The client is one of the leading train manufacturers, maintainers and train refurbishers in the world; employing 31,500 people worldwide with 23,800 in Europe.
The client was awarded the contract to refurbish the complete District Line 78 stock totalling 65 X 6 car units.
The client was encountering concerns delivering the required units on time to the customer, which was leading to high levels of liquated damages. On a required takt time of a 12 hour line move, the company was averaging a cycle time in excess of 28 hours to move the line.
Project 7 deployed a two phased approach to support the throughput. Firstly Project 7 trained leading methods engineers and production team leaders in 5 basic lean tools: 5s, Visualisation, 7 Wastes, Yamazumi and Kaizen. Following on from this class room training, Project 7 led the team through an on the job training program, which applied the classroom training in a real life situation.
- Line move time reduced from 28 hours to 11 hours. 61% reduction.
- Headcount reduction of 14 operators through waste elimination. 10% Reduction
- A total of £1,600,000 savings identified and implemented.
- ROI of 9 : 1 agreed
- Material cost reduction of £100,000 per unit set identified.
- 55% increase in lean manufacturing tools understanding.