>€4m margin gain from client team solving warranty issues

Process control – leading wind turbine blade manufacturer



Severely capacity constrained PE-owned renewables company


Reduce warranty exposure and increase Right First Time Output


•  Right First Time Output increased by 25% in 3 months

•  Polyester resin yield loss reduced from 28% to 8%

•  Bottom line value >€4m p.a. in NW Europe before global roll out


•  Intensive on the job coaching for a multi-disciplinary team, using our proprietary problem solving approach

•  Build variable tree for resin, glass fibre and vacuum (>30 variables)

•  Understand internal and external drivers of loss, where and when fault occurs through forensics

•  Re-design the process to be semi-automatic using “hole in one” approach

•  Engage suppliers successfully to resolve hidden variation in raw material variables

Use project as rallying flag to launch a global change programme