Manufacturing company in Dublin


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The Challenge.

  • This manufacturing company has a production workshop manufacturing parts on a number of CNC machines. These parts are then used in the assembly department.
  • The company predominantly works on Day shift, 5 days per week.
  • Machine efficiency levels were low in the workshop which resulted in the company needing to subcontract the manufacture of parts to avoid delays in product build in Assembly

A Collaborative Solution.

  • Working with Production and with Process Engineering, we first set up a PIT process to monitor and visualise the results in the Workshop.
  • OEE2 was selected as the key performance indicator on the line. It was clear that an opportunity existed to improve the Line OEE2 results.
  • An A3/DMAIC problem solving project was started with the team. Results were measured and the baseline OEE2 was measured before the improvement program began.
  • We worked with the operators and with Manufacturing engineering to identify the main losses. The main loss was associated with the time taken to changeover the machines from 1 product to another.
  • The team were trained in SMED techniques and then we started work in analysing and reducing the changeover time. It was discovered that a lot of machine downtime was caused by manual deburring and final touching up of finished parts.
  • This work was moved to a dedicated Finishing Operator to enable all CNC machines to start producing the next parts as quickly as possible. Progress was monitored daily at the PIT meetings.

Impact and Results.

  • Production Productivity was improved by over 100% in the first 4 months and production volumes increased to reduce the need for subcontracting.
  • Savings of more than €250k pa were realised by the team. Capability was built within the team to enable them to do further problem solving, and a new target was agreed to improve OEE2 in the department by a further 20% in the following months.


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