Case Study: Jigsaw and ACT work takes top prizes for innovation

gall+logoJigsaw was approached by Applied Component Technology (ACT) to support the launch of a totally new design lightweight aircraft galley cart. This new product had to be completed in just seven months. In addition to the timing challenges the product uses new materials which have not been previously used for such applications and ACTs development and manufacturing experience did not include Aerospace industry. The short development time, limited budget and resource constraints of ACT meant without external support there was no chance to deliver this accelerated development project. Jigsaw provided core resources which, together with ACT team members, formed an integrated, collocated project team. We provided Programme Management, launch, purchasing and quality support, as well as Production Management. The project called for immediate concept review, re-design to suit targets, cost base and employing lessons learnt from the automotive experience of both businesses. Key tools used in product design included DFMEA, QFD & APQP and to keep plant assembly capital cost and expenditure to a minimum, DFM techniques were deployed. The supply base was also revamped to bring in expertise from the Aerospace industries. The result of the teams work was that all technical and commercial targets were achieved within the seven months development programme. The product was successfully tested and launched at the Hamburg Air-show as required, while the work with the supply base delivered significantly reduced cost BOM (>30%) and despite introducing a high quality, fully traceable, ‘no-fault-forward’ automated production line to suit volumes of c. 60,000 p.a. and new presses for composite production, total capex was less held at than £500k.

The impact of this innovative work has been recognised with a number of awards.

EEF/Aldermore Future Manufacturing National Awards

  • Gold Prize – Smart Product Award

EEF Future Manufacturers Regional Awards

  • EEF NW Gold – Environmental Efficiency Award
  • EEF NW Gold – Smart Product Award
  • EEF NE Silver – Environmental Efficiency Award
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Service: Business ImprovementSupply Chain