Case Studies

Case Studies

Improved Syrup Yields

A blue-chip manufacturer complained that it was wasting syrup through its process, which was affecting its profitability.

A review of the process identified a number of improvement areas from the syrup room to the production line. An activities map was developed with the client’s team to involve and obtain their buy-in.

Simple six sigma graphs were also developed that enabled the teams in each focus area to trend their progress over time.

The results were fantastic with an increase in profitability of over £1,000,000.

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Facilities Management – Contract and Operational Reviews

An FM provider requested a review of a number of under-performing contracts with the objective of improving operational efficiencies and profitability.

Critical focus areas were defined and reviewed from the contracts through to the operational delivery. Several improvements were identified that not only improved the operational delivery within the contracts, but also optimised costs and increased revenues.

The overall results were cost efficiencies and improved revenues totalling in excess of £2,400,000.

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Increasing AD Gas Output through Lean Six Sigma

An anaerobic facility was generating on average 64% electrical output through its CHP’s and was seeking to improve performance.

A review of the following 3 areas was carried out – Input Materials, Process and Operator Training.

Through a robust review of the operation with the client’s team, the infeed material mix was optimised and a number of process parameters introduced that increased gate fee revenues, reduced downtime and increased electrical output to 90%.

Six Sigma control charts were used to effectively trend key process parameters, enabling a better control of the process.

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Repair & Rebuilding of Existing Screws – Saving £18,000

We repair and rebuild existing screws for a third of the cost of a new unit.

A major recycling company uses specially designed screw conveyors for conveying wet materials. These screw conveyors are constructed from 317L stainless steel materials, which are very expensive, and the cost of a new unit was £36,000.

We repaired and rebuilt the existing screws for half the cost of a new unit, saving £18,000 per unit. Typical repairs include resurfacing the shafts and rebuilding the worn flights, returning the equipment to its original specifications.

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Mixer Blade Rebuild Using Resistant Materials increases its lifespan by 150%.

An anaerobic digestion facility utilised specially designed mixers to feed waste into their process. The mixers are designed to mix waste and are in constant contact with glass and other abrasive materials.

The mixer heads are subjected to extreme temperature and abrasion. Working very closely with the customer, we rebuild the mixer heads using ultra abrasion resistant materials.

We not only reduced the cost of maintenance, but also increased the life of the mixer heads by 150% compared to the original design, saving circa £120k pa.

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Moulding Operation productivity improved by 60%

A moulding company was under pressure to increase production due to increased customer demand.

The company was looking to develop further mould tooling to meet demand. However, on reviewing their moulding processes it was found that the moulding cycle was excessively long due to poorly maintained mould tools and a moulding programme that was not optimised.

By improving the mould maintenance schedule, demoulding of the component and moulding programme it was possible to increase productivity by 60%, saving the company unnecessary tooling costs.

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Improved Quality Monitoring to reduce reject costs.

A European customer was suffering from a high level of quality failures, which resulted in large product recalls and costs.

By developing a Six Sigma quality monitoring programme we were able to trend and understand product variation. This enabled us to adjust and control the process to tight quality parameters reducing quality issues and associated costs, saving the client £85,000 pa.

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Plant breakdown support saving thousands of pounds.

A customer was facing an eminent plant shutdown due to equipment failure that would have brought the plant to a stop, causing disruption to its customers and reducing revenue.

We were able to manufacture and install the components required within a short timeframe that did not affect their operations and kept them producing during a busy period. This resulted in zero loss of revenue and high levels of customer confidence.

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Plant installation ahead of time and on budget

This project involved the installation of several modular sections of plant. We ensured the levels and alignment of the sections prior to fixing them into their final position. Some of the modular parts had to be modified on site by our fabrication team to allow them to be lifted and fixed safely. The project was completed ahead of time and within budget.

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Planned weekend tank installation

The scope for this work was to manufacture new storage silos that were to be installed during a weekend shutdown, to ensure normal start-up and operation on Monday morning. Our team fabricated the silos and installed them over a weekend, delivering the project to the client’s tight timescales and budget as planned.

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Planned shutdown and improvement works

We work with numerous heavy plant operators to ensure the success of their maintenance shutdown programmes. This project involved the installation of a new chimney and structural support. The work was carried out over the weekend and completed on time for a successful Monday start-up.

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We believe that all organisational change comes through people, hence our approach is a people focussed approach, based on practical solutions to deliver sustainable bottom line improvements.