Case Studies 

PPL Biomechanics www.pplbiomechanics.com 

PPL Biomechanics – Custom Products Foot Orthotics Optimisation Project 
Situation 
Pembroke Alliance were engaged by PPL Biomechanics to improve Custom Products foot orthotics optimisation through lean techniques and other business models. 
OEE was used as key metric for performance measurement. 
PPL Biomechanics is constrained by use of a small floor space c. 6000 sq. ft. so optimisation is critical for overall business performance. Covid-19 restrictions has increased this constraint. 
 
Objectives 
Improve Optimisation through; 
5S – using improved training of 5S principles 
Standardisation work practices 
Staff engagement – improved communication and training 
Accountability – better understanding of metrics and owning results 
OEE Improvement – additional 40 units per week = €200k per annum opportunity in sales. 
Key Challenges 
Implementing a Change Management Culture 
Overcoming staff scepticism 
Creating meaningful KPI’s 
Gaining consistency across all 5 production areas 
Covid-19 impact on day-to-day operations 
Key Changes 
Better Employee Engagement - empowerment 
Employee understanding of their part in overall performance of the business 
Better organised work environment 
Improved Scheduling of work to Takt and Cycle Times 
Improved lead-times 
 
 
Results and benefits so far (Dec-20) 
The following opportunities and benefits were identified and achieved during the initial project: 
Significant improvement of 20% in OEE (based on available run time) – 
No additional headcount required to achieve above. 
Improved visual metrics so everyone at every level is working off the same KPIs. 
Business now thinking more strategically as well as operationally on how to continue to improve. 
Reduced lead-times, improved capacity, reduced waste. 
Sales Growth (based on Q4 2020 rolling 12 mths) = +20%  
Ongoing 2021 
Further improvement in CD – CadCam Devices with purchase of new software system to be installed in Feb 2021. 
Continued emphasis of level loading the factory should lead to further OEE improvements. 
New business opportunities Post Brexit – both in Traded and Custom products for export. 
2nd Lean Plus project to be undertaken – Feb-2021. 

PPL Biomechanics www.pplbiomechanics.com 

PPL Biomechanics – Custom Products Foot Orthotics Optimisation Project 
Situation 
Pembroke Alliance were engaged by PPL Biomechanics to improve Custom Products foot orthotics optimisation through lean techniques and other business models. 
OEE was used as key metric for performance measurement. 
PPL Biomechanics is constrained by use of a small floor space c. 6000 sq. ft. so optimisation is critical for overall business performance. Covid-19 restrictions has increased this constraint. 
 
Objectives 
Improve Optimisation through; 
5S – Cleaner factory / operating environment 
Standardisation work practices 
Staff engagement – improved communication and training 
Accountability – better understanding of metrics and owning results 
OEE Improvement – additional 40 units per week = €200k per annum opportunity in sales. 
Key Challenges 
Implementing a Change Management Culture 
Overcoming staff scepticism 
Creating meaningful KPI’s 
Gaining consistency across all 5 production areas 
Covid-19 impact on day-to-day operations 
Key Changes 
Better Employee Engagement - empowerment 
Employee understanding of their part in overall performance of the business 
Cleaner, better organised work environment 
Improved Scheduling of work to Takt and Cycle Times 
Improved lead-times 
 
 
Results and benefits so far (Dec-20) 
The following opportunities and benefits were identified and achieved during the initial project: 
Significant improvement of 20% in OEE (based on available run time) – 
No additional headcount required to achieve above. 
Improved visual metrics so everyone at every level working of same KPI’s 
Business now thinking more strategically as well as operationally on how to continue to improve. 
Reduced lead-times, improved capacity, reduced waste 
Sales Growth (based on Q4 2020 rolling 12 mths) = +20% (€200k T/O)! 
Ongoing 2021 
Further improvement in CD – CadCam Devices with purchase of NEW Voxelcare system to be installed in Feb 2021. 
Continued emphasis of level loading the factory should lead to further OEE improvements. 
New business opportunities Post Brexit – both in Traded and Custom products for export. 
2nd Lean Plus project to be undertaken – Feb-2021. 
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