Dufaylite: creating a 400% increase in output
Project challenges
Dufaylite were facing a growing market with lots of opportunity but needed support in unlocking greater efficiency and productivity without impacting lead times.
Business challenge
Process Innovation
Growth & Scaling
Sector
SME
Manufacturing
Technology or capability
Process Design
Product Design
Collaborating with Dufaylite to improve efficiency and increase productivity
Dufaylite have manufactured recycled paper honeycomb since 1955 and are one of the leading sustainable packaging suppliers in Europe - their mission is to rid the world of polystyrene. Dufaylite innovates by using their design skills alongside their honeycomb products to deliver a sustainable product that has multiple uses across a variety of market sectors. MTC were originally tasked to deliver and implement a process improvement programme to increase the output from their factory in St Neots, which then led to further projects that showcases the strength of a long-term, collaborative partnership and the benefits it can bring to SMEs.
Discover more about their story below.
With the improvements in the project, we've seen a 400% increase in our output speed on the lamination line. It's quite clear what the benefits are there for us. Now we can process work faster, we can handle more work and we can really service this growing market.
Ashley Moscrop, Managing Director, Dufaylite
MTC's Solution
- Line walk and holistic understanding of Dufaylite's business
- Aligning manufacturing strategy with the sales strategy
- Value stream maps were created to identify the bottlenecks in the processes
- Research into key technologies
- Prototyping
- A future vision and a new optimised factory layout created
- Lean values and behaviours were embedded within the whole organisation
The Outcome
- 400% increase in output speed
- Increase in output of board from 300,000 linear metres per year to over 1 million
- Optimised factory layout, avoiding the need to relocate
- Specification created for future investment in technology including what to buy and when to invest
- Reduction in work in progress
- Reduction in production costs
- Workforce brought into the improvement programme
A lot of people ask us why we chose the MTC, obviously we had a need and we went to Coventry to visit the facility and look at the whole set up and what goes on there and to be honest it was mind blowing. And we felt that was the partner for us. We wanted people pushing innovation and looking to drive things forward.
Ashley Moscrop, Managing Director, Dufaylite
This long-standing relationship between MTC and Dufaylite is built on a foundation of trust, collaboration, and shared ambition. Through close partnership and continuous improvement, we've not only delivered measurable impact already but also paved the way for future projects in automation, artificial intelligence and other emerging technologies - ensuring Dufaylite remains at the forefront of innovation and equipped to meet their business objectives.
