Colin Copeland
Industrial ceramics manufacturing facility with robotic handling equipment
Client Case Studies

Real Results from the Shop Floor

Every engagement is measured by the value it delivers. Here are five examples of what that looks like in practice.

5

Studies

5

Sectors

£m+

Value delivered

Each case study below represents a real client engagement — different sectors, different challenges, the same disciplined approach to sustainable improvement.

Building Materials01

Flow Analysis Unlocks 13% Output Gain at Automated Brick Plant

A major brick manufacturer had invested heavily in new automated plant but was failing to meet budgeted output targets. Despite sustained engineering effort to reduce unplanned downtime, performance remained below expectation. A fresh, data-driven perspective was needed to identify the real constraints.

13%

increase in weekly output

Identified

true constraint — not downtime

Balanced

throughput across automated line

Reduced

starvation and stoppage losses

Flow AnalysisBottleneck EliminationWaste EliminationThroughput ImprovementCycle Time Reduction
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print02

SMED Programme Reduces Changeover Time by 40%

A specialist print business was constrained by lengthy changeovers that limited the number of product runs achievable per shift. A 40% reduction in changeover time enabled more frequent changes to meet short customer lead times and released additional line capacity.

52% → 71%

OEE improvement

£1.2m

capacity recovered (avoided capex)

40%

reduction in changeover time

employees

engaged in the process

OEESMEDTPMChangeover Reduction
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Aerospace03

Value Stream Mapping Drives Seven Improvement Projects Across Aerospace Supply Chain

A precision engineering manufacturer supplying the aerospace sector engaged CIF to map its Specialised Products value stream and build a structured improvement roadmap. Current and future state maps identified seven key projects, spanning product flow, planning, cell layouts, drawing control and workshop 6S — with a whole-factory layout concept developed to support continued growth.

7

structured improvement projects delivered

Faster

quoting response to aerospace customers

Improved

factory flow and cell layout

Growth

factory layout concept developed

Value Stream MappingAerospace6SLayoutFlow ImprovementSupply Chain
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Ceramics04

Transformation Improves Internal Quality by c3% in Ceramics Production

A major ceramics manufacturer was losing 8% of output to defects, eroding margin and delivery confidence. A structured Masterclass quality improvement programme identified root causes across all manufacturing processes and delivered c3% reduction in defect rate, which equated to c£2.44m company additional sales value over a 3 year period.

3%

reduction in defect rate

£2.44m

company evaluated benefits from scrap and rework

92% →95%

quality yield

Sustained

over three consecutive years

MasterclassRoot Cause AnalysisWaste EliminationStandardisationDefect Reduction
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Machinery & Equipment05

CIF Manufacturing Assessment Prioritises Improvements and Restores Delivery Performance

A machine manufacturer experiencing manufacturing capacity and growth constraints commissioned an assessment to identify priority issues. Using process mapping, QCD data analysis and activity sampling, a structured diagnostic report gave the leadership team the clarity to act — and improved monthly delivery performance followed.

Objective

independent view of priority issues

3 methods

mapping, QCD analysis and activity sampling

Diagnostic

report with prioritised recommendations

Delivery

monthly delivery performance achieved

Manufacturing AssessmentProcess MappingQCD AnalysisActivity SamplingDelivery Improvement
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