Westbury Operational Excellence

Client outcomes

Transformations that speak for themselves.

Every engagement is different. The results are consistent.

SMED PROCESS IMPROVEMENT

Northwest Precision Manufacturer

50% reduction on critical asset process

"Westbury didn't just identify the problems — they embedded with our team and drove the change from the inside."

— Managing Director

The challenge

A precision engineering firm was failing OTD due to long lead times and inconsistent changeovers. Production bottlenecks were costing an estimated 160 hours per year in lost capacity.

Our approach

We deployed a Lean transformation programme — mapping the full process & identifying 3 critical areas, asset capability, standard work and total productive maintenance. By combining all 3 areas to improve on, changeovers were quicker and standard throughout operations, critical parts repaired and spares shelved. Finally empowering ownership to the operators to perform daily TPM's for safety and performance.

Outcomes

  • 50% reduction in changeovers
  • Change over time from 70 to 35 minutes
  • £202k capacity valued recovered
  • Team trained in TPM & standard work principles for self-sustaining improvement
PROCESS IMPROVEMENT

Engineering SME, Yorkshire

51% process improvement in finishing department

"Their DMAIC approach along with coaching & mentoring our workforce was an eye opener, the operators have fully bought into this improvement"

— Operations Director

The challenge

In process finishing department creating bottleneck at final phase of production & affecting OTD.

Our approach

We conducted a full process walk-through, collected OEE data and a full health check of the machines. We followed the science and manufacturer's guidebook to establish optimised running of consumables, confirmed & published new standard recipes for all parts, re-trained operators and established a controlled production plan.

Outcomes

  • Lead times drastically reduced from 6 weeks to 2 weeks
  • Average run time reduce from 91 to 51 minutes
  • An extra 20k parts processed per month
  • Team ownership & accountability
QUALITY IMPROVEMENT

Engineering SME, Midlands

£40k annual savings from internal defects & remakes

"A genuine turnaround partner. They brought structure, pace and the expertise we needed at exactly the right moment."

— Quality Director

The challenge

In process quality issues were causing lead times to increase thus affecting OTD to the customer.

Our approach

DMAIC team including operators, team leaders & managers to walk through the process and brainstorm over a fishbone diagram. Made engineering repairs and adjustments to mandrel supports to eliminate variation of the product. Re-trained operators to best practice. Created a visual catalogue to identify quality issues and how to solve them.

Outcomes

  • Lead times reduced from 3 weeks to 12 days
  • Simplified training to allow more operators and flexibility on the process
  • Single piece flow achieved throughout the process
  • On-going support provided with coaching other managers on how to use the correct tools

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Whether you're facing a crisis or planning for growth, we have the experience to help you move fast and get it right.