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FIRST CASE STUDY

The Challenge

Their current operational setup up caused:

  • Constrained product flow and productivity

This transpired through:

  • Excessive transportation to fetch tooling & materials
  • Difficulties measuring KPI’s
  • Most importantly, excessive WIP

Case Study

Bespoke Stairlifts are a manufacturer of high quality stairlifts in Huddersfield with a strong philosophy that to be the best, anything other than the best isn’t an option.

The Solution

Stairlift production was:

  • Mapped and balanced with clearly defined sub-assembly lines to enhance product flow
  • A full-scale layout change was implemented which reduced transportation and encouraged natural communication
  • Performance was made visible through a visual performance dashboard

The Outcomes

The solutions implemented allowed for both output and productivity gains which are displayed in the following charts and figures.

Testimony

We recently worked with Fluere on our Lean Manufacturing implementation. Having been through this iteration a few times, the hands-on, no BS, adaptation to our culture was a refreshing change.


As expected in this type of project, we had our ups and downs, our missed targets and wrongly defined requirements, but we always got their in the end. Whilst we must have been a source of frustration at times, never once did they show this externally, always with a smile, and always with empathy. If you are about to engage in a Lean Project, add Fluere to your list.

Martin Crangle, Operations business partner, Bespoke stairlifts

Second CASE STUDY

Case Study

Debar is a leading manufacturer and supplier of high-quality bifold doors and hardware components.

The Challenge

  • The ability to rapidly adapt to customer needs is a priority for Debar
  • Productivity was hindered through excessive finished goods on hand. This was adopted to protect against variation in demand.
  • The overall goal was to achieve the above whilst increasing productivity and efficiency.

The Solution

To pilot a manufacturing cell for Debar’s cleats within assembly. Focusing on implementing 4 lean improvement techniques:

  • Single piece flow
  • Bottleneck management
  • Cellular manufacturing
  • Set-up reduction

The Outcomes

The Debar team and the pilot ‘proof of concept’ achieved some outstanding results by working smarter, NOT harder. The before and after graphs shown are not exaggerated in any way!

Testimony

Well what can I say apart from…..FANTASTIC
These guys have been with us here at Debar for only a few months, and what a transformation.


The team of Paul, Jake and Barney have been magnificent throughout our whole process. The improvements made have been really significant and our staff here at Debar have ALL welcomed the Fluere team and worked really well together. Well done guy’s and keep up the great work.

Richard Glasbey, Production Manager, Debar

Third CASE STUDY

Case Study

Platinum Stairlifts is an award winning stairlifts manufacturer based in Keighley, providing high quality custom and off the shelf products to a number of stockists internationally.

The Challenge

With demand increasing rapidly and ambitious growth targets, the company needed to increase productivity to ensure that product is always available from stock.

The challenge was to design and implement a new production line which could facilitate withdrawing from finished goods and maximise the output in the same facility with no additional resources.

The Solution

We conducted an assessment and mapping of Platinum’s production line to identify wasteful activities:

  • Flow interruptions
  • Handling methods
  • Transportation of all goods and people

We designed a new flow model by:

  • Redesigning the production layout
  • Creating guides, and providing training to reduce the movement of materials and people
  • Using dashboards to increase the visibility of production

The Value

The Platinum team achieved some outstanding results. The before and after graphs shown below are not exaggerated in any way!

Testimony

This is our first project with Fluere. The new production line they have designed is significantly easier to manage and has improved our productivity dramatically. Fluere listened to our needs attentively and worked with the team, involving them at every step. They have provided a holistic service, considered all areas of the production and provided us with the necessary tools to continuously improve and grow the business. We are extremely happy with their service and looking forward to continuing work with them.

Richard Morrison, Operations Director, Platinum Stairlifts

Fourth CASE STUDY

Case Study

Bifold Network, a leading door and window manufacturer in Sheffield, were experiencing significant sales growth and needed to keep pace in Operations.

Their current operational setup up caused:

  • Constrained product flow and productivity

This transpired through:

  • Excessive transportation to fetch tooling & materials
  • Difficulties measuring KPI’s
  • Most importantly, excessive WIP

The Challenge

With increasing reliance on key staff and growing demand in both the office and manufacturing environments, the company wished to identify opportunities to increase productivity to match demand.

The initial scope was to conduct an in-depth business review that identified the greatest improvement opportunities to improve productivity and support the sales growth.

The Solution

  • Interactive workshops, process observations and data analysis aided the business assessment.
  • This assessment formed a business improvement plan for each area.
  • Bottlenecks were also identified and quantified.
  • The findings yielded a categorised list of improvement areas, ranked by ease of implementation and impact to the business.

The Value

These achievements collectively demonstrate our commitment to continuous improvement and operational excellence.

Testimony

“Fluere have worked extremely well with our team, really getting to know and understand both the individual and business needs. The review and its recommendations have provided us with the foundations to drive serious growth into the business. We are now implementing these with Fluere and are already generating productivity improvements. Fluere have been instrumental in helping to grow the business and I look forward to continuing to work with them.

Allan Ensor, Director, Bifold Network