Driving OEM Production Forward Through Strategic Teamwork

A manufacturing partnership with a global OEM evolves, as increased demand for genset solutions prompts a major upgrade to production capabilities.

Eminox has been manufacturing genset units for a world-leading supplier of industrial and marine applications for around 15 years. In response to growing market demand for our power generation solutions, it was evident that the original production cell footprint required a significant upgrade to meet this need. 

Clear scope and a shared objective

A team was created to define a clear scope for repurposing the weld cell, whilst managing the continuous flow of parts from supporting functions. This included kitting, lineside storage, labelling, packing, and leak testing, so the whole value stream could deliver higher volume production. The new cell was conceived as a better lit, spacious environment with a single piece flow and a pull system. Dedicated kitting and packing areas were built into the concept to create a linear production line.

Teamwork central to the solution

The success of this project embodied Eminox’s values around the importance and power of teamwork. A workshop involving a cross-functional team focused on practical, health and safety and quality topics, which resulted in several ideas for improvements. A detailed time study and line balance activity confirmed that the proposed layout could meet the new demand.

Smart engineering for streamlined flow

The line balance activity highlighted key stations where pinch points had occurred. Several ergonomic and process enhancements were made thanks to valuable input from operatives. For example, more efficient leak testing equipment was introduced and bespoke lifting solutions were developed to aid product handling. This included the fabrication of a new height adjustable rotating welding station to improve safety, quality and process time for the welding team. Supporting functions were also updated, to ensure a constant flow of parts, and a reduction in waste.

Another example is the introduction of a rotating welding fixture, which allows operatives to weld in the down hand position, for more consistent welds with less physical strain. 

The cell now benefits from an open plan, streamlined layout, with better lighting that provides a brighter and cleaner working environment. 

Our OEM customer, the Director of Supply Network Resiliency, said: 

“I wanted to take a moment to compliment the Eminox team on your performance. This is a fantastic accomplishment and improvement, and we are very satisfied with your results.”

(L-R) Anthony Wyman, Dave Clarke, Daniel Taylor, Gavin Batty, Chris Barwell, Danny Booth and Craig Grimbleby.

(Not pictured) Mick Dixon, John Babington, Dave Fretwell, Paul Banwell and Damian Kata were all instrumental to the success of the project.

Demonstrating our values through collaboration

Overall, this project clearly demonstrated how Eminox’s company values translate into real world results when teams come together around a shared challenge. Individual engagement and focused collaboration across welding, engineering and supporting functions were essential in transforming the production cell into a high performing operation. 

Greg Kent, Operations Director, Eminox, said:

“Delivering a 100% increase in genset volume for our customer in just six months demonstrates the strength and capability of our dedicated team. Working together effectively meant they solved a complex challenge, whilst prioritising safety, quality and customer trust.”

Thanks to everyone involved and for working together to make this project a real success!