Exception EMS, one of Europe’s leading electronics outsourcers, has significantly improved its manufacturing performance, and customer satisfaction, following the adoption of lean manufacturing principles at its Calne, Wilshire facility.

As a result of the new manufacturing methodology at Exception, the level of customer returns have been reduced by 25 per cent, work in progress (WIP) has been reduced by £250,000 in some instances and zero defect quality delivery has now reached between 97 and 100 per cent. This dramatic improvement in business performance has been achieved with fewer staff – enabling Exception to dispense with expensive temporary staff, as well as halving the factory space needed to manufacture finished goods.

Richard Brighton, managing director of Exception EMS, said: “While the principles of lean manufacturing are not new, their adoption into UK electronics engineering is still in its infancy. Understanding the theory of best practice is one thing, but introducing it into a UK facility is an altogether different challenge. We have worked closely with specialist manufacturing consultancy Spitfire, which has helped us implement some powerful visual management systems at our Calne plant.”

Marc Sylvester of Spitfire said: “The senior management team at Exception wanted to bring about radical change to a business that was facing rising costs and competitive pressures from both UK-based and overseas rivals. By introducing tried and tested communications tools – such as TAKT and business boards – we have really empowered the engineering teams to take responsibility for their own performance. And customers are delighted with the turnaround.”

The new approach has forged closer links with customers and has even involved members of the Exception team touring clients’ premises to gain a better understanding of where the products end up.

With a change culture now firmly embedded at Exception’s Calne facility, the business is now spreading the lean philosophy across all of its manufacturing operations, creating cells for each of its customers. 

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For further information please contact St. John White or Dermot O’Flynn at Prova PR on 01926 776 900.