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Operational Efficiency

Lean manufacturing increases productivity by 30% for Kids Funtime Beds

The Business

Kids Funtime Beds are a mass customization bed manufacturer based in Wythenshawe, Manchester. The business produces a range of children’s beds which can be personalised to the customers specification.

Kids Funtime Beds was established by Managing Director Tony Smith in 2014, initially working from a converted bedroom. The business has now grown to employ 27 people at the Wythenshawe Factory.

Kids Funtime Beds received support for GC Business Growth Hub's manufacturing service

Kids Funtime Beds personalise the beds to their customers specification.

Kids Funtime Beds increased productivity by 30% by using lean manufacturing

Paint wasn't drying correctly which was creating expensive rework.

The Challenge

The rapid growth of the business has ensured a healthy order book, but as production increased so did rework. A keystone to the businesses success is Tony’s eye for detail, his threshold is that every bed the company manufactures is a special gift for a child so nothing should leave the factory unless it is correct - but the rework problem was beginning to effect lead times.

Tony approached the GC Business Growth Hub for help and was introduced to specialist Manufacturing Advisor Geoff Crossley. Geoff conducted a Productivity Audit, walking the site and getting to know the business to understand their aspirations and their challenges. This provided the business with a set of recommendations to help

 

“Kids Funtime Beds were producing a high quality unique product, but the lead times to meet the order book were becoming problematic. On walking the site the first thing I noticed was inventory in stock, spare components and work in progress (WIP)."

In addition to this it became apparent that they also had problems with the quality of paint, which wasn’t drying correctly and was requiring expensive rework.”

Geoff Crossley, Manufacturing Advisor, GC Business Growth Hub

The Results

Tony said;

“The recommendations that Geoff made to the business at first seemed daunting as there was a lot to do. But Geoff guided us through the process and helped us prioritise the most important tasks. Whilst it has taken time the benefits outweigh this ten-fold.”

The priority was to develop the skills of the workforce and Tony signed up Team Leader Liam Morris to The Manufacturing Institute’s Team Leader training course, to ensure that the company had the correct management skills to support future growth.

Geoff then delivered a 5S and waste elimination workshop to embed a Lean culture within the manufacturing team. He worked with Tony and the team to implement a pull system on the shopfloor designed to reduce WIP.

Kids Funtime Beds customise their products

The team took part in a 5S and waste elimination workshop.

Then followed a redesign of the preparation areas and improved efficiencies of the spray booth to rectify the issues with the paint. In addition, Geoff helped the business to review the layout and organisation of the workshop, and looked at the material handling by operatives to consider how to improve flow across the business 

“We have seen a significant reduction in rework and inventory, which has helped us to increase production by 30%. The reduction in lead times and increased quality has seen improved customer service, and our website is now full of 5* reviews from happy customers – which will help us to develop new business."

At one stage we were considering moving the factory to larger premise,s however Lean manufacturing has enabled us to increase production and decrease rework utilising our existing factory space more efficiently.”

Tony Smith, Managing Director, Kids Funtime Beds

Following support from the GC Business Growth Hub, the business has started to increase their product range and increase headcount. Tony said:

“We have invested in a new CNC machine and also taken on new staff to build our capacity and keep pace with the growth of the business. More recently we received a grant from the Manufacturing Growth Fund which has enabled us to introduce new product options to our range by developing a new production area and increasing the capacity of our paint spray facility.”

Find out how the GC Business Growth Hub can help you to improve efficiency, develop new products and increase productivity. 

Get a free Productivity Audit

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