Case Studies
Production Industrialisation
Reduction in piece price and increase in production volume on a large range of cast metal, injection molded, and electronic parts for a European client.
Client wished to take European production volume of 100 units per week to 2000 per month. With supply routes identified and implemented in the Far East, and a full supplier audit roadmap carried out, OHB helped to implement both the required cost-down (avg. 17% per part) and the increased production ramp-up within the required time frame. This was achieved whilst still keeping to RFT and OTD KPIs set by the client.
Factory Development & Production Launch
Client needing presence within emerging markets to reduce costs.
Our client needed a way to ensure they could deliver product into North America without the significant oncost of being based there.
OHB helped the client to launch a facility within South America to support local supply to their North American customers, and successfully ramped up Production to target volumes, whilst helping the client navigate production delays due to the impact of continued worldwide supply chain disruption.
Efficiency Improvements
Increased efficiency across an Asian based automotive production line for a top-end American customer.
Over a 6 month period, the efficiency of the line rose from 93% to 98.4% with a 12% reduction in labour, through the implementation of Poke Yoke and Lean Manufacturing techniques.
In line with this, OHB helped to implement SPC controls across the production line, and used core tools to help the PPM score across the line reduce from 500 to 73.
Audit Readiness
Helped CN based client reach and maintain ISO9001 accreditation.
Within 4 months, OHB carried out an audit across client site and implemented corrective and preventative actions to ensure that the plant was audit ready for Western customer visits. This included amendments to the client's QMS to ensure that they conformed to all necessary requirements.
When brought in after 12 months, certification had been gained, and 4 client visits had been reported as being completed with an audit pass.
Factory Layout
OHB worked with a Hong Kong based client to provide planning and support with a move into a new factory.
Client was provided with full floor layout, jig and fixture requirements to help Poke Yoke processes, and were able to improve output by 23%. This went in line with an ability to identify and implement new fixtures due to an increase in available floorspace. This improved automation and increase in error-proof manufacturing led to a reduction in customer complaints by 11%.
