E&I Engineering

Optimising Factory Output by Re-Thinking Scheduling Process

E&I Engineering

Founded in 1987, E&I Engineering manufactures bespoke Electrical Switchgear (E&I Engineering Ltd) and Busbar Trunking Systems (Powerbar Ltd) for the building services sector. There is also a manufacturing facility in the United Arab Emirates (UAE) to service the Middle East region, while the company has opened a facility in the USA to service the US market. Due to the significant growth in business, E&I saw that the current project management and production scheduling systems were too manual and cumbersome to allow for live and accurate information to be available. A significant overhaul was needed.


Process Mapping was used to understand the end-to-end process, and to help identify different categories of projects/changes required in order to work towards a future state. A lead time profile by operation was identified for each category of project. In addition:

  • Online visual management was used to communicate and manage the process;¬†to measure, display and act on data daily in order to highlight progress and issues.
  • Heijunka (level loading) techniques were used to develop¬†scheduling process.
  • The Lean Principle of Pull System was applied to develop a backward scheduling process.
  • Daily PIT meetings were introduced to review performance to plan.


Throughput30%+ increase
Productivity20%+ improvement


A fully functional scheduling process.

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