Re-thinking operations

Office furniture manufacturer Flexiform saw growth exceeding supply, so engaged the MTC to help develop a scalable plan to service demand incrementally. The site was constrained and tentative plans had been explored to increase the operational footprint to accommodate additional plant. The key aim was to deliver operational capacity, balanced to demand, within the existing footprint.

The MTC proposed a plan to develop modern manufacturing methods, enhanced by proven technology, to improve effectiveness and efficiency. Working with the senior management team, the current state was mapped, issues were quantified and qualified, as well as the joined up relationships of the issues. The business was remapped to meet all key requirements, based upon data and practical considerations. Relevant technologies were identified to address issues and enhance manufacturing.

Flexiform now has a detailed map of the infrastructure and layout to link order receipts, project management, customer management and order fulfilment. With the MTC’s help, the senior management team developed a high level sequenced transformation plan that will achieve their operational capacity targets

Benefits include increased nominal capacity by 40%, plus a further 20% surge capacity, without increasing site footprint and reduced working week, from 24/7 to 24/5, while delivering the increase in output.

"I found the MTC invaluable in this process guiding us, educating us and keeping us true to our goals at all times. I would highly recommend all business leaders to take time out, engage with the MTC, and carry out a VSM exercise,” says Nick Hewitt, MD, Flexiform.