Renewables Process Control | Marchington Consulting

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

Process control – leading wind turbine blade manufacturer

Business

Owner:

Severely capacity constrained PE-owned renewables company

Objective:

Reduce warranty exposure and increase Right First Time Output

Results:

• 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

Approach

• 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