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Knott (UK) Ltd provide braking system solutions to their customers. A wide range of KNOTT cam, wedge, hydraulic servo, hydraulic simplex, wet multi disc and disc calliper brakes are designed and manufactured for applications within the niche construction, agricultural, industrial, military and truck markets. Additionally, they manufacture and supply spread lever brakes, overrun couplings, jockey wheels and brake cables for the industrial trailer market. Knott (UK) Ltd offer a turnkey design and development brake solution service for new customers and applications, ensuring the delivery of optimum braking performance. Their customer base includes many prestigious original equipment manufacturers and tier one axle, transmission and hydraulic motor manufacturers. A subsidiary of Knott GmbH, based in Bavaria, Knott (UK) Ltd utilise their flexible worldwide group manufacturing facilities to provide high quality components and assemblies that are then supplied from their Burton-upon-Trent site at highly competitive prices. Contact: Grenville
Luxton
VOLEX WIRING SYSTEMS
Volex Wiring Systems Division is the Group's centre of excellence for the design and manufacture of vehicle electrical power and signal distribution systems. Their plant in Leigh, near Manchester, employs 700 in the design and manufacture of wiring harnesses, electronic controls and fuseboxes, with additional manufacturing capacity overseas in the Czech Republic and Slovakia. Focused on the off-highway equipment and commercial vehicle markets, Volex Wiring Systems work with their customers to provide a full service supply - undertaking the design of the vehicle electrical system from concept using the Division's extensive engineering and CAD resource right through to production in customer specific manufacturing cells. The QS and ISO 9000 accreditation of the Division is supported with in-process full electrical testing to assure product conformance. Volex Wiring Systems Division is a major supplier to CNH, Hanomag, Terex, JCB, Cummins Engine Co and Komatsu UK - who voted Volex "Supplier of the Year 2000". Contact: Paul
Chapman
A
COMPANY THAT KNOWS
Against this backdrop the challenge of the Operations Team is to determine how VWS can continue to apply and sustain lean manufacturing techniques in this incredibly dynamic environment. In recent years the company has made significant steps forward. The introduction of lean concepts has enabled huge benefits to be achieved. The full potential of these developments has not been realised, due largely to the demands of managing the accelerating rate of product change. Having completed a project with the SMMT Industry Forum Master Class this problem was put into perspective. Having successfully re-designed the cells for a range of bus chassis harnesses the product was replaced in its entirety by a design change within six months. Recognising the rapid rate of change VWS has been forced to develop and adapt its approach to lean manufacturing in the following manner:
2. To focus on each new product introduction as an opportunity to establish a step change in performance. During each new project the process flows and cell designs are challenged to determine how best practices can be adopted. The purpose being to ensure that capital projects and implementation plans incorporate process improvement initiatives in addition to the essential equipment to support the new products.
4. To train production employees in recognition of waste and basic housekeeping techniques. Specific training programmes have been developed to encourage increased ownership of the manufacturing cell designs and to target kaizen activities within the workplace. The object of the training is to better equip the employees to make improvements in their working practices.
Volex
Wiring Systems
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Meet
the
KNOTT
(UK) LTD
Volex
Group plc is one of the world's largest producers of electrical, electronic
and fibre optic cable assemblies with 29 manufacturing plants and
10,000 employees worldwide. Their customers include the world's
leading manufacturers of computers, telecommunication systems, automotive,
aerospace and industrial products.
In
the year 2000 Volex Wiring Systems (VWS) introduced over 1,800 new
products into production. The high rate of change reflects the
Division's success in establishing its position as a supplier of highly
complex wiring systems. Ten years ago VWS's product range was focused
on the high volume passenger car market. Success in the construction,
agricultural and commercial vehicle sectors has led to dramatic changes
in batch sizes, lead times and design changes.
1.
To recognise that lean manufacturing provides a "tool-kit"
of ideas and concepts that can be applied and developed in a manner
to suit the product range in question. The high variety within the
current product range demands a higher degree of creativity when applying
solutions to ensure that they are both appropriate but also sustainable.
3.
To focus process improvements at a macro (product group) level rather
than a micro (part number) level. To counteract the high rate of product
change improvements are designed to be transferable across a series
of part numbers within a product range. 
Whilst
each of these developments is simple in its concept it provides a
direction and focus for the ongoing adoption of lean manufacturing
techniques and best practices within VWS.
