SUCCESS STORY
Transformation to Lean yields cost base reduction of more than €10m
- A global manufacturer of consumer electronic products, with factories in Europe, South America and Asia, and many other companies subcontracted to manufacture products.
our impact
This was a long-term project requiring broad expertise and the ability to bring the client’s team along with us. As a result of our work throughout the project, the factory in question has been confirmed as the most advanced Lean site amongst all the customer’s factories implementing Lean.
Moreover, substantial cost savings led to a reduction in the cost base of more than €10m.
the Business challenge
Our Approach
Henkan was engaged throughout as the lead consultants at a television assembly plant in Hungary
We started by preparing the management team for the Lean journey, including training for essential awareness of, and need for, Lean methodologies
Finally the model line was selected
We facilitated the full application of Lean to the model line, including production of current and future state maps from which a kaizen plan was produced. Kaizen Events were then applied to the line to reduce waste
We reviewed the organisational structure and altered it to align with Lean application requirements. This included the creation of a team leader, group leader and area managers
The techniques implemented on the model line were rolled out to the remainder of the factory, including the inbound and outbound warehouse, offices and workshops.
Paul from Henkan is energetic, compassionate and straightforward and has the ability to both coach and deliver on improvements. He is an expert in many fields and he is able to transfer his knowledge to others in a very professional way. He is very creative and can come up with unusual ideas, also considering the business needs. His personality, way of working and recommendations were well accepted by the whole organisation.