Over the course of a year, improvements made include the construction of a new compressor, a new despatch area, and the creation of unified machine shop areas.
Gerhardt operates around the clock designing and manufacturing bespoke dies and gears on site using precision equipment. The works were implemented without stopping production.
By shortening the distance the dies travel during their manufacture by 85 per cent, efficiency increased and the amount of internally scrapped dies reduced significantly. According to Lorien, this gave the highest delivery reliability in the industry at 98.5 per cent.
The increase in efficiency has been so significant that the process is being repeated at Gerhardt sites in the USA and Denmark.