Developing a Storage & Distribution SystemAlex Packard’s project enables GKN AutoStructures to supply spare parts for products that the company no longer manufactures, economically and with as
little disruption as possible to their current production line.
Background
GKN AutoStructures produces structural under body components for the Automotive and Commercial Vehicle industries. GKN produce mainly for the UK market, but also supply to Turkey. Major customers include Ford, Land Rover, Aston Martin, Jaguar, Toyota
and Nissan. The company employs approximately 800 people.
Approach
GKN AutoStructures have to be able to supply parts for products for fifteen years past the production end date. As it is not economically viable for the company to manufacture the spare parts when they are needed, a large quantity of the parts need to be made in advance and
stored. Alex’s challenge was to find a way of storing the parts which would preserve them in perfect condition, and allow them to be shipped to the customer when required. He started by investigating the possibility of using grease to preserve the parts and plastic bags to store
them, however his trials proved that these options did not work well enough. As a result of further research, Alex found a product which can be sprayed onto the parts to protect the exposed steel, and will peel off without leaving any residue when the parts need to dispatched.
Results
Alex’s project has saved money, and improved the company’s efficiency by removing the extra costs and labour involved in having to produce parts as the demand arose. Changing the production line equipment over to produce the obsolete parts would cost GKN £16,566 every time they
did it. Instead, as a result of Alex’s project, the company is now able to produce as many of the spare parts as they will ever need, and store them effectively. This will allow the company to supply the two necessary variants of deadbeam for the fifteen years of their service obligation,
efficiently and without incurring unnecessary cost. Alex’s work can also be applied to other components in the future.
‘Alex has consistently exceeded our expectations, and has undertaken a variety of duties with enthusiasm and professionalism. His contribution to the effective running of the department is considerable, and he can be trusted to manage customer related issues with minimal guidance and supervision.’
Robert Close
Product Manager, GKN AutoStructures Ltd | 
