Batch Control for Magnet Schultz

Magnet Schultz Ltd, manufacturers of solenoid-based engineering solutions, is a small business based in Old Woking, Surrey – design expertise and in-house assembly capabilities under one roof allow Magnet Schultz to provide short lead times on each product. Its ongoing success is based on a passion for innovation, keeping one-step ahead of the competition in order to continually suit the bespoke needs of its loyal customer base.

Recently working with the Manufacturing Advisory Service (MAS) on a lean implementation programme, Magnet Schultz has reshaped its existing shopfloor and removed all unnecessary waste from production.

Production is now self-managed through the use of kanban cards and visual production boards – an effective system that tells Magnet Schultz what to produce, when to produce it, and how much to produce. Magnet Schultz also now use ABC classification, an effective way of categorising /grouping products, consignment stocking and kanban call-outs, in order to minimise stock holding.

Sylvain Briand, MAS Specialist, also facilitated the development of a new second generation line of Electro Kabuki ready for launch - the award-winning Electro Kabuki is a solenoid based mechanism that enables the release of drapes, cables and dummies. Sylvain guided Magnet Schultz on a new product development journey whereby Critical-to-Quality requirements were identified, parts count minimised and assembly simplified – the build time for an Electro Kabuki mechanism is now less than a quarter of an hour.

Andrew Newton, Managing Director, Magnet Schultz, said: “We are delighted with the results that lean manufacturing has achieved with our available resources – MAS  has really kick started our lean journey and we’re keen to continue our learning ensuring that the lessons stick and remain fresh. Using our own internal expertise, we are now planning the lean transformation of future product lines, formalising new product introduction processes.”