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CASE STUDY 1

Manufacturing facility

  • Client

company confidential

  • Category

Manufacturing

  • Date

Summer 2019

  • Location

Staffs, UK

Agreed Objectives & Targets
  • Increase OTIF, reduce lead time and build capacity

  • Reduce WIP in production by 60%

  • Introduce daily lean checks and controls

  • Coach the production team and management in Lean thinking
Project KPI - reduce WIP by

0%

Target Condition: 65% of customer orders completed within 2 days.

Movement of goods analysed and layout changed to reduce waste of motion and build up of WIP.

project results
  • WIP reduced by 65% and controlled by customer pull

  • Customer Lead time reduced from 2 weeks to 2 days (for majority)
  • OTIF improved significantly without overtime

  • Lean team is motivated and looking for further improvement

WIP Actually Reduced by

0%

CASE STUDY 2

Lean Warehousing

  • Client

company confidential

  • Category

Warehousing

  • Date

Autumn 2021

  • Location

South Coast, UK

Agreed Objectives & Targets
  • Reduce stock holding by 30%

  • Increase stock turn from 6.5 to 12
  • Create flow in the warehouse

Reduce Stock Holding by

0%
‘Measles’ chart showed picking hotspots. Most frequently picked items identified
 and hotspots re-located to reduce waste of motion.

Stock holding analysed. Stock sorted into 3 categories & different rules applied
. Safety Stock for each re-calculated in line with best practice.

project results
  • Stock holding reduced by £120k
  • Stock turn increased from 6.5 to 11
  • Throughput capacity increased by 20%
Throughput capacity increased by

0%
-£ 0 ,000

Reduction in Stock Holding

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Jon Mitchell

Managing Director - Marlow Ropes

I can’t stress enough the positive effect working with ALC has had on the business …from a number of angles and I feel sure there will be further work that we will want to engage them with.

Vicki Ward

Head of Global Shared Services - Experian plc

ALC helped us embed a continuous improvement culture… training the team in Lean methodology, and helping us embed a continuous improvement culture that will continue long after Tim’s contract ends. Tim has helped us lead the changes by understanding our requirements, developing a unique branding for the program and adapting the methodology to our finance processes.

Paul W. Rodwell

Group Finance SS Director – Experian plc

Tim’s knowledge, expertise and professional approach engaged management and staff at all levels to ensure the success of the EmPower programme for Experian’s Global Finance Shared Service Centres. ALC’s EmPower programme successfully established Lean awareness and understanding with all SSC team members globally. The programme successfully realised financial savings and significant efficiency benefits through process improvements and the elimination of low-value activities.

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