Develop Consulting significantly improved a UK lens manufacturer’s quality control and efficiency.
Our team was tasked with reviewing and then improving the client’s approach to identifying and solving quality defects, and improving the process flow.
Through interrogation of the clients existing quality data, we observed the that the glass manufacturing side of the business was only achieving a 72% Right First Time (RFT) throughput, with a scrap rate of 17%.
With the business struggling to engage and retain new resource, it was identified that by increasing the RFT, the requirement for additional resource could be significantly reduced.
The glass manufacturing department struggled to maintain a FIFO process, relying on one individual to move material between processes, with batches of lenses often then becoming late, resulting in lower levels of quality when trying to catch back.
Using a lean skills matrix, Develop Consulting assessed the Manufacturing Engineering Team and observed a lack of capability for structured Problem Solving.
Develop Consulting were asked to review and then improve their approach to identifying and solving quality defects, and to improve the process flow.
We coached and mentored the production and engineering teams through: