Cost Reduction
"We would never been able to make these improvements without Fault Tree Modelling (Chartwell's best-in-class problem-solving technique)" - Spinning Production Leader
Industry
Industrial products - synthetic fibres
Support Level
4 consultants leading 12 different improvement teams over a one year project
Objective
Reduce costs in the order of millions of euros to return company to profitability
Results
- Labour efficiency increases of 30-40 % across multiple departments
- Major sources of waste reduced by up to 90 %
- Delivery times reduced 41 %
Why did this fibre manufacturer join forces with chartwell?
This German synthetic fibre manufacturer was under very high cost pressure; to return to profit, manufacturing costs needed to be reduced by several million euros per year. To achieve this goal, substantial productivity improvements needed to be made across all factory departments, so Chartwell were brought on board to accelerate the work of the local team in delivering those savings.
The second largest cost in yarn manufacturing is labour and initial analysis showed there was scope to improve labour efficiencies by 25-40 % across most departments.
Results of the project
Spinning:
- 26 % Labour efficiency improvement
- 20 % more output on bottlenecked product group
Site Wide:
- Labour efficiency increases of 30-40 % across other departments
- Major sources of waste reduced by up to 90 %
- Delivery times reduced 41 %
These improvements formed a solid basis for driving the turn-around of the business.
