How a US Electronics Subsidiary Became Market Leader in the UK

A company that made surface-mount printed circuit boards, (i.e. with the chips mounted on them), ranking second in the UK market, had ambitions to expand. The CEO had heard of my TYM approach from a supplier of base boards (see Case Study 2), and asked my opinion. 

Analysis and Findings

After a brief survey, I showed how, by changing the way they worked:

• They could make products faster. In just 1 day rather than the present 7 days,
• They could increase productivity by 100% in their present factory, and 
• They could make products 100% right first time (RFT).

Implementing these would slash costs, free up cash, and enhance customer service. Specifically, they would provide by far the best customer service in terms of delivery and quality.

TYM Program Implementation

The company formed a small team who worked with me on a ten-week TYM program. 

We identified the necessary steps, assigned responsibilities, and developed an implementation plan highlighting financial and business benefits. 

The board approved our plan. Over the next six months, I guided the team to realise these benefits.

Transformative Results

The company used specialist Japanese production lines to manufacture their boards. Their RFT score on these lines was zero. Not one board came off these lines right first time. They had an army of people at the end of each line reworking the boards manually before testing. 

I trained the team in my unique ‘Input Control’ root cause analysis, (part of my TYM program), and by using that improved their RFT score to 99%+. This transformed the business. 

While competitors still offered a ten-day delivery, my client offered five-day, with a premium three-day option. (They made all their boards in a day.) Business and profits soared.

They reallocated the re-workers on to other lines brought in to cope with the leap in demand. 

 Within a year, they became Market Leader in the UK, and the best performing subsidiary.

Compelling Conclusion

The key to success here was applying the right root cause analysis tool to boost line quality. That enabled them to achieve their lead time and productivity goals. 

Call to Action

Curious about how my TYM program can transform your business? Explore the other pages of this website.