SUCCESS STORY
€19M+ cost reduction
Transforming performance and culture through Lean
- A global electronics manufacturer improved value stream performance while developing & engaging the workforce
Outcomes
cost reduction
Operational improvements led to savings of €10M+
lean maturity
First site to successfully exit phase 3 of the company’s Lean programme
flagship site
Recognised as the organisation’s most advanced Lean site
cultural transformation
Leadership and team engagement embedded change that sticks
BACKGROUND
The client is a global manufacturer of consumer electronics and personal care products.
The company, which has factories in Europe, South America and Asia and subcontracts manufacturing to many other companies, had launched a 5-phase Lean-based manufacturing programme.
the challenge
The client’s goal was to build internal capability and improve value stream performance, with a view to scaling Lean principles across the broader supply chain. Achieving this required transforming manufacturing culture, systems, and processes, while also developing and engaging the workforce across multiple global sites to create a world-class operation.
SOLUTION
Henkan was engaged to support the programme from its inception, initially at a television assembly plant in Europe. Key steps included:
- Preparing the management team for the Lean journey through training and structural changes
- Applying Lean methodologies to a model value stream (‘Dock to Dock’)
- Delivering a 10-day leadership training programme for team and group leaders
- Using a train-the-trainer approach to scale learning and embed capability across the site
- Rolling out the approach beyond the model line to warehouses, offices and workshops
“We hired Henkan to support our organisation through our Lean journey. Our factory was confirmed as the most effective Lean site of all our factories implementing it”
Vice President
HNK105