Case Study
From Departmental Bottlenecks to Balanced Flow
Client Type: Regulated Manufacturer
Engagement Length: 52 Weeks
Primary Challenge: Inconsistent production flow and labour imbalance across a major assembly department
Outcome: Stable production flow, improved quality and £2.6M annual savings
The Challenge
Production flow across a major assembly department was inconsistent and unstable. Shift‑to‑shift throughput varied significantly, quality defects were emerging from rushed work on certain derivatives, and operators reported uneven workloads. Leadership requested a full redesign of the department’s operating model to stabilise flow, improve quality, and increase throughput.
A comprehensive operational diagnostic identified significant workload imbalances, derivative-driven bottlenecks and variation in operator performance across both shifts.
Detailed time and motion studies, assembly sequence analysis and workload balancing activities confirmed that production capacity was being constrained by uneven labour utilisation and process instability rather than resource availability.
Diagnostic Insight (4 Weeks)
Using the diagnostic findings, a future-state production workflow was designed to rebalance workloads, improve labour utilisation and create a more stable manufacturing environment. The solution focused on optimising assembly sequences, reducing operational bottlenecks and establishing a more consistent flow of work across both shifts.
Solution Developed (28 Weeks)
Following completion of the diagnostic and planning phase, the redesigned operating model was deployed across both shifts using a phased implementation approach.
Updated standardised work, revised operator instructions, workload balancing, and structured stakeholder engagement ensured a smooth transition with minimal disruption to production.
The implementation successfully stabilised flow, reduced variation, and established a more predictable operating environment.
Implementation (16 Weeks)
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The redesign delivered significant operational improvements:
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Throughput increased by approximately 20%
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Labour requirement reduced by 13 operators per shift without compromising quality
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Quality improved through balanced workloads and reduced rushed work
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Shift-to-shift variation significantly reduced through standardised work
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Production flow stabilised across a large multi-shift operation
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These outcomes created a more predictable, stable, and efficient production environment.
Business Impact
Operational Impact
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Annual Savings: £2,600,000
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Total Project Cost: £1,200,000
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Payback period: <5 Months