Flow in a High Mix Organization

Much of the lean literature is focused on the automotive industry. Simple flow models are easy to understand, but are difficult to relate to a high mix environment with a rapid rate of new product introduction. The presentation aims to share the successes in lean implementation together with the learning Boots Manufacturing have gained along the way. Key themes in the presentation are:

• The impact of demand amplification and the development of production cycles that reflect sales, enabling better service, but also have provided a more level load in production improving manufacturing efficiency.
• Speeding up the downstream flow through improvements in the quality release process, identifying the key enablers to achieve this.
• The introduction of pull systems within the factory to improve control of work in progress and reduce waiting times.

The Boots Company plc is the UKs leading health & beauty retailer and one of the best known names in the UK.  The company employs around 60,000 people, has over 150 years of health & beauty expertise, develop and sells own branded goods as well as other world famous products.  Own branded goods are also sold in 10 countries.

Boots Manufacturing is part of the Boots Company plc. A wide range of healthcare, beauty and personal care products are manufactured at the site in Nottingham, England alongside factories in France and Germany. The factory in Nottingham employs 1300 people and produces liquids and creams, including medicines, mouthwash, skincare creams and lotions, hair wax and bathing products. Monthly production output is approximately 20 million units.

Mark Pyrah, Senior Lean Coach

Mark graduated in Mechanical Engineering in 1987, became chartered in 1991 and has spent his working life in Manufacturing. His first exposure to lean came in the 1990s whilst working in the bearing industry. He led several plant reorganizations to move from traditional process layouts to flow lines and cells. Mark joined Boots Manufacturing in 2001 in the Business Improvement department, working initially in the tablet factory and latterly in beauty and personal care. During the last five years he has implemented many lean initiatives including improved flow, level scheduling, vendor managed replenishment, pull systems, Kaizen Blitz, TPM, SMED. Mark has learned through hands on experience – both success and failure. He joined the Cardiff University MSc in Lean Operations in September 2004 and is currently undertaking my dissertation on the topic “Developing Effective Pull Systems in a High Mix FMCG Environment”.