Company: Pharmaceutical Manufacturer - Scandinavia

Problem: Urgent need to reduce costs due to increased competition.

Solution: Implemented significant culture change to achieve relentless focus on cost and cost reduction through the deployment of Lean Manufacturing Methodologies.

Results Achieved: Achieved a 50% reduction in throughput days, 20% capacity increase and 20% efficiency improvements across Production, Packaging and Laboratories operations.

Company: Cosmetics Manufacturer - Ireland

Problem: Requirement to increase output by 15% through operating efficiency improvements

Solution: Using Overall Equipment Effectiveness (OEE) as a key performance measurement indicator, well proven methodologies such as "Quick Changeovers", "5S Workplace Organization", "Standardised Work Practice" and "Collaborative Work Teams" were implemented in an aggressive time frame.

Results Achieved: OEE increased by 10% which yielded a capacity increase in excess of 15% in a six month time period.

Company: Automotive Components Manufacturer - Ireland

Problem: As part of a large multinational, the Irish plant needed to achieve marked improvements in Product Yields, Delivery Precision and Labour Costs in order to compete with the companies expanding manufacturing base in Eastern Europe and Asia.

Solution: Following a detailed root and branch assessment of current operations, a detailed performance improvement plan with the required resources and structures was implemented. Working over a twelve month period, the various project teams drove significant change in the operations at the plant. Key changes included, re-layout of production lines to achieve cellular manufacturing, implementation of effective daily work cell meetings, deployment of lean/sigma tools and techniques and implementation of Key Performance Indicators to measure overall progress of the programme.

Results Achieved: Products Yields improved from 92 to 97%, Delivery Precision (meeting customer requirement delivery dates) improved from 93% range to 100% and Direct Labour Efficiency increased by 17%.