Sector 

Concrete Product Manufacturing 

The Challenge

The client was experiencing frequent production stoppages caused by a combination of mechanical, electrical, and operational issues. These interruptions reduced overall output and directly impacted profitability. The organisation needed to improve process reliability and efficiency to restore productivity and strengthen its competitive position. 

Our Approach 

The Centre for Competitiveness facilitated a structured improvement project to identify and address the root causes of downtime. A cross-functional team was established, including the Production Manager, Team Leader, operators, and administrative support. Using a data-driven methodology, downtime records were analysed and prioritised through Pareto analysis to focus on the most critical issues. Clear objectives and project goals were defined. Improvement measures were then implemented, supported by a robust Control Plan to sustain gains through routine monitoring and continuous review. 

The Outcome 

The project achieved a 5.5% improvement in production efficiency, representing a reduction in lost revenue of approximately £1.5 million per year. Beyond the measurable financial gain, the engagement improved cross-departmental collaboration, embedded structured problem-solving capability within the team, and established a culture of continuous improvement. 

Why It Matters 

This initiative demonstrates how a data-led, collaborative approach can deliver immediate performance improvements while building long-term capabilities. By focusing on efficiency and control, the organisation strengthened its competitiveness, aligning directly with CforC’s mission to help clients achieve sustainable operational excellence. 

Services Featured 

– Data Analytics – Continuous Improvement – Business Process Optimisation – Operational Excellence Facilitation