MAS helps Melton manufacturer get packing on productivity

Leicestershire‟s Hallmark Consumer Services is saving thousands of pounds each year, thanks to efficiency measures introduced after support received from the Manufacturing Advisory Service (MAS).
Since involving MAS with his £2.4 million Melton Mowbray-based fulfilment operation, Hallmark‟s Managing Director, Chris Hall, has seen an immediate 10% increase in productivity which will add up to almost £20,000 annually.
Speaking about the improvements made to the business with the help of MAS, Chris said: “We wanted to improve our productivity for picking and packing and establish accurate picking times so we could standardise our pricing. Our automated system has built-in logic to help us minimise picking times, but we weren‟t exploiting its potential.”
Chris, a former marketing director at Mattel, set up Hallmark in Melton nearly 18 years ago after he lost faith in the fulfilment houses he was dealing with.
From its roots in sales promotion fulfilment, it‟s evolved into direct mail, mail order fulfilment and more recently e-commerce, specialising in integrating clients‟ websites with its own order processing software.
Clients include the BBC for whom Hallmark handles sales of its popular Countryfile calendar and the Woodland Trust – the company fulfils catalogue and web orders generated by the charity‟s Christmas gift range.
“The initial diagnostic process, which involved a lot of walking and talking on the warehouse floor, was free and the week-long time study and analysis of work processes and practices was 50% subsidised.
“So at just £1,500, it‟s been a small price to pay for the improvements we‟re seeing as well as the knock-on effects such as increased capacity.”
MAS‟s study clearly identified „spikes‟ in picking and packing times caused by problems such as confusing delivery destinations - now Hallmark can iron out these glitches.
MAS also helped the company establish better principles for stock layout so that picking could be carried out as effectively as possible. “It was a eureka moment for us when our MAS Advisor discovered that picking from a truck for racking at high level was as efficient as a pedestrian picker at floor level. As a result we‟ve changed certain storage locations,” added Chris.
“Our MAS Advisor quickly got the staff on side. He skilfully guided and mentored our warehouse team leader – she quickly became a big fan and convert and now has a much better understanding of lean practices and work organisation. “We were also recommended to introduce a visual management style to improve communication as well as motivated staff before, but now they‟re even more focused.”
MAS in the East Midlands is funded by East Midlands Development Agency (emda)