Henry Halstead's single-link supply chain boosts business for Willerby
Component supply and management specialist Henry Halstead continues to play a pivotal role in the success story of Manufacturer of the Year 2008 Willerby Holiday Homes.
Static caravan maker Willerby transformed its operations to become a world class lean manufacturer after developing a strategic partnership with Henry Halstead.
This involves the Preston and Sunderland-based company using digitally managed Kanban stations to distribute some 20 million small components and consumables annually, direct to Willerby assembly points in its manufacturing facility.
The relationship began in 2003 when Hull-based Willerby reduced its supply chain from 18 suppliers to just one – Henry Halstead.
"The importance of the Kanban system is that it creates a single, constant flow of stock that allows us to use components at precisely the time we need them," said Willerby purchasing manager William Dennett. "This means we never have to order stock, carry obsolete stock, or become involved in quality issues, all of which are managed by Henry Halstead.
"Our production methods are fast-moving and flexible so our supply chain has to be equally dynamic and responsive. Henry Halstead is a great example of these qualities.
"They deliver a simple, visible system that is self-managing and requires only one consolidated invoice, compared to 500 per month that we used to get before we went down the lean manufacturing route. As a result, there are considerable operational savings – much less opportunity for running out of stock, much less paperwork, and much less administrative time."
Mr Dennett added: "When we turned away from traditional sourcing to a long-term relationship with Henry Halstead they became an integral part of our development team and contribute significantly to our success going forward."
Employing more than 60 staff at facilities in Preston and Sunderland, Henry Halstead also has an onsite ‘envoy' based permanently at Willerby's headquarters to ensure a smooth running supply chain.
"The manufacturing industry has changed enormously over the past 20 years," says Henry Halstead's Sunderland general manager, Gary Russell.
"We help leading UK companies with their lean initiatives by supplying a logistics system that ensures parts and materials are in the right place at the right time. This is totally demand-driven and our customers have no involvement in the supply chain, other than consumption.
"We are always looking to reduce our own supply base and recently put all Willerby's furniture fittings into the Kanban system without any price increase. We are also looking at the possibility of bringing in a supplier in the Far East to drive down our costs still further," added Mr Russell.