Case Studies
Applied Lean Consulting can help you achieve efficiencies within your business.
Case Study 1
Manufacturing facility
Objectives:
- 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
%
To reduce Work in Progress
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.
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
%
Reduced Work in Progress
Case Study 2
Lean Warehousing
Objectives:
- Reduce stock holding by 30%
- Increase stock turn from 6.5 to 12
- Create flow in the warehouse
%
To reduce Stock Holding
Increase stock turn to
‘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.
Results:
- Stock holding reduced by £120k
- Stock turn increased from 6.5 to 11
- Throughput capacity increased by 20%
%
Thru-put capacity increased by
Reduction in stock holding (£,000's)
What some of our clients have said about our work
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