Advanced Manufacturing Supply Chain Initiative (AMSCI)

Delphi secures jobs and future in the UK with AMSCI support

With 1.5 million vehicles and 2.5 million engines produced each year, the automotive industry is a leading sector in the UK economy, and Delphi Automotive a key member of its supply chain. The manufacturer boasts an annual turnover of £9.8 ($16.5) billion, and its subsidiary company, Delphi Diesel Systems, is a key supplier of diesel… Read more »

Leadership Development

Building leadership capability for the future in the Aerospace sector

A case study in leadership development Background Our client is one of the world’s largest suppliers of technologically advanced aerospace and defence products. They design, manufacture and service systems and components as well as providing integrated solutions for commercial, regional, business and military aircraft, helicopters and other platforms. They are also a major supplier to… Read more »

Lean Awareness

Upskilling and application of 5S as one of the foundations of a lean business

Background The client company is a provider of advanced composite materials and technologies. Having previously applied the principles of 5S in other areas of the business and seen operational and efficiency improvements, they wished to further apply the approach in an attempt to sustain a culture of continuous improvement, while using a successful, standardised and… Read more »

Developing practical 8D problem solving capability

Background The client is a major supplier in the automotive industry. They develop and produce mechatronics systems for vehicle doors and seats as well as electric motors. Within an organisation of over 50 locations across the globe, the UK division has seen phenomenal growth in recent years. With this growth set to continue, the client… Read more »

ELE Advanced Technologies

A case study in the introduction of lean training for employees. Background Formed in 1955, and privately owned since 2000, ELE Advanced Technologies (ELE) located in Lancashire, specialises in non-conventional machining for aerospace and land based industrial gas turbines. They also produce precision components for the automotive industry.  Key customers include Rolls-Royce, Siemens and Alstom…. Read more »

Leyland Trucks Ltd

Improving assembly processes through the application of lean manufacturing. Background Leyland Trucks manufactures the full range of DAF Trucks, from 7.5 to 44 tonnes, at its facility in Leyland. All vehicles are produced on one line at a rate of 20,000 per year. The facility operates in line with the Paccar Production System (PPS) and… Read more »

Process Improvement Activity MasterClass

Emmett UK

A case study of a process improvement MasterClass in the Fresh Produce sector. The activity focussed on productivity improvement and cost reduction in a packing process and was achieved using techniques including data analysis, takt, line balance and visual management. “The Masterclass has provided us with the tools and techniques to establish and plan the… Read more »

Salad Days

Quality downtime and line balance improvements at a major salads supplier. Background A salad products supplier to the UK retail market, this client supplies direct to major supermarkets. Within this market, lead times are short with a need to react rapidly to end customer demands much of which may be weather driven. The Challenge Daily… Read more »

Productivity and Competitiveness Framework

Valve Train Components Ltd

A case study in implementing the Productivity and Competitiveness (PAC) framework in the Automotive Sector. The activity focussed on productivity and quality improvement and was underpinned by the NVQ level 2 in Business Improvement Techniques. It was achieved using techniques including effective teamwork, problem solving, 5C/5S, standard operations and visual management. “The PAC exercise enabled… Read more »

Teal Patents Ltd

A case study in implementing the Productivity and Competitiveness (PAC) framework in the Electrical Appliances sector. This activity focussed on productivity and capacity improvement and was underpinned by the NVQ level 2 in Business Improvement Techniques. It was achieved using techniques including effective teamwork, standard operations, 7 wastes, workplace organisation (5C / 5S) and organisational… Read more »

Supply Chain Development

Gardner Aerospace-Basildon Ltd

A National Supply Chain Group case study in the Aerospace Sector. This supply chain development activity focussed on delivery improvement and lead time reduction. This was achieved using techniques including data analysis, workplace organisation, visual management, standard operations and set up improvement (SMED). The Customer The Host GKN Aerospace specialises in the design, testing, manufacture… Read more »

Renold Gears Ltd

A case study of Process Improvement in the Automotive Sector. This supply chain development activity focussed on defect reduction and productivity improvement. This was achieved using techniques including effective teamwork, 5C / 5S, flexible production systems, standard operations, single piece flow and visual management. “It is not just the achievement of the solution, which wouldn’t… Read more »

Goodrich Power Systems

A case study in Supply Chain Improvements in the Aerospace Sector. This supply chain development activity focussed on delivery improvement and was underpinned by the NVQ level 3 in Business Improvement Techniques. It was achieved using techniques including effective teamwork, flexible production systems, 5C /5S, standard operations and visual management. “In September 2005 the Goodrich… Read more »

Maxpower Automotive Ltd

A case study in Supply Chain Improvements in the Power Generation sector. This supply chain development activity focussed on delivery and productivity improvement and was achieved using techniques including effective teamwork, 5C / 5S, flexible production systems, visual management, standard operations and set up improvement (SMED). “Because of commitments to other programmes at the time,… Read more »

