Case study

A UK telecoms products manufacturer

Manufacturing improvement for a UK telecoms products manufacturer

This telecoms manufacturer was being squeezed on a number of fronts with market share falling and profits slipping. Productivity and quality in some plants was seen as poor and the company was not ready to manufacture efficiently a range of new technology products in the pipeline.

In addition, there was a lack of factual data on work standards and performance, which made it difficult to compare performance across the sites or predict the likely costs of the new products.
   
PA conducted an in-depth review of processes and performance across the sites, identified change and improvement plans to address deficiencies in people, product and process-related areas and set up action teams to address specific issues.

The PA team created a database of standard data categories enabling accurate prediction of standard assembly for new products, and therefore a basis for standard costing. Key staff were trained in work measurement and improvement techniques.

Projected multi-million-pound savings per annum were forecast to arise from a 30% staff reduction, a 24% increase in line capacity and (in one particular product area) a 75% improvement in productivity.