Turnover doubled through lean programme

Posted on 23 Nov 2012 by The Manufacturer

Wetherby-based inspirepac doubled its turnover to £24m in four years thanks to using lean teachniques.

inspirepac, a manufacturer of printed corrugated packaging used the Manufacturing Advisory Service (MAS) help structure and guide progress with in the implementation of lean.

Using the commonly praised Japanese business methodology has increased efficiency, removed bottlenecks and improved output at inspirepac’s Sandbeck Lane plant.

These improvements freed up capacity for a major sales drive which saw annual turnover rockets from £11m in 2008 to £24m this year.

Martin Brown, plant director and Peter Holden, continuous improvement manager at inspirepac
Martin Brown, plant director said that the assistance of MAS was pivotal in achieving this success.

“We had tried to embark on lean a few months before,” he explained.  “But it didn’t quite work out as we didn’t have the complete buy-in of all the staff.”

The impartial and experienced perspective MAS was able to bring to the implementation of lean techniques gave “a more holistic and strategic view of what we were doing,” said Mr Brown.

MAS undertook an initial review of the inspirepac business to identify opportunities for improvement and the acceleration of business strategy.

The government service then trained inspirepac staff in the lean leadership techniques and advised throughout the implementation of the lean programme.

“This had the desired effect in securing the complete buy-in of the staff,” said Brown. “Original equipment effectiveness is up by 50% and the flow of communication – starting in the offices at the point of order – has improved dramatically.”

The process improvements and rise in turnover gained through inspirepacs lean initiative have helped justify the case for more investment in capital equipment too. Recently the company bought a six colour in-line rotary die-cut Göpfert for £3.8m.

inspirepac, which is part of the Logson Group, employs 125 people at its Wetherby factory. It is now engaging with MAS to share its own improvement journey with peers through a series of best practice visits.

About MAS

MAS, is funded by the Department for Business, Innovation and Skills (BIS). It offers free and subsidized service focused on achieving growth in British manufacturing SMEs.

MAS has developed a range of services, tools and techniques to help shape and improve business strategy, new product introduction, waste reduction and supply chain operations.

Companies can take advantage of a free MAS review to identify priority areas for improvement.

For further information, please visit www.mymas.org or follow us at @mas_works.