Applied Component Technology (ACT) case study

• Jigsaw Business Group 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 within only seven months to be launched at the Hamburg Air-show;
• In addition to the timing challenges the product used new materials which had not been previously used for such applications;
• ACTs development and manufacturing experience did not include the 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 Business Group provided core resources which, together with ACT team members, formed an integrated, collocated project team;
• The company 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.

• A proven track record with a team possessing real industry experience with empathy to support businesses accordingly, understanding individual pain points;
• Access to an impressive pool of STEM practitioners across the UK and further afield that are ready to be deployed;
• Unrivalled sector knowledge and technical expertise with an ability to look at things from a fresh perspective to deliver process driven solutions that help businesses to reduce costs, increase efficiencies and streamline business operations;
• A progressive company delivering premium level support services working in strict adherence with robust in-house best practices in accordance with all industry standards.

• The teamwork resulted in achieving all technical and commercial targets within the seven months development programme;
• The product was successfully tested and launched at the Hamburg Air-show as required;
• The work with the supply base delivered a significantly reduced cost BOM (>30%);
• 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 was recognised with a number of awards including:

EEF/Aldermore Future Manufacturing National Awards

• Gold Prize – Smart Product Awards

EEF Future Manufacturers Regional Awards

• EEF NW Gold – Environmental Efficiency Award
• EEF NW Gold – Smart Product Award
• EEF NE Silver – Environmental Efficiency Award.