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Manufacturing & Assembly

Case Study 1 - MRO Facility - Laptop repair

  • Low Customer Satisfaction - TAT not at target

  • High stress operation

  • Low/No margin

  • Strategy to close operation and exit country for cheaper alternative 

Creating flow to save the business

High product mix with highly variable demand required a wide range of specialist technical expertise. Each operator diagnosed, stripped, part ordered, rebuilt, tested and cleaned the laptop units for return shipment.

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Customer unhappy due to poor service levels.

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Increasingly high cost of doing business due to overtime, inventory burden, high staff turnover and penalties associated with missed TAT targets meant no meaningful margin.

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Unless there was change, the business would be lost.

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Analysis and implementation of lean based solutions significantly improved service level and gross margin, saving the jobs of the employees. The cell based layout with redistribution of work for laptop flow and kanban material controls for lowest inventory became the model for laptop repair internationally.​​​​

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Get in touch for more examples of previous improvement work in design, manufacturing and assembly.​​

Benefits

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"A driving force in lean and improvement. His energy and enthusiasm is boundless and he has a real understanding of how he can apply his skills and knowledge towards shaping an organisation to deliver their goals"

Robert Burton, Director of Quality & Business Improvements at Rolls Royce

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