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Responsiveness
Customisation
New products
Personalisation
Cost reduction
Reduced capital
Localisation

Reinventing manufacturing for new products and services

All manufacturers have a desire to give their consumers exactly what they want: innovative, aspirational products, available when and how they want them. The world’s leading manufacturers don’t just create these products, they do so in a way that creates maximum commercial value for their business.

But traditional value chain models – supply, operations, logistics and distribution – often block strategic ambition. Increasingly, this is having an impact on business performance. New solutions and approaches are constrained by existing manufacturing and supply chain infrastructures.

In our experience, you can reinvent the market and gain significant competitive advantage by radically changing the way your products are brought together. By reinventing your key manufacturing platforms, you can deliver totally new products, explore new channels and go-to-market strategies and significantly reduce costs. We have identified seven key areas that you need to address as part of such a transformation.

Select from one of the options on the right to find out more

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Responsiveness – Making a flexible supply chain to seize market opportunities

A leading drinks manufacturer asked us to help them raise their game to meet changing consumer demand. This meant responding more flexibly to shifts in the market and making the most of opportunities for revenue growth. The answer lay in developing a smarter, more responsive supply chain that combined flexible manufacturing processes, demand-driven principles and new approaches to delivery.

Our team designed a new end-to-end supply chain to make this happen. We looked at each element of the supply chain design and created a detailed strategy and approach to put our recommendations in place. In parallel, we defined a new-to-the-world manufacturing solution that enabled the ambitious supply chain model to be realised while delivering a new-to-the-industry cost structure.

The result? The company could more than halve their inventory days of supply, from 50 to 20 days. And they are moving to a highly responsive supply chain that can make to order, satisfying changing consumer and customer demands.

To discuss reinventing manufacturing for your future product, value chain and service portfolio, please contact us now.

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Responsiveness

Customisation – Helping customisation happen on a global scale

After getting new insight into consumer preferences, a large global consumer healthcare company realised they needed to increase the variety of individual items for one of their biggest selling products. As their existing factories focused on large-scale batch manufacture, this type of customisation was impossible without significant extra costs.

Our team assessed the technical and market demands and created a new concept to enable customisation. The solution was to make the base materials in bulk using existing capital and to customise the product just before packing through an inline mixing and dosing system that added a variety of ingredients (such as flavours and colours). We then developed a proof of concept, prototype and high-volume pilot-line process.

The final model – completed in just 18 months – enabled production of bulk and then customisation to meet market demand in real time. It helped the business introduce new products while reducing business risks and their minimum batch size at no extra cost. Our solution provided a platform for replication across several sites to create a global supply network able to customise products cost-effectively and meet the current and future demands of customers.

To discuss reinventing manufacturing for your future product, value chain and service portfolio, please contact us now.

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Customisation

New products – Developing and delivering an iconic new product within 12 months

Although there has been a steady climb in market demand and penetration, the household kitchen towel sector has seen no genuine product innovation since its inception in 1931. Working closely with our client, Better All Round, we have challenged the norm. We developed, and are now supplying the market with, a revolutionary new kitchen towel product – Ora.

Ora has been developed to make using kitchen towels easier by layering single round sheets through an innovative stacking system. As there are no perforations, you simply lift off a sheet with one hand. Each stack contains the equivalent of two traditional kitchen towel rolls held in a waterproof card base rather than on a roll. Everyone wins: Ora’s space-saving design and round shape means 20% less packaging, over 30% fewer trucks on the road and less space required in the supermarket and in the home. And less waste for our planet.

Driving this development – from the business design and concept to finished product in store within 12 months – has been a real achievement. With no pre-existing equipment available, we developed a completely new manufacturing process at our Technology Centre in Cambridge.

To discuss reinventing manufacturing for your future product, value chain and service portfolio, please contact us now.

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New Products

"What the PA guys did was to deliver the hard practical engineering support to make the product a reality and bring innovation to what was previously a staid, lacklustre category."

Oday Abbosh, CEO of BAR

We helped create the new Ora kitchen towel, from concept to supermarket shelves in less than 12 months [6NIB6znZQjg]

Personalisation – Leading the personalisation revolution

As customers increasingly expect products to meet their individual needs, personalisation presents a rapidly growing opportunity for consumer goods companies worldwide. Meeting consumers’ demands will require nothing less than the reinvention of manufacturing. We are making personalisation possible – and affordable – by helping companies turn new technology into commercially viable, practical solutions. We are using additive manufacturing (also known as high speed 3D printing) to give consumer goods companies new opportunities to tailor the product offerings for individual consumers or customers.

