Precision Manufacturing Ltd: 35% Efficiency Boost
How implementing lean manufacturing principles and real-time quality monitoring transformed operations and delivered £2.1M cost savings in the first year.
35%
EFFICIENCY INCREASE
67%
WASTE REDUCTION
£2.1M
ANNUAL SAVINGS
98%
QUALITY IMPROVEMENT
Client Overview
Company Precision Manufacturing Ltd
LocationBirmingham, UK
IndustryAutomotive Components
EquipmentCNC Machining Centers, Assembly Lines
Resources
The Challenge
Precision Manufacturing Ltd, a leading automotive component manufacturer, was facing critical operational challenges that were impacting their competitiveness and profitability.
Key Challenges:
High Waste Rates: Material waste was averaging 23% across all production lines, significantly impacting costs
Quality Issues: Inconsistent quality control was resulting in a 12% defect rate and customer complaints
Production Delays: Frequent bottlenecks were causing delivery delays, affecting customer relationships
Manual Processes: Heavy reliance on manual monitoring and reporting was creating inefficiencies
Financial Impact: These issues were collectively causing £2M in annual losses
The company needed a comprehensive transformation to remain competitive in the demanding automotive sector.
Our Approach
What We Were Tasked To Do
TJ Digital Systems was tasked with delivering a comprehensive digital transformation including:
Implement lean manufacturing principles across all production lines
Establish real-time quality monitoring and control systems
Develop and deliver comprehensive staff training programs
Create standardized processes and procedures
Install performance analytics and reporting dashboard
Achieve a minimum 25% efficiency improvement within 6 months
The project needed to be completed while maintaining full production capacity and ensuring zero disruption to existing customer commitments.
How We Delivered
Phase 1: Assessment & Planning (Month 1)
Conducted comprehensive value stream mapping across all production lines
Identified and prioritized improvement opportunities
Developed detailed implementation roadmap with stakeholder buy-in
Phase 2: Lean Implementation (Months 2-3)
Redesigned production layouts to eliminate waste and optimize flow
Implemented 5S methodology and visual management systems
Established pull-based production scheduling system
Phase 3: Quality Systems (Months 3-4)
Installed IoT sensors and real-time monitoring equipment
Developed custom quality control dashboards
Implemented statistical process control (SPC) methods
Phase 4: Training & Optimization (Months 5-6)
Delivered comprehensive lean manufacturing training to 120+ employees
Established continuous improvement culture and teams
Fine-tuned processes based on performance data
Results & Impact
35%
EFFICEINCY INCREASE
67%
WASTE REDUCTION
£2.1M
ANNUAL SAVINGS
98%
QUALITY IMPROVEMENT
Key Achievements
Reduced production cycle time from 8 hours to 5.2 hours
Implemented real-time quality monitoring system
Achieved 99.7% on-time delivery rate
Eliminated 3 major production bottlenecks
Reduced material waste by 67%
Improved employee satisfaction scores by 24%Impact Summary
The transformation delivered exceptional results that exceeded all initial targets:
Operational Excellence: Production efficiency increased by 35%, with cycle times reduced from 8 hours to 5.2 hours.
Quality Transformation: Defect rates dropped from 12% to 0.3%, while material waste was reduced by 67%.
"TJ Digital Systems transformed our operations completely. The ROI was evident within 3 months, and we continue to see improvements every quarter."
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