In Business Together
Lean manufacturing puts profits in the frame for Plastex
Redditch-based fabricator Plastex has tripled its turnover and increased its weekly output by nearly 200% in just two years, after being introduced to the concept of ‘lean manufacturing’ at an 'In Business Together' seminar hosted by its systems supplier, WHS Halo System 10.
Taking the lean manufacturing philosophy of eliminating waste and inefficiency, Plastex has implemented a range of changes across the business, from production and installation right through to HR, delivering dramatic results, with 400 frames now being manufactured each week compared to 135 in 2004.
The company was first inspired to consider lean manufacturing at the ‘In Business Together’ seminar organised by WHS Halo System 10, as part of its unique fabricator support package. Faced with a changing market, Plastex seized the opportunity to improve its competitive advantage, as Managing Director Roger Hussell explains:
“In 2004, our customer base was evolving, with leads from the domestic market declining and more and more of our business coming from the commercial sector. As times became tougher, the lean manufacturing seminar highlighted just how crucial it was for us to review and improve our business practices if we were to survive.
“The first step on our journey to lean manufacturing was to video our shopfloor and it certainly helped to bring home just where our problems and inefficiencies lay. Led by our HR department and with real buy-in from our employees, we introduced a programme of continuous improvement that resulted in a number of important changes.
“We have improved the factory layout, invested heavily in new technology and introduced a new structure for our installations team, leading to increased productivity, a reduced inventory, improved working conditions and a boost in staff morale. On the HR side, we have introduced employee satisfaction surveys and personal development reviews and have also committed to Investors in People, as part of a strategy to improve our business efficiency by motivating our staff.”
Roger concludes: “Yes, the results have been incredible but it’s important to emphasise that lean manufacturing is a journey rather than a destination. It may sound like a cliché but we are now on a journey of continuous improvement, with several more changes in the pipeline that will help to measurably improve our business performance.”
Mike Stevenson, Sales and Marketing Director, Public Sector, for WHS Halo System 10, adds: “It can be difficult for fabricators to find the time to take a step back and really review how efficient their operations are but the experiences of Plastex show just how powerful lean manufacturing can be. With rising energy costs, a difficult domestic market and an increasingly competitive commercial arena, adopting lean manufacturing principles with the support of your systems supplier can make a real contribution to business survival.
“By offering regular seminars covering valuable topics like this as part of our In Business Together package, we are working hard to support our fabricators in a way that will help them to grow their business in the public sector.”
 For more information on any of the courses we run, please contact Pamela Fay on 0121 749 8209.
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