Bergstrom: Case Study
Production Line Efficiencies Push Up Productivity
Introduction
Ystrad Mynach-based Bergstrom, is the largest designer and manufacturer of HVAC (Heating, Ventilating and Air Conditioning) systems to the off-highway and niche automotive vehicle industry.
Its clients include JCB, Caterpillar, Case New Holland, McCormick Tractors and also Lotus Cars.
Over the last few years the company has enjoyed substantial growth, with turnover reaching £22 million.
Although the company HQ is in Illinois USA, the South Wales plant is fully integrated with all processes from design and manufacture to sales and marketing based on site.
The company employs 155 staff; and around 35 per cent of its output is exported to Europe, the USA and Japan.
Why work with Manufacturing Advisory Service Wales?
In order to maintain its competitive edge in the marketplace, Bergstrom needed to improve productivity on its assembly lines.
“No company can afford to stand still, and we knew that an innovative approach was needed to enhance production processes,” explained manufacturing manager Sean Jones. “We contacted MAS Wales because the organisation’s consultants are not simply desk-based engineers, they have hands-on experience and consequently are able to deliver results.”
MAS Wales carried out a work study/waste analysis that gave Bergstrom a new balance for its assembly line.
Benefits of working with MAS & FDM-UK
Thanks to specialist expertise from FDM-UK Bergstrom increased its productivity by 40 per cent per person per day on its highest volume production line.
In addition to this raised output, MAS Wales enabled the company to increase capacity within the plant by helping it to make more effective use of its production lines.
The company is now able to tender for a broader range of contracts.
Increased efficiency on its existing production lines means that the extra goods can be manufactured at the present plant, without the need for relocation.
“Our work with MAS Wales has been so successful that we are now working together on another project.” confirmed Sean Jones. “We are very happy, as not only have we improved productivity, but we have successfully standardised production so quality and delivery has improved but without raising costs.”
Paul Byard, MAS Wales chief executive added:
“The key advantage of our consultants FDM-UK is that they are practitioners, so they understand the client’s needs and can provide workable solutions, as the outcome with Bergstrom proves.”
