Danu Solutions, an operational improvement consultancy based in the North-east of Scotland, has helped a manufacturer of offshore equipment reduce average build times from 60 days to 38 days - a 37% reduction - generating annual savings of £406,000 and a return on investment of 14:1.
The company, which produces bespoke equipment for the offshore industry, was facing significant capacity constraints and rising costs due to long build cycles. With an average project time of 12 weeks, the business was exploring expensive options such as expanding its facilities or outsourcing additional work.
Danu Solutions conducted a value stream mapping exercise to identify bottlenecks and non-value-adding activities across the production process. The team then implemented process optimisation measures, improved communication channels, and introduced Objectives and Key Results (OKRs) to strengthen team ownership, accountability and visibility.
"This project is a great example of what can be achieved with the right methodology and a focus on the fundamentals," said Diana Gormley from Danu Solutions. "Lean principles are not just for high-volume manufacturing, and significant improvements can be made without complex digital technology. Getting the basics right first delivered an exceptional return for our client."
In addition to the 37% reduction in build time, the project delivered a 26% cut in build costs, with improvements to capacity, throughput, cycle time and customer satisfaction.
Danu Solutions works with businesses across manufacturing and beyond to improve operational performance using a range of proven methodologies tailored to each client. More information is available at www.danusolutions.co.uk or by emailing info@danusolutions.co.uk.