Manufacturing is enjoying a renaissance with higher levels of investment and political will to create powerhouses with wealth creation capabilities. Over the past 40 years Bourton Group has worked with blue chip and SME manufacturers on their individual journeys to excellence.

We understand the complexities of global supply chains, through design and manufacturing processes, underpinned by Lean Six Sigma process improvement methodologies and the role of leadership and management in creating a culture of Continuous Improvement.

Case Studies

Cobham Aviation Services: Reorganising for Growth and Process Efficiency

Manufacturing

Cobham Aviation Services operates and maintains specially modified aircraft using state of the art technology to provide airborne special mission operations to military and governments in Australia, the United Kingdom, Europe and the Middle East.

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Cobham Aviation Service: Reorganising for Growth and Process Efficiency

Manufacturing

Cobham Aviation Services operates and maintains specially modified aircraft using state of the art technology to provide airborne special mission operations and training in Australia, the United Kingdom, Europe and the Middle East.

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Vectura Pharmaceuticals: Leadership Development Programme

Manufacturing

Leadership skills development programme helps scientists instil performance orientated culture.

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Zodiac Aerospace: Developing Supply Chain Capability and Capacity

Manufacturing

Zodiac Seats UK designs, certifies and assembles bespoke first class, business class, and premium economy class passenger seats for major
global carriers. Zodiac Seats UK, has formed part of the Zodiac Aerospace Group since 2012. Its two production sites are in Cwmbran and Camberley.

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MetsäWood: Developing the facilitation skills of Lean Coaches and Line Managers, Building capability to support business critical improvement projects

Manufacturing

Metsä Wood supply wood-based products, systems and services to customers in the building and construction, industrial, distribution and retail sectors. The business achieved a turnover of EUR 940 million in 2011, employing about 2,900 people. It is one of the largest companies in the forest products sector in Europe.

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International Paints: Improving Customer Service Whilst Cutting Cost

Manufacturing

Our client, a leading manufacturer and distributor of specialist paint and coatings based in the UK, is part of a major global corporation. The site that was the focus of this assignment manufactures over 20 million litres of specialist paint per year. This is distributed to stockists and end-users through seven European Regional Distribution Centres (RDC’s), all managed from the UK site.

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Improving Customer Service Whilst Cutting Cost

Manufacturing

Our client, a leading manufacturer and distributor of specialist paint and coatings based in the UK, is part of a major global corporation. The site that was the focus of this assignment manufactures over 20 million litres of specialist paint per year. This is distributed to stockists and end-users through seven European Regional Distribution Centres (RDC’s), all managed from the UK site.

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Rolls-Royce: Enabling Robust Design

Manufacturing

Most areas in manufacturing are facing dramatic changes in market forces. Those like Rolls‐Royce, who are at the leading edge of technological advancement, are facing more changes than most.

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Medical manufacturing output and quality improvements result in increased capacity

Manufacturing

Torbay Pharmaceuticals are on a journey of change having moved to new premises, appointed a new Managing Director, their order book had grown and made good commercial progress for the NHS Trust, all within the last 12 months.

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Cutting through productivity issues at medical knife manufacturer to double output

Manufacturing

Bourton Group visited the production facility and through a combination of work study methods, Process Mapping, data collection and detailed analysis we quickly identified opportunities to increase outputs and increase quality.

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Plant Efficiency Review

Manufacturing

CPL Products was created as a spin off from British Coal in the early 1990’s and provides home heating solid fuel Briquettes. The plant was originally built by Petrofina in 1985 and the process had not changed significantly since 1997. The review focused on the two production plants MHT1 & MHT2 at the Immingham site with a view to increasing capacity and driving costs down.

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Kaman Featured Image

Kaman: Improving productivity & quality with a sustainable culture

Defence & AerospaceManufacturing

Key improvements were made by looking at the Gross Margin products. Plants were re-laid, contracts were reviewed, and quality data analysis was undertaken to allow initiatives to be put in place in order to reduce scrap across a range of products.

By the end of the first six months, significant increases to the bottom line had been achieved (>£1.3m annualised improvement).

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Improving efficiency, effectiveness and capability in design, fabrication and production functions.

Manufacturing

The business was experiencing problems in fulfilling customer orders and achieving financial performance targets, despite having a significant order book.

To uphold its position, it was important to transform ways of working, redefine processes and build capability.

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Tecomet Featured image

Tecomet forges ahead with Productivity Improvements

Defence & AerospaceManufacturing

A programme based on Machine shop re-layout, supervisory and management training, leadership coaching and shop floor scheduling. Bourton Group worked closely with the management team over twelve months analysing processes and routines and coaching staff in the new ways of working.

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Manufacturing

A manufacturer of engineered products based in the South-West region of the UK

Manufacturing

Our client is a manufacturer of bespoke engineered metal products for a range of industries, based in the South West of England.

The initial aim of the project was to review the business, establishing how much of the margin reduction was due to known changes and how much was related to out of date and inappropriate general business practices, and make recommendations for improvement. A second phase was subsequently agreed in which we helped facilitate the identified improvements.

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Working together

What we do

What we do

We provide practical, feet-on-the-ground consulting that emphasises partnership, transfer of knowledge and lasting results. At Bourton Group we utilise an Operational Excellence model that is proven to achieve excellence.

Experience

Experience

We have helped hundreds of clients, from a wide range of industries, to significantly improve their manufacturing and operational performance, as well gain maximum value from supply chains. We ensure operations and processes are configured to optimum performance; operating effectively, efficiently and to high standards of quality.

Approach

Our approach

We ensure the improvement methodology is designed around the needs of the organisation and helps to raise awareness and positively promote the need for change. We provide full on the ground support until Operational Excellence is fully embedded, while moving at pace so your organisation rapidly becomes self-sufficient.

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