Manufacturing
Operations Excellence
Rebuilding the production plan for a mid-size manufacturer
Client
Hartwell Components
+38%
throughput in nine months
−21%
unplanned downtime
9 months
Engagement length
Project details
Client
Hartwell Components
Industry
Manufacturing
Service
Operations Excellence
Duration
9 months
A precision parts maker was missing delivery dates despite running three shifts. We rebuilt planning around real capacity and gave every line a daily target it could hit.
01
The challenge
Hartwell’s order book had doubled in two years, but output had not kept up. Planning lived in spreadsheets, changeovers ate whole shifts and supervisors spent their mornings firefighting instead of running the line.
02
Our approach
We spent two weeks on the floor mapping every product flow and changeover. Together with the plant team we built a simple capacity model, reset the weekly planning rhythm and introduced a 15-minute daily line huddle with three numbers on one board.
03
The results
Throughput up 38% with the same headcount
Unplanned downtime cut by 21%
On-time delivery rose from 71% to 94%
Planning time reduced from two days to half a day each week
For the first time in years we plan the week on Monday and actually hit it on Friday.
Daniel Hartwell
COO, Hartwell Components
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