Red Line® Method Increase the efficiency of your manufacturing plants by up to 40%, within six months, without capital expenditure.
The Red Line® method has yielded improvements of this magnitude even in environments where Lean and/or Six Sigma have already been widely applied for many years, and can be run in parallel with existing improvement programmes.
Benefits achieved by applying the Red Line® method have included:
40%
Improvement in efficiency
50%
Increase in productivity
90%
Reduction in waste production
80% Reduction in product quality rejects
7 Point increase in profit margin percentage
Multi-million pound cost base reductions
These have led to vital improvements in:
Customer satisfaction
Market
share
Morale and job satisfaction
The Red Line® method was developed to address the shortcomings of other improvement methodologies and help businesses to deliver rapid, dramatic and sustainable performance improvement.
Click here for the key elements of the Red Line® method
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Proven Capability:
Food Industry Efficiency
Background:
- Increased competition from abroad and increasing energy prices were devastating profit margins
- Business needed to increase efficiency fast, without capital expenditure, to remain competitive.
Solutions:
- Rapid step change programme at one key factory increasing total throughput by 10% in 2 months
- Training and coaching of the staff across all 5 other sites, together with building a sustainable improvement process, leading to record breaking performances at every site.
£5 million of extra profit in 1st 12 months
Textile Factory Capacity
Background:
- “Every month, our existing customers request 15% more volume than we are able to supply them. Worse still, new customers that would represent a 10% increase in sales have to be turned away because we are unable to meet the extra demand.”
General Manager
Solutions:
- OEE improvement programme increased throughput of the facility by 17% in less than 2 months
- Training and coaching in continuous improvement skills and techniques enabled the local workforce to build an improvement programme and sustain the results achieved.
£1.1 million of extra profit in less than 2 #months
Global Beverage Company
30% improvement in productivity of a particular product group in 2 months, eliminating all need for co-packing of that product, saving over $1 million per year.
Global Tissue Manufacturer
Achieved a consistent improvement in speed of tissue converting lines of 30 – 40%, taking approximately 1 month per line to achieve.
Major Packaging Company
10-33% improvement in productivity and up to 90% reduction in waste across all high-priority areas, in two plants, in 6 months.
Major Brewing Company
Conducted assessments which discovered £12.5 million of opportunity to increase profitability through OEE and yield improvements in a single brewery.
Multi National Petrochemical Company
10% improvement in the overall output of an entire petrochemical facility in 10 weeks, resulting in an increase in profitability of €1million.
Global FMCG Business
Reduced the start-up learning curve of a complex manufacturing line from 4.5 months to 1 month, and increased the final production rate by 10%.
View the article ‘Driving success in continuous improvement’ - The Manufacturer Magazine
