Case studies

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Iron Ore

Mining is notoriously driven by volume targets, which in the Lean Operating System, can present ongoing challenges (due to the waste of over-production).

From pit to port, from drill to blast, GENEO has helped mining organisations to transform their processes and empower people to own the required change.

Our experience in Operations, Maintenance, Engineering, Supply and Human Resources has helped organisations like yours to adapt to a lean environment.

Client

Iron Ore

Scope

Introduce Lean Operating System to reduce operating cost

Diagnostic

4 week diagnostic from pit to port

Actions

  • Introduce buffer management across the value chain
  • Introduce production control to comply with principle of pull and synchronise mines with demand
  • Introduce TPM on haulage fleet to move from ‘utilisation’ to ‘effectiveness’
  • Introduce Information Centres to drive shift, daily, weekly interactions

Results

  • Fleet haulage reduced by 6%
  • Fuel costs reduced
  • Auxiliary equipment reduced across the value chain
  • Load cycle time reduced by 19% on average across mines
  • 89% engagement of employees in Continuous Improvement and problem solving

1st Tier Automotive – Case Study 1

1st Tier Automotive Lean Deployment

 

GENEO’s expertise in the automotive industry is extensive, thanks to the ex-Toyota employees in our team.

Through hands-on experience transforming projects into successes, our lean consultants are able to bring about change and reduced costs along the full line, including Paint, Manufacturing, Weld, Logistics, Engineering, Assembly.

Client

1st Tier Automotive

Scope

100 day recovery to prevent closure

Diagnostic

Week-long diagnostic with VSM focus

Actions

  • Immediate containment loops in quality process. End of line inspection augmented to capture issues and feedback to point of cause
  • Introduction of Info Centres to drive accountability
  • Short interval control on key lines to drive delivery focus
  • CRASH team to resolve problems rapidly and inject countermeasures into design and ME
  • Logistics intervention to overcome ERP generated haemorrhaging of inventory and WIP
  • Standardised Work for all processes on production lines to contain issues

Results

  • 7 of 10 balance scorecard targets reached in the 100 days
  • Customer retained and agreed to ongoing, longer term action plan
  • Line shortages eliminated using pull systems and market places
  • Profitable in third month of engagement

A UK based 3rd Party Maintenance and Repair Organisation

Reduction in Aviation Maintenance Turnover Times

 

Our Lean Consultation team has experience throughout the MRO industry across three continents.

From planning and engineering to maintenance on the line and repair in the hangar; improving the value stream has been achieved by reviewing the flow from top to bottom – including reducing inventory and material holdings, shortening turnaround times for assets, and better margins.

Client

A UK based 3rd Party Maintenance and Repair Organisation

Scope

Reduce aircraft turnaround times by 40% to meet growing customer demand for the restricted hangar footprint.

Diagnostic

  • Performed rapid diagnostic of scheduling, engineering and production processes
  • Direct observations of current check turnarounds

Actions

  • Performed QCO activities on all aspects of the check turnaround streams: trades, planning, material flow
  • Reorganised planning process to meet a RFT target on maintenance adherence
  • Introduced visual management and short interval control
  • Redefined roles of check managers across shifts

Results

  • An average annual reduction of 47% across the fleet releasing capacity for further customer demand
  • 32% increase in schedule adherence resulting in a 9% reduction in deferred defects
  • On Time In Full delivery into service improved by 23%

Manufacturer of high value products for mining

Our TPM programme has helped to reduce maintenance and operating costs for clients by up to 25 percent.

GENEO’s approach helps clients to reduce their maintenance burden through our rationalisation programme and turn planned maintenance activities into effective work standards for use in the workplace.

Client

Manufacturer of high value products for mining

Scope

Introduce Total Productive Maintenance to lift line performance in order to consolidate European operations. A unique opportunity to insource from Asia.

Diagnostic

  • Full review of maintenance practices and performance
  • Identify bottlenecks on 3 key production lines

Actions

  • Introduce OEE (manual data collection and calc) on identified bottlenecks with uptime on secondaries and tertiaries
  • Re-allocation of Planned Maintenance activities to drive operator maintenance
  • Introduce line-side stock for key parts and consumables
  • Early Equipment Management introduced for next generation equipment ready for delivery in 6 month horizon
  • Quick Change Over activities on line start-ups, tool changes and product changeovers

Results

  • Shift requirements reduced from 5 to 4
  • 4 products in-sourced from Asia improving quality and unit cost
  • TPM programme deployed across the group

1st Tier Automotive – Case Study 2

1st Tier Automotive Lean Logistics

 

Logistics are often an afterthought for many businesses, whereas the Lean methodology for success has shown that putting Logistics first in the value system can often transform a company.

Putting Lean Logistical Practices in place can help to improve line stops, inventory turns, materials management, and work-in-progress.

Our Lean consultants have repeatedly helped companies move from just-in-case inventory management to dynamic pull systems with levelled production and Kanban systems suited to their environment.

Client

1st Tier Automotive

Scope

Eliminate chronic material shortages for a key sequencing plant with turnover in excess of £1bn

Diagnostic

  • Materials assessment
  • Logistics diagnostic

Actions

  • Introduce Lean logistics provider to optimise routes across Europe
  • Establish supermarket and line-side delivery based on pull, level scheduling of product, and the de-activation of ERP launches
  • Plan per part mapping to improve bill of material accuracy
  • Elimination of high bay storage

Results

  • £12m one-off inventory saving
  • Line stoppages due to material supply reduced to zero
  • Line delivery to OTIF improved by 46%
  • 100% of material controlled by pull systems within an 8 week production horizon

Trialled and perfected transformation method

GENEO has developed a unique deployment model to accelerate your Lean transformation. Contact us to understand how GENEO can help boost your Lean transformation.
Read which industries our Lean Consultants have helped

Continual success stories

GENEO continues to grow its business based on the great results we achieve with our clients. No engagement is ever the same, each one presenting a unique set of challenges for our team, challenges that we heartily accept and overcome jointly with our clients.
Read our Lean consulting case studies

Leadership training

We are training leaders to make a difference by leading Lean with the appropriate behaviours to make a significant difference to their Continuous Improvement culture. It’s all about people and we are all about people.
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Reduce maintenance turnaround time by 50%!
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  • Analyze the hour-by-hour compliance to plan with the associated losses incurred throughout the turnaround event.
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