Did you know that there are 22 different foam components needed to make up the boot of the Evoque and Discovery Sport at Halewood? That’s a combined total of 12 for the Evoque and 10 for the Discovery Sport, despite the fact that many of these parts are in fact very similar.
One of the key projects concentrated on reducing our material cost is Ignite which is now under Pillar 3 – delivered cost per car – as part of Refocus. It has a target saving of £2,500 per car.
That’s why colleagues in the Plant Launch team at Halewood have taken it upon themselves to find a new way of reducing the complexities across Halewood’s products and to give unnecessary parts, storage and labour costs the boot!
By making simple design modifications to the current foams, they are confident it will more than halve the total number of parts needed, taking them from 22 to 10, which would significantly drive down Halewood’s cost per unit by as much as 15 per cent.
Antony Cole, Project Ignite Analyst and Coordinator, who has been leading on this Ignite – now Refocus – project, said: “Having 22 different boot foams across two cars seems madness - especially when you look at all the different complexities at play.
“You have a high volume of parts which means more storage and labour to move them and then there’s the freight. When we looked at this, we discovered the shipping costs were nearly the same price as the average part cost as the supplier was based in Poland.
“With all the challenges our industry has faced, particularly over the last 12 months since the start of the pandemic, it’s more important than ever that we find new, smarter ways to work as efficiently and collaboratively as possible to keep cash in the business and create more value. This project is a great example of that and shows the importance of cross-functional working.”
Tom Cotterill, Degree Apprentice Plant Launch Quality Engineer, who has been working with Antony on the project, said: “We have been supported by teams across the plant, from purchasing all the way through to the CAD engineers, who have helped us create these new proposals, which will reduce the complexities involved and take the total number of boot foams down to 10 for both cars.
“Based on parts reductions alone, this will drive down costs per unit by 15 per cent, which doesn’t even take into account the labour savings from transporting these parts from various parts of the factory to the line or even freeing up storage in the stores.”
However the savings don’t stop there, as Tom added: “The team's design also reduces freight cost but among the options, they're already looking for more local capacity with our supplier partners.”
“As a plant, we need to find new, smarter ways to deliver what we do right first time, to the highest quality level, every day. This is key to delivering Refocus, the engine room of Jaguar Land Rover’s new Reimagine strategy, and helping to transform the business is our day job now. The boot foam project is a brilliant example of this in practice as it will significantly drive down Halewood’s cost per unit and help towards delivering this target reduction of £2500.”
Graham Miller, Senior Manager for Plant Launch at HalewoodJaguar Land Rover