Client: Bombardier

Location: Crewe, UK

Services: Business Improvement, Supply Chain, Training & Development

Project Summary

A multinational manufacturer of business jets and rail – Bombardier – commissioned Jigsaw Business Group to conduct a value stream review, verify data, recommend and implement improvements to its 2-shift Bogey re-manufacturing operation at its Crewe manufacturing plant. From the review process the company made a series of recommendations that significantly enhanced the re-manufacturing process.

The Challenge

  • Under new management, Bombardier required an analysis of its rail rolling-stock bogeys being re-manufactured at its Crewe facilities; 
  • The company wanted to engage with a specialist that would be able to analyse the operation and recommend improvements to significantly improve efficiencies of the remanufacturing operations. 

Why Jigsaw Business Group

  • A proven track record with a team possessing real industry experience with empathy to support businesses accordingly understanding individual pain points;
  • 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 Solution

  • Jigsaw Business Group produced value stream maps – a lean-management method for analysing the current and future design state – for the bogey strip and rebuild operations;
  • The company further conducted time studies across both shifts observing the following: 
    • Different methods/times on each shift;
    • Batch building with significant bottlenecks;
    • No performance monitoring – no production smoothing;
    • Significant losses in waiting time;
    • Poor workflow and housekeeping.

Key Achievements

Jigsaw Business Group successfully:

  • Implemented Standard Operating Procedures (SOP) on both shifts;
  • Implemented second turnover station and other layout changes to eliminate bottlenecks;
  • Implemented QA schedule to remove waiting time;
  • Produced method to produce all bogeys on a single shift with 18 headcounts (initial headcount across 2 shifts = 39).