Industrial automation and controls group wanted to fund growth and acquisition plans by reducing waste and defects

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The business

We worked with a £9 billion global industrial automation and controls group in North America and Europe. We worked with the electronics divisions in several plants in USA, Mexico and UK making appliance controls, automation systems, semiconductor components, power supplies and measurement instruments.

Their needs

The client had aggressive growth and acquisition plans in order to achieve leadership in its chosen markets worldwide. To help realise these objectives it wanted to fund future acquisitions by reducing aggressively waste and defects from all key processes. The company became one of the first organisations to adopt Lean and Six Sigma techniques as the key operational excellence drivers across all existing sites and acquired businesses.

How we helped

We designed and executed the company's pioneering worldwide Lean and Six Sigma approach and deployment. Our consultants led numerous Kaizen workshops and 10 Six Sigma Black Belt waves as part of a range of multidivisional classes designed to share best practice across diverse divisions. All trainees were coached and mentored to deliver successful improvement projects.

Benefits achieved

Numerous space saving, scrap, rework and cycle time reduction projects were completed, leading to a strong continuous improvement delivery and cost reduction mentality in the management and workforce. During our involvement with the electronics division of the organisation, 40 projects were completed, delivering a 36-fold return on investment, on subjects including:

• Reduced surface mount component defects
• Reduced soldering defects
• Improved Overall Equipment Effectiveness
• Reduced assembly rework
• Reduced surface mount assembly cycle time
• Reduced cost of photo etching 

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