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The challenge for Top Dog was to increase capacity and keep costs down. They have established themselves as a flexible and keenly priced supplier for kennels and stables but found that rising demand meant they had to expand and move into expanded premises. Manufacturing Solutions gave the workforce and management, training in Lean manufacturing techniques and worked on site to help them implement a continuous flow system in the new production area. Looking at the whole Value Stream meant some low cost suppliers were dropped in favour of more reliable, if a little more expensive (on the surface) suppliers. The new layout and improvements plus the setting of targets with the introduction standardised work has increased the output per man and the new guide time per panel. The introduction of a carefully controlled 'supermarket' of finished panels has meant they can respond swiftly to customer demand and smooth out the peaks to production. The improvements not yet implemented will mean the total cost is driven down even further but the annualised savings estimating 20,000 panels a year has exceeded £80,000.
Total annualised savings = £83,840. |
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