Case Study

Management of a supply base to deliver exponential increase in volumes of a consumer product to meet unplanned demand after product launch.

Creation of a ramp-up plan to increase capacity and output by a factor of 15 over a 9 month period in order to meet unforeseen customer demand. Close management of suppliers in US and China and investment in manufacturing facilities and tooling.

Key achievements

Volume increase from 1M to 15M per annum achieved on time and to plan
Reduction in customer returns from 7% to 0.1% through design and process improvement
£15Mn Capex budget delivered under target.

Supplier Management

Establish plan across a multi-tier supplier base, involving electronics complex assembly and some very challenging patented technology in a complex and innovative.
Worldwide supplier base delivering to a worldwide market
Increase annualised output from 1Mn to 15Mn over a 9 month period
Identify risks and mitigation plan.
Develop and deliver a capital budget to achieve ramp up.

Operational Excellence

Plastic injection moulding, flat film heater technology. Patented insulation technology, metal finishing and complex assembly.
Management of new manufacturing equipment, injection mould tools and expansion assembly lines.
Improvement plans for internal yield and OEE of suppliers.
Implementation of weekly KPI to manage quality, cost and delivery performance.

Quality Management

Review and analysis of customer returns.
Engaging multi-functional teams in problem resolution through the deployment of 8d methodology.
Maintain and improve up existing products.
Close liaison with markets.