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Delivering Operational Excellence and Improved Business Performance

New Factory
Start Up

Factory

Major Carbon Fibre manufacturing factory – UK 

Lopaz was engaged by a major UK High Performance Automotive manufacturer to support the development of their new Carbon Fibre manufacturing facility in Yorkshire. The key deliverable was to establish world class processes and operating systems for production of their new carbon fibre monocoque.

This was an extensive piece of work covering several key work streams from establishing the factory to installations of all process and ancillary equipment.

Factory design – For all Processes and Staff areas (offices)

Factory Fit Out – representing client at all Project meetings with the site installation management.

Equipment specification – Working with the Technical Director and Manufacturing Engineers to specify all process equipment along with detailed analysis for process capability and evaluation and selection criteria. Also working closely with the Commercial team.

Process design & Layouts – Designing all layouts for a a 5 year plan whilst managing an external CAD recourses to details these. These changed many times - several iterations.

Material Handling – Identifying whether manual or automated handling systems were to employed, evaluation of suppliers and solutions.

5 Year Capital plan – pull together based on factory / process design

Manufacturing Systems – Review the opportunity for use of MES from various sources and liaise with IT dept. to provision for this within the factory.

Operations System – Working with the newly appointed Plant Director to establish best practice systems for:

Maintenance – TPM, OEE, PPM, PPS etc
Production – Std Work, Shift Patterns, Skills, Manning (RTO analysis), 5S,cycle times etc
Logistics – Kanban, racking, call systems, trollies etc

Production Control – NOT yet established
Quality – CMM definition, CTQ, CTS. Quality Plan
Visual management – based on SQCDP

Manage EH&S specialists (third party) - Ensure the new factory was compliant in all respects of EH&S legislation.

Interface with Builders and Fit out team – Support regular (weekly) meetings with the Builders and Fit out team, having specified utility requirements to support the processes and factory.

Achievements:
New factory design approved to support a 5 year investment plan
All utilities and services identified
5 Year Capital plan identified
Process equipment defined with clear specifications  

© Lopaz Consulting Ltd. 2019 | Company No: 07317696