Successfully reported this slideshow.
We use your LinkedIn profile and activity data to personalize ads and to show you more relevant ads. You can change your ad preferences anytime.
 
BRIAN STANDBRIDGE UK OPERATIONS & EMEA SOURCING DIRECTOR IDEAL STANDARD INTERNATIONAL OPPORTUNITIES WITH ROBOTICS AND FACT...
Introduction  <ul><ul><li>Privately owned company employing over 10,500 </li></ul></ul><ul><ul><li>European HQ in Brussels...
Recently – the site has developed from a multi level casting facility to single level (2000). It has seen a progressive re...
History in the UK <ul><ul><li>1999 / 2000  Acquisition of Armitage Shanks in the UK  and Ceramica Dolomite (Italy) </li></...
 
Key Strategy for the Plants Evolution <ul><ul><li>Conversion to 100% pressure casting facility (UK & Italy) </li></ul></ul...
Key Strategic aims  … <ul><ul><li>Equipment installed in quest of strategy of:- </li></ul></ul><ul><ul><li>Highest product...
2000 2002 2001 2003 2004 2005 2006 2007 2009 2008 Pre 2000 Dorst & Porvair basin pressure casting machines 16 x glaze appl...
KEY ACHIEVEMENTS – BEFORE / AFTER TRADITIONAL  PLANT CONVERTED AUTOMATED PLANT RoSPA Gold medal Winners Reduction of recor...
KEY ACHIEVEMENTS – BEFORE / AFTER TRADITIONAL  PLANT CONVERTED AUTOMATED PLANT Typically 30% labour needed Engineering  ba...
16,250 Co 2 /annum Rugeley plant Traditional plant Asian Sourced Product Saving
SUMMARY <ul><li>WE BELIEVE … </li></ul><ul><li>Made in Staffordshire </li></ul><ul><li>Highest productivity and reliabilit...
 
Upcoming SlideShare
Loading in …5
×

Brian Standbridge, Ideal Standard - Opportunities with Robotics and Factory Automation

1,150 views

Published on

Published in: Business, Technology
  • Be the first to comment

  • Be the first to like this

Brian Standbridge, Ideal Standard - Opportunities with Robotics and Factory Automation

