The company operates 3 production sites, employing approximately 1800 people. Manufacturing is partially automated however there is still a significant reliance on manual labour
To remain competitive, our client needed to ensure their sites were operating according to ‘LEAN’ principles and achieving ‘best in class’ levels of productivity

• Optimise manning levels across all sites and production lines
• Assess, quantify and reduce current levels of waste
• Carry out LEAN assessments across sites to identify further opportunities for improvement

Our approach followed a two-stage process.

Stage 1: Assessment

• The assessment included a detailed analysis of all production lines, including manning levels, positions and product flow. Syngroup carried out detailed line observations to understand how labour was deployed and utilised.
• We ran workshops involving line operators to better understand the challenges they were facing, including poor design of layout and ergonomics which was impacting their productivity

Stage 2: Recommendation and Implementation

• Our detailed studies led to a number of recommendations, including changes to layout and ergonomics. These changes together with the introduction of LEAN principles enabled certain positions to be amalgamated.
• Recommendations were initially trialled to ensure they were workable in practice.
• All recommended actions were successfully implemented

• LEAN
• Machine Studies
• Manning Optimisation
• Layout Optimisation