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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.