Newton Industrial Consultants

25% improvement in output and an increased profit of £400k to a £2.5 million plant

The Client

This factory is part of large engineering conglomerate making machined components for the engineering, automotive and aerospace industries. This factory produces carbon fibre components for the aerospace industry.

The Chanllenge

As a technically superior product in the industry the market for the products is growing. The factory must satisfy this demand whilst always maintaining the product’s superior physical properties or the customer will source supply elsewhere.

The Project

Since the first objective was to reduce scrap and, therefore, increase profit. The first step was to make understand the biggest scrap losses and then to prove to the production teams that solving these technical problems is possible using structured, logical problem solving techniques. The team then focussed on the production planning systems other de-bottlenecking problems to increase the output of the factory.

Work on process de-bottlenecking, installing effective planning processes and performance measures increased output whilst work on reducing scrap was essential to increase profitability.

On achieving these results the team now plans to use the performance measures and planning structure and systems across the other factories.

‘Thanks to you (Newton) we are making 30% more but more importantly we have solved our biggest scrap problems and are planning and producing what we actually need.’

A 10% - 50% increase in the performance of any manufacturing process in 2 - 6 months without capital expenditure