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Lean Case Study - Manufacturer of Acoustic Ceiling Tiles

A lean programme using very focused Kaizen Blitz events carried out in four manufacturing sites across the UK and their sales office.  Techniques used included Line Balancing, Red Tagging, 5S, 7 Wastes, Set-up Time Reduction, Visual Control, Plan-Do-Check-Act Cycle and Standardisation.  

Benefits included:
 
  • Output of large ceiling panels doubled, potential to triple it in future identified
  • Non-value adding time reduced by 39% in press shop
  • 50% improvement in grid line productivity
  • Space reduction from 230 sq.m to 100 sq.m
  • Work-in-progress reduced from 1 week to 1 day
  • Headcount reduced by 25%

    We won the 2002 Management Consultancy Association Awards with this work.

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