The principles of lean manufacturing have long been acknowledged across the UK manufacturing sector. Yet, despite widespread awareness, significant untapped opportunities for cost savings and operational efficiencies remain. For manufacturers with bold ambitions, the key lies in adopting a holistic approach to system design and site-wide optimisation.
The Case for a Site-Wide Audit
Realising the true potential of operational efficiency starts with a comprehensive site-wide audit. Assessing equipment and systems in isolation often leaves substantial savings on the table—savings that could directly enhance profit margins.
At Vistech, we specialise in enhancing competitiveness and operational efficiency for UK manufacturers, with a focus on designing and installing world-class water cooling systems. By considering the system as an interconnected whole, rather than as individual components, manufacturers can achieve superior energy efficiency and operational performance.
System Efficiency vs Component Efficiency
One of the most common pitfalls in improving operational efficiency is focusing solely on the efficiency ratings of individual components. While this approach may seem logical, it often fails to deliver the anticipated returns if the overall system design has not been optimised.
For example, a high-efficiency motor running at full capacity 24/7 may seem ideal on paper, but if it operates when unnecessary or is oversized for the system, it wastes energy and resources. Instead, intelligent control systems that adjust water delivery to meet process demands offer far more effective energy savings.
Integrated Projects for Maximum Gains
Considering projects in isolation can also result in missed opportunities for synergy. A recent example from one of our clients demonstrates this. They were planning to invest in solar power to lower their electricity costs and carbon footprint. However, their calculations were based on current energy consumption, much of which came from an inefficient cooling system.
By addressing both projects simultaneously, we identified significant opportunities to reduce energy consumption through an optimised cooling system. This approach not only improved the ROI on the solar installation but also lowered the upfront capital expenditure for the solar project due to the reduced electricity demand.
A Roadmap for Legacy Systems
For manufacturers operating legacy systems, adopting a phased approach to investment can deliver significant returns. Whilst not all upgrades need to occur at once, developing a roadmap for efficiency ensures that individual investments are aligned with a long-term vision. This includes optimising the control and distribution of water throughout the factory to ensure each component works seamlessly as part of a larger, efficient system.
Partner with Vistech
At Vistech, we understand the challenges manufacturers face in balancing operational demands with efficiency goals. Our 3-step process provides a clear pathway to designing and implementing high-performance systems tailored to your specific needs.
If you’re ready to unlock significant cost savings and enhance your competitiveness, arrange an initial consultation with one of our solution consultants today. Together, we can help you map out a strategy to deliver sustainable efficiency gains that boost your bottom line.