Spring manufacturer saves £50,000 through lean techniques

The spring industry is highly competitive and profit margins are extremely tight, so the need to improve productivity and reduce costs is imperative. A free performance review visit by MAS identified scope to improve process flows within the operation and remove areas of waste to add value.

By mapping the manufacturing processes to identify delays and wastes, improving the workplace organisation, and training staff in lean manufacturing principles, the business was able to eliminate waste and double handling thereby - boosting productivity and saving 50,000.

The lead time on a key product line was reduced by 15 days to improve levels of customer service and give the business a key competitive advantage, while inventory levels have been reduced by 10 per cent to free up cash flow.

The project, which was part-funded by the North West Aerospace Alliance, has created a continuous improvement culture within the business, with all employees involved in contributing to the change. Fifteen small teams have been formed to work on productivity improvement, customer satisfaction and shop floor layout.

Les Caffrey, operations manager, says: "The work we have done so far with the MAS team has been a much needed springboard for our site. Improvements are giving us bottom line benefits - but, just as importantly, we have switched a light on in our workforce and we are all working together now to drive waste out of the business."

Brian Pickford, general manager, adds: "The improvement project has helped generate a great team spirit at the site. There is a genuine desire among our people to work together in continuous improvement activity - a strength we can build on as we face the challenges of the future."

The Manufacturing Institute began delivering MAS in the North West in April 2002 and since that time has helped manufacturers in the region to make savings of more than 481million.