Case Study: Jigsaw & ACT Work Takes Top Prizes for Innovation

gall+logoJigsaw and ACT work takes top prizes for innovation

Problem statement:

  • Jigsaw 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 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.

What we did:

  • Jigsaw provided core resources which, together with ACT team members, formed an integrated, collocated project team.

How we did it:

  • 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:

  • The teams work 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 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:

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
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Service: Business ImprovementSupply Chain