For a major consumer products company, we developed new technology to enable them to produce personalised products on a larger scale and at speeds approaching existing production lines. We are going beyond what is achievable using current manufacturing technologies by bringing full digital capability into play, allowing for the personalisation of physical appearance, internal structure, texture, content and functionality of mass produced goods. Our technical digital manufacturing solution is underpinned by the development of smarter logistics and sourcing arrangements.

To discuss reinventing manufacturing for your future product, value chain and service portfolio, please contact us now.

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Personalisation

Cost reduction – Saving tens of millions in production for a new product

One of the largest food companies in the world had launched an ice cream product that was proving extremely successful with consumers. As a result of this success, the company found their manufacturing line being stretched like never before. They needed to produce the volumes required to satisfy demand while getting more value from their manufacturing equipment. Our team of experts in materials-handling and packaging helped them achieve this goal.

Our team started by mapping the product’s entire ‘journey’ from raw ingredient to point of sale. On the back of this, we brainstormed 100 new ideas for how the product could theoretically be manufactured for less cost, developing 18 of these ideas into workable concepts. After sharing these concepts with the in-house team, we narrowed them down to four proposals with the greatest potential. For each of these, we developed processes and packaging to show how they could be realised, supported by a watertight business case.

By looking at how their product could be manufactured, we gave the company an approach that was unconstrained by conventional thinking. Our proposal has the potential to save them tens of millions of dollars by reducing cost of goods by over 15%.

To discuss reinventing manufacturing for your future product, value chain and service portfolio, please contact us now.

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Cost Reduction

Reduced capital – Ramping up production without breaking the bank

A new bold-flavoured snack range had been launched onto the market and was proving incredibly successful with the public. The manufacturers found themselves in a position where they urgently needed to ramp up production to meet growing demand. They were considering building a new manufacturing capability but this was capital-intensive and imposed significant time constraints. Without an alternative approach, they faced having to pull advertising for the product.

To find a solution, our team assessed the company’s processing and packaging equipment and provided a view of system architectural options. We assessed key parameters influencing production speed and product quality and how these could be monitored, controlled and optimised. We then looked for innovative production solutions that would deliver against short-term needs while providing a platform for efficient future capital expansion.

The short-term solution reduced process cycle times by 60%, enabling the company to meet market demands and avoiding the need to replicate lines and factory locations whilst reducing energy costs and providing more consistent quality. For the long-term, we helped the company rethink their supply chain strategy and get management buy-in for the next generation (and more cost-effective) process lines.

To discuss reinventing manufacturing for your future product, value chain and service portfolio, please contact us now.

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Reduced capital

Localisation – Making localisation a reality

A pharmaceutical start-up had a brilliant idea for making tablets, which involved adding the active ingredient of the drug to the bulk tablet as a surface coating rather than mixing it in at an earlier stage. Through this novel approach, they realised they could mass-produce bulk tablets at a central location, distribute them worldwide, and then have them customised locally. The potential benefits included cutting transit time to enabling a distributed supply strategy that would cut tax liabilities.

Our team were integral in creating the platform to make this ambition a reality. The concept drew on powder deposition using electrostatics – adapting principles used in photocopying – to enable the direct digital printing of the tablets. The new system enabled the efficient manufacture of ultra-low batch quantities, which provided improved flexibility, allowing the company to achieve rapid and controlled changeover between surface coverage and dosage level. We then created a full pilot line to assess performance of the concept through to clinical trials.

This novel approach completely challenged traditional means of tablet manufacture and opened up bold new opportunities for delivering value from local finishing at country or regional level.

To discuss reinventing manufacturing for your future product, value chain and service portfolio, please contact us now.

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Localisation
Home Responsiveness Customisation New products Personalisation Cost reduction Reduced capital Localisation

Home

Reinventing manufacturing for new products and services

All manufacturers have a desire to give their consumers exactly what they want: innovative, aspirational products, available when and how they want them. The world’s leading manufacturers don’t just create these products, they do so in a way that creates maximum commercial value for their business.

But traditional value chain models – supply, operations, logistics and distribution – often block strategic ambition. Increasingly, this is having an impact on business performance. New solutions and approaches are constrained by existing manufacturing and supply chain infrastructures.

In our experience, you can reinvent the market and gain significant competitive advantage by radically changing the way your products are brought together. By reinventing your key manufacturing platforms, you can deliver totally new products, explore new channels and go-to-market strategies and significantly reduce costs. We have identified seven key areas that you need to address as part of such a transformation.

PAnorama Reinventing manufacturing TG
/our-thinking/reinventing-manufacturing/
http://www.paconsulting.com/our-thinking/reinventing-manufacturing/
http://www.paconsulting.com/our-thinking/reinventing-manufacturing/rm/

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