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Case Study

New Product Introduction of a Hybrid Vaping Device

Full programme management of the industrialisation of a consumer product from early design stages to market launch

Key achievements

Key Achievements

  • The product was launched on time and volume ramp-up achieved.
  • Capacity installed and proven.
  • £10M saving on the capital budget.
  • £6.5M annualised saving on COGs.
  • PPAP and PSW submission and hand over of capable supply base to business as usual operations team.

New Product Introduction

  • Product Manufacturing Project management responsibility covering all aspects of supplier base.
  • Integrating activities with Client R&D, programme management, procurement, marketing, S&OP  and the suppliers.
  • Deployment of APQP Across Program and Supplier Base.

Supplier Management

  • Overall management of multi-tier supply base for the manufacture of complex battery-powered electronic vaping device and associated consumables.
  • All products manufactured China and sold globally.
  • Control of £30Mn capital budget for tooling and manufacturing equipment.
  • Installation of capacity to achieve required 400K devices per month and 45Mn Consumables per month.

Quality Management

  • Plastic injection tool design, manufacturing and processing expertise
  • Assembly expertise including automated assembly and associated processes
  • Reduction in tooling investment from 118 to 70 tools, shot weight and cycle times optimised. Operation manpower reduction 3100 to 1400 operators achieving volume.