Case Studies

DRIVING EFFICIENCY IN BUSINESS

APPLIED LEAN CONSULTING

These case studies are based on real-life customer issues and the work carried out by ALC.

CASE STUDY 1

Manufacturing facility

company confidential

Manufacturing

Staffs, UK

Agreed Objectives & Targets

Project KPI - reduce WIP by

Target Condition: 65% of customer orders completed within 2 days.

Movement of goods analysed and layout changed to reduce waste of motion and build up of WIP.

project results

WIP Actually Reduced by

CASE STUDY 2

Lean Warehousing

company confidential

Warehousing

South Coast, UK

Agreed Objectives & Targets

Reduce Stock Holding by

‘Measles’ chart showed picking hotspots. Most frequently picked items identified  and hotspots re-located to reduce waste of motion.

Stock holding analysed. Stock sorted into 3 categories & different rules applied . Safety Stock for each re-calculated in line with best practice.

project results

Throughput capacity increased by

-£ 0 ^,000

Reduction in Stock Holding

Martin Haswell

MD - Furniture by Martin

Working with Tim from ALC, we realised that Lean applied not just to production, but to our order receipt and design processes too. 18 months after Tim started with us our ‘On Time Delivery’ is almost at 100%, our quality rate is the highest ever, we’ve changed our layout so goods flow better through the factory and our production team are motivated and performing well. We’ve built a good relationship with ALC and look forward to their help and advice as the business grows.

Jon Mitchell

Managing Director - Marlow Ropes

I can’t stress enough the positive effect working with ALC has had on the business …from a number of angles and I feel sure there will be further work that we will want to engage them with.

Vicki Ward

Head of Global Shared Services - Experian plc

ALC helped us embed a continuous improvement culture… training the team in Lean methodology, and helping us embed a continuous improvement culture that will continue long after Tim’s contract ends. Tim has helped us lead the changes by understanding our requirements, developing a unique branding for the program and adapting the methodology to our finance processes.

Paul W. Rodwell

Group Finance SS Director – Experian plc

Tim’s knowledge, expertise and professional approach engaged management and staff at all levels to ensure the success of the EmPower programme for Experian’s Global Finance Shared Service Centres. ALC’s EmPower programme successfully established Lean awareness and understanding with all SSC team members globally. The programme successfully realised financial savings and significant efficiency benefits through process improvements and the elimination of low-value activities.

Teresa Stroud

Director - 3Ways Displays

Tim and the ALC team have helped us enormously over the past 6 months by: Mapping how we work and helping us identify where problems occur. Putting in place standard practices to reduce duplication of effort and waste. Organising our production to flow through the factory better. Holding our teams accountable to one another. We’ve benefitted from ALC’s experience in bringing structure and reporting disciplines into our business and we’re looking forward to working with them to implement a new MRP system and introduce metrics and performance management processes through the business over the coming 12 months.

Martin Haswell

MD - Furniture by Martin

Jon Mitchell

Managing Director - Marlow Ropes

I can’t stress enough the positive effect working with ALC has had on the business …from a number of angles and I feel sure there will be further work that we will want to engage them with.

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What Our Clients Are Saying

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Case Studies

DRIVING EFFICIENCY IN BUSINESS

APPLIED LEAN CONSULTING

CASE STUDY 1

Manufacturing facility

Agreed Objectives & Targets

Project KPI - reduce WIP by

project results

WIP Actually Reduced by

CASE STUDY 2

Lean Warehousing

Agreed Objectives & Targets

Reduce Stock Holding by

project results

Throughput capacity increased by

Reduction in Stock Holding

TESTIMONIALS

What Our Clients Are Saying

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