Improving quality, efficiency and effectiveness within niche automotive manufacturer

An industry-leading British automotive manufacturer responsible for producing top-of-the-range supercars approached Develop Consulting to assist with its inefficient logistics operation within the production facilities.

This was a barrier in increasing production volume and meeting demand. The business’s target was to grow production from 3500 units in 2017 by 30% to 4,600 units by the end of 2018.

93%

Improvement of stock-flow

80%

Stock Accuracy

31%

Production Increase

Improving quality, efficiency and effectiveness within niche automotive manufacturer

Results

• A stable flow of stock within the warehouse improved from 65% to 92.5% in a year
• Number of faults per vehicle reduced from 50 to 15 and missing parts reduced to an average of two per vehicle
• Increase in productivity from 12 parts per hour picked to 18 per hour
• Line side layout changes improved
• Stock accuracy improved from 50 - 80% in a year
• A sustainable culture of teamwork with improved morale and productivity
• A 31% increase in production, exceeding the original target

Improving quality, efficiency and effectiveness within niche automotive manufacturer

Observations

• Specific areas identified as problems included the inefficient registration of car parts, causing delays in production
• On average up to 50 missing parts or quality inconsistencies per vehicle

Improving quality, efficiency and effectiveness within niche automotive manufacturer

Objectives

To grow production from 3,500 units to 4,600 units in a year

Improving quality, efficiency and effectiveness within niche automotive manufacturer

Actions

• The process for handling automotive components was smoothed to ensure a better flow throughout the manufacturing building
• Physical layout of the factory and warehouse was reorganised to simplify and make visual the control of parts within the facility
• Assembly process order in manufacturing was replicated in warehouse to allow location of components and reflect assembly process
• Introduction of team-based working