The Problem
Fairline wanted to increase the output for two of its models, by reducing the takt time, in five production stages, to build a boat in three days.
Objectives
Establish a pilot boat line.
Introduce tools and train to improve control and visibility.
For the 45 Line reduce takt from 9 to 6 days, improving the pace, capacity and quality.
Improvement Activity
Assessed over 800 activities, then balanced these tasks to achieve an improved takt time.
Implemented visual management to demonstrate manpower requirements, visually display build progress versus the business plan and improve the frequency to monitor clocked build hours against budget.
Result
15% labour cost, per boat = £34,500 per boat saving.
Increased output from 22 boats to 27 boats p.a. at £530k per boat.
Revenue increase of x5 boats at £530k each = £2.6m for 2022.
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