SMAS help Aker Solutions to increase their manufacturing capacity

The company

An international company, with 28,000 employees worldwide, Aker Solutions provide oilfield products, systems and services to its global customers in the oil and gas industry. The company's expertise, knowledge and technologies extend from the reservoir and production, through the entire life of a field.

In Aberdeen alone, the firm employs more than 2,700 people across four key business areas. This includes Aker Solutions Subsea Business, a large, long-established specialist arm that's enjoying significant growth in the UK. Around 250 people are working within the assembly/manufacturing operation that spans four workshops and a satellite R&D department.

The challenge

Short lead times, complex specifications and a high level of competition make for a challenging oil and gas market.

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Historically, firms have operated reactively, sourcing additional equipment, resource and subcontracted manufacturing to fulfil demand. But recently, the focus has shifted to a proactive stance. Increasingly, businesses are taking the lead and changing practices to meet customers' quality, cost, delivery and service criteria.

Thanks to successful business delivery and a growing order book, Aker Solutions, were faced with the enviable prospect of doubling its manufacturing capacity within the year.

How SMAS helped

A strong partnership developed between SMAS and Aker Solutions, which has helped to improve the business through continuous improvement and culture change. SMAS brought the skills, experience and the necessary tools / techniques to support the Aker Solutions teams in identifying the projects that helped drive their business forward.

The specific project deliverables were:

• 17 improvement plans created through end-to-end process mapping. These were then integrated into Aker Solutions Business Improvement Team
• Factory layout and required process improvement identified to double throughput within the existing footprint
• 5S principles, process and implementation within a pilot area, giving the Aker Solutions team the tools for continued roll out
• Increased visibility of production status and scheduling
• Significant improvement in value-added activity and the reduction of waste within the workshop areas
• Increased awareness, ownership and a desire for improvement at shop floor level

Impact

Continual Improvement, culture change and a strong partnership between SMAS and Aker Solutions has brought competitive advantage. SMAS' skills, experience, tools and techniques have helped the firm match its specialist services to projects in order to grow its market share.

Some key successes have been:

• Promoting a culture of Continual Improvement in a dynamic, fast-changing environment
• Integrating an implementation plan into an established Business Improvement Team
• Creating ownership at factory floor level
• Developing Lean Awareness and Education within a very traditional manufacturing culture

Outcomes

Aker Solutions is realising the benefits associated with having fully engaged employees in continuous improvement as a result of the partnership with SMAS.

Their manufacturing capacity has improved as a result of their employees working together to improve the products, processes and procedures. Aker Solutions has found real value in working with SMAS, and have been able to quickly double their manufacturing capacity and they look to build on the improvements going forward.

What Aker Solutions say

“We have a wealth of knowledge and experience within our business. However, with the specific expertise and fresh pair of eyes perspective that SMAS brought to the table we now have more clarity on the road to increased manufacturing capacity. We have already enlisted SMAS to support us in other areas of the business.”

Karon McDonald, Vice President, Operations and Manufacturing

Next steps

Find out how SMAS can help your business