Perkins Engines

A case study of increasing profitability through the development of a world-class supply chain. Background Perkins Engines at Stafford intended to support rapid growth in volumes and to drive an increase in profitability by developing a supply chain capable of world-class performance. The Challenge Perkins Engines at Stafford produces medium-to-large size engines for the Electrical… Read more »

Team Leader Training

Coleman Milne

A case study in Enhanced Team Leader Training incorporating NVQ Level 3 in Business Improvement techniques in the Coach Built Vehicle sector. The activity focussed on improving both productivity and quality and was achieved using techniques including standard operations and 7 wastes. “I’ve really enjoyed compiling the evidence for my Business Improvement Techniques qualification. I’m… Read more »

Total Productive Maintenance

TPM application in Fresh Food Processing

Applying Focussed Improvement and Autonomous Maintenance to increase yield and throughput   Background The client processes fresh natural raw material to prepare for further processing at another internal business unit. The process is labour intensive, but relies on a handful of key machines to keep productivity globally competitive. The site believed they were close to… Read more »

Philips Lighting

A case study in reducing costs through the application of Total Productive Maintenance (TPM). Background Philips (Uden) produces and delivers ceramic light components to internal Philips customers. The products go into two main Philips products, SON and MASTERColour lamps. These products are widely used in street lighting in greenhouses, for lighting of buildings and for… Read more »

Process Minerals

Global TPM Transformation Deployment in the Industrial Components sector Background This global manufacturer processes minerals to produce great volumes of product used all over the world supplying high specification material to the automotive, marine, energy and renewables sectors.  A vital factor to stay ahead of competition is to maximise the return on capital associated with… Read more »

Automotive TPM

Reducing costs through the application of Total Productive Maintenance Background This electrical component provider produces and delivers key electrical components to a wide number of customers. The products go into two main categories and the manufacturing and supply chain process is developed to ensure this. These products are widely used in street lighting, in greenhouses… Read more »

Food Processing

Using TPM to enable an environment for change to happen Background This well recognised foods producer started their TPM journey in 2010. They had done some good work but their factory was spread over a large area in individual business units. Change Agent roles were in place but reporting to a central steering group meant… Read more »

Food Processing 2

Using TPM to help help develop business strategy Background This client started their TPM journey in 2009 with the implementation of some initial pillars but they were independent and were not working collectively or collaboratively. Completion between the pillars meant that standards were often imposed and not collectively agreed or developed.  All pillars were launched… Read more »

Value Stream Mapping

Automotive – Optimising Layout & Flow To Match Customer Demand

A layout and line balancing improvement activity, supporting the company’s achievement of customer requirements and corporate growth plans, avoiding €2M capital expenditure   Background The client company is a leading global automotive supplier supporting the sector with manufacturing plants in 29 countries. In late 2011 a plant was built in Hungary to support a major… Read more »

Injection Moulded Trim Parts

A case study in value stream transformation at an automotive interior components supplier. Background The client is one of the world’s largest suppliers of automotive interior components who supply all of the major automotive OEMs. Their core product categories include door and trim systems, instrument panels, consoles, cockpits, flooring, acoustic systems, headliner and overhead systems… Read more »

Albon Engineering & Manufacturing PLC

A Value Stream Mapping and O.E.E. improvement activity, supporting Albon’s investment in machinery and tooling, resulting in a 70% increase in line output Background Albon Plc. is a large, independent design and manufacturing company specialising in the machining and assembly of engine components for automotive and diesel manufacturers world-wide. Current activities consist of high volume… Read more »

ENER-G Holdings plc

A business process improvement programme resulting in a 60% reduction in lead times. Background ENER-G designs, develops and finances energy efficient, sustainable and renewable solutions on a business-to-business basis globally. Components, primarily engines, are purchased from automotive suppliers to support the business. The engines are used at the heart of ENER-G’s efficient Combined Heat and… Read more »

ELE Advanced Technologies

A case study in the Value Stream Mapping of business processes (manufacturing). Background Formed in 1955, and privately owned since 2000, ELE Advanced Technologies (ELE) located in Lancashire, specialises in non-conventional machining for aerospace and land based industrial gas turbines. They also produce precision components for the automotive industry.  Key customers include Rolls-Royce, Siemens and… Read more »

Electron Technical Solutions Ltd

A case study in increasing capacity through the implementation of lean tools & techniques – Value Stream Mapping. Background Electron Technical Solutions Ltd (Electron) is a UK leader in the painting of plastic components, providing matt, semi-gloss, full-gloss, soft feel, spatter, metallic and chrome effect finishes. Electron has facilities to produce small or large volumes,… Read more »