Manufacturing, West Midlands
A family-owned fabricator losing £40k a month on rework
The MD knew quality costs were high but couldn't pinpoint where. We embedded an analyst in the production line for two weeks, tracked every reject and traced root causes to three specific machine settings and one supplier's inconsistent raw material.
We redesigned the incoming inspection protocol, renegotiated the supplier contract with penalty clauses, and retrained two shift supervisors on statistical process control.
Rework costs dropped 72% within four months. Annual saving: £346,000.
The engagement lasted nine weeks. Our fee was recovered in the first 30 days of improved yield.