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This company is a key supplier of GRP
moulds to a large producer of luxury yachts. They were struggling
to keep pace with demand.
A lot of time was spent retrieving the mould tools from outside
and then due to being stored outside spending excessive time cleaning
them prior to the application of moulding release wax in preparation
for moulding.
After studying the manufacturing process it was soon apparent
that there were a number of issues to address:
The biggest problem was the excessive movement of materials and
the waiting & delay of people and products within the production
process. This became the primary focus for the improvement activities.
In addition the moulds were now wrapped with shrink film as soon
as production was completed. This ensured they would stay clean
when moved back outside to the storage areas.
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The workshop also had a mezzanine floor
which was used to store material. It was evaluated that 90% of
it was not needed. This created a large area to store small and
regularly used moulds inside the workshop and the larger ones
that remained outside were colour coded by boat type.
In addition the moulds were now wrapped with shrink film as soon
as they were empty which kept them clean when stored outside.
This simple and inexpensive change meant
a reduction of pre cleaning and preparation for each mould of
up to 5 hours.
This equated to 100 hours per week or £105,000 potential
saving per annum!
Back to case studies
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Marine Leisure
Manufacture of molds for boat hulls
£105,000
saving per year.
"I am amazed at what was achieved in only three days."
Pete Smith
Production Team Leader
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