At its Fabergé factory in Leeds, Unilever wanted to develop a cost-effective means of restoring a roller system to full capacity to avoid production disruptions.
Investigations by Brammer's revealed that several rollers and slates had been damaged beyond repair, due to inadequate tension control and programming issues, causing the chain on the drive and outfeed roller to be stretched.
That, in turn, had caused the chain to be caught and jammed in the diverter.
Based on route cause analysis coupled with previous experience and expertise, Brammer decided the best solution was to replace the diverter.
To prevent the issue from recurring, Brammer also developed a three-month training module for Unilever's engineers, designed to complement its lean manufacturing strategy.
Brammer and Unilever reckon savings of 16% have been achieved, and further work is being done to quantify savings due to reductions in downtime.
Based on current assumptions, each shutdown is believed to have cost Unilever more than £11,000. By working with Brammer, Unilever will have saved at least £77,000 every week in downtime prevention. Across the range of benefits, savings were found to be £640,640.
Now in their eighth year, the awards recognise manufacturing companies who have achieved outstanding results.
The event was held at the Silverstone Wing, part of the Silverstone race track, and attended by more than 200 senior industry executives.