Case Study
From Full Automation to Targeted Process Improvement
Client Type: Regulated Manufacturer
Engagement Length: 8 Weeks
Primary Challenge: Ramping Demand and Inconsistent operator performance
Outcome: 211% Throughput Increase and Deferred £250k-£500k Automation Investment
The Challenge
The client faced increasing customer demand, inconsistent throughput, delivery pressures and growing overtime costs. Management believed full automation would be required to achieve future capacity requirements.
Operators reported process variation, handling difficulties, ergonomic concerns and frequent interruptions that affected productivity and consistency.
The assessment revealed that capacity was not constrained by labour availability or a lack of automation. Process instability, operator variation and inefficient material handling were limiting performance.
Significant gains could be achieved through targeted semi-automation and workflow optimisation rather than a full automation programme.
Diagnostic Insight
Rather than pursuing a full automation programme, a targeted semi-automation strategy was developed to remove the identified process constraints. The solution focused on improving operator consistency, reducing handling inefficiencies and strengthening process control through ergonomic aids, semi-automated production equipment, standardised work instructions, simplified defect criteria and updated maintenance controls.
Solution Developed
The programme combined workflow optimisation, ergonomic redesign, semi-automated equipment, operator training and updated quality standards. New fixtures and equipment were developed using DFMA and DfAM principles to ensure sustainability.
Implementation (8 Weeks)
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Throughput increased by 211%
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Cycle time reduced by 32.8 seconds per unit
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Additional production capacity created without increasing headcount
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Operator variation reduced by 78%
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Rework reduced through clearer defect standards
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Unplanned set‑ups virtually eliminated
Business Impact
Operational Impact
Direct financial Return
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£39,000 Annual Savings
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Payback period: 6 Months
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Deferred £250-500k Automation Investment