  1. 2. BRIAN STANDBRIDGE UK OPERATIONS & EMEA SOURCING DIRECTOR IDEAL STANDARD INTERNATIONAL OPPORTUNITIES WITH ROBOTICS AND FACTORY AUTOMATION 14 OCTOBER 2010
  2. 3. Introduction <ul><ul><li>Privately owned company employing over 10,500 </li></ul></ul><ul><ul><li>European HQ in Brussels </li></ul></ul><ul><ul><li>Operations in Europe, Middle East, Africa and Latin Americas </li></ul></ul><ul><ul><li>Brands </li></ul></ul><ul><ul><li>UK - Main manufacturing warehouse site at Armitage, Rugeley </li></ul></ul><ul><ul><li>- Employing over 50% of 1,200 UK employees </li></ul></ul>
  3. 4. Recently – the site has developed from a multi level casting facility to single level (2000). It has seen a progressive removal of all plaster moulds (the last of which was removed in 2004). Combined with the introduction of automation.
  4. 5. History in the UK <ul><ul><li>1999 / 2000 Acquisition of Armitage Shanks in the UK and Ceramica Dolomite (Italy) </li></ul></ul><ul><ul><li>2000 – to date Consolidation of ‘general purpose ’ sites </li></ul></ul><ul><ul><li>£7.5m manufacturing investment and </li></ul></ul><ul><ul><li>£2.5m warehouse investment </li></ul></ul><ul><ul><li>Focused Commitment of American owners to plant in Armitage village (Rugeley) on producing bulk of UK sales in a single plant. </li></ul></ul>
  5. 7. Key Strategy for the Plants Evolution <ul><ul><li>Conversion to 100% pressure casting facility (UK & Italy) </li></ul></ul><ul><ul><li>Installation of 3 generation of pressure casting equipment based on technology available </li></ul></ul><ul><ul><li>1. Pressure Cast – manual demoulding/finishing </li></ul></ul><ul><ul><li>2. Pressure Cast – robot demoulding / manual finishing </li></ul></ul><ul><ul><li>3. Pressure Cast – 100% robot demould / finishing </li></ul></ul><ul><ul><li>24x7 Plant – 350 days / year </li></ul></ul><ul><ul><li>Balanced flow – all machines integrated in flowline production facility with transportation elimination and 100% robotic glaze application </li></ul></ul><ul><ul><li>Installation of best practise recycling equipment for glaze usage. </li></ul></ul>
  6. 8. Key Strategic aims … <ul><ul><li>Equipment installed in quest of strategy of:- </li></ul></ul><ul><ul><li>Highest productivity plant in ISI </li></ul></ul><ul><ul><li>Lowest material usage – highest yield and zero waste </li></ul></ul><ul><ul><li>Tighter process control – quality and yield </li></ul></ul><ul><ul><li>Produced locally, sold locally, supported locally </li></ul></ul><ul><ul><li>Lowest carbon footprint (UK manufactured) </li></ul></ul><ul><ul><li>Cost position towards goal of «  CHINA + SHIPPING  » </li></ul></ul>
  7. 9. 2000 2002 2001 2003 2004 2005 2006 2007 2009 2008 Pre 2000 Dorst & Porvair basin pressure casting machines 16 x glaze application robots Bead milling Glaze preparation unit 1 x Porvair 4 part bowl Pressure casting machine 1 x Porvair 4 part bowl Pressure casting machine 1 x Porvair 5 part bowl Pressure casting machine Xtract glaze reclamation unit SACMI automated tank cell 1 x Porvair COBR & WHB Pressure casting machine 1 x Porvair FFC basin & ped Pressure casting machine 492 451 395 378 323 303 306 300 297 286 Headcount reduction ( redeployment/natural wastage / voluntary) Capacity growth from 1,35m to 1,9m pcs (+40%) Introduction of new technology Continuous Introduction of Footprint
  8. 10. KEY ACHIEVEMENTS – BEFORE / AFTER TRADITIONAL PLANT CONVERTED AUTOMATED PLANT RoSPA Gold medal Winners Reduction of recordable incidents Over -90% Now Single Digit per year Safety Culture Safety Record Poor Claims Culture Customer Lead Times long (2 weeks) with backlog variation Manufacturing leads times from 5 days to below 36 hours Inventory Reduction – 28% Mould changed daily Next day delivery introduced Variability of Quality Yields and Conformance of products 15% higher FPY Highest FPY in Group Return on Sales halved (Warranty )
  9. 11. KEY ACHIEVEMENTS – BEFORE / AFTER TRADITIONAL PLANT CONVERTED AUTOMATED PLANT Typically 30% labour needed Engineering based plant with Ceramic knowledge Manually-intensive plant. Craft style skills Mixed technologies Batch produced Traceability difficult Standard flow technology (UK/Italian produced) Continuous 24x7 operations Barcoded 100% Tranxfer production Real time fully integrated SAP Energy-intensive (drying) Material intensive (Moulds, clay, waste) Energy consumption units/1000’s Gas = 62% average Electricity = 58% average Mould life > 50k Materials = 75% Zero waste philosophy
  10. 12. 16,250 Co 2 /annum Rugeley plant Traditional plant Asian Sourced Product Saving
  11. 13. SUMMARY <ul><li>WE BELIEVE … </li></ul><ul><li>Made in Staffordshire </li></ul><ul><li>Highest productivity and reliability </li></ul><ul><li>Pride in quality and lifetime guaranteed! </li></ul><ul><li>Loyal (15 year average) and skilled workforce who are keen and adaptable to change. </li></ul><ul><li>Can be used in a large company ‘balance’ exchange rates </li></ul><ul><li>No 25% labour inflation </li></ul><ul><li>No 40% transportation inflation </li></ul><ul><li>Best solution for CHINA + SHIPPING </li></ul>

×