WMG's help in factory adjustments leads to 10% increased productivity on important automotive line

With the automotive sector continuing to look for cost efficiencies, Barkley Plastics was determined to streamline its assembly processes so they could speed up production and reduce operator usage.

This focused on a specific line that supplies high running parts that require additional sub-assembly operations for JLR and BMW – worth roughly 25% of its total £7m turnover.

However, Barkley Plastics was struggling to find the time to instigate this exercise and also wanted to avoid the cost of reorganising the shopfloor without any guarantee of success.

The Solution
WMG introduced the firm to advanced process optimisation methods by using a combination of 3D simulation modelling software and proven Six Sigma techniques.

This clearly showed how the new layout would deliver potential improvements to cycle time, operator usage and a reduction in waste, giving the production team a clear view of the benefits they could achieve by moving the line.

Once the decision was made, Barkley Plastics was given continued support during the implementation of the new processes.

The Impact
Changing the layout of the factory floor has delivered a 10% productivity improvement on this high-volume line, reducing the number of operators on the three parts by 15% – meaning that additional labour could be utilised elsewhere.

In addition, WMG support has also introduced a number of new methods of working that has improved the flow of packaging and additional sub-assemblies, whilst also speeding up operations significantly.

WMG work with companies large and small at every stage of their innovation journey. If you manufacture in the UK, our experts can work with you to update processes, make new products, or explore new and more profitable markets and business models.

Contact: 
WMG, University of Warwick, Coventry, CV4 7AL, United Kingdom
TE:: +44 (0)24 765 24871
www.warwick.ac.uk/fac/sci/wmg/business