from 80
seconds to less than 60 seconds
The IF Solution
Supply Chain Groups provided a structured framework approach bringing together customers and suppliers from different tiers in the Supply Chain. Developed by Industry Forum the 3 pronged approach enables individual businesses not only to see real gains in QCD, but also to improve the level of partnership between companies and to develop the improvement skills capability within each company.
Overview of Activity Structure
Description of skills to profitability link
Return on Stakeholders' Investment
Seven Measures of QCD Competitiveness
| Delivery Schedule Achievement | |||
|---|---|---|---|
| Before: | 84.0% | After: | 97.1% |
| People Productivity | |||
| Before: | 32 pipes per hour | After: | 41 pipes per hour |
| Overall Equipment Effectiveness (DB75 Pipe Bender) | |||
| Before: | 52.0% | After: | 67.0% |
Financial Benefits
The Productivity Improvement reduced the cost of overtime and other disruptions by over £11,000 per annum. The additional flexibility and capacity created has allowed the company to bid, successfully, for additional business.
Upskilling for Sustained Continuous Improvement
Following the conclusion of the Supply Chain activity, Maxpower nominated 9 internal candidates who are currently completing their NVQ Level 3 Business Improvement Techniques to sustain and spread the Lean Tools through the organisation.
Working in Partnership with:
Reference File Click here to download