Ghost Rolls Busters: More benefits from Lean Apprenticeship for Altro

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Cidori client Altro make of some of the best flooring and wall cladding solutions – from schools (example pictured below) to hospitals they really have it covered.

Together our teams designed a tailored Lean Manufacturing Operative (LMO) Level 2 programme, delivered by Barnet Southgate College and funded by our client’s apprenticeship levy pot.

KEY PROJECT: ‘Ghost Rolls Busters’ 

  • Scanning & labelling issues with rolls of material
  • Ghost Rolls: don’t exist yet on system to order
  • Invalid Rolls: exist yet not in system & written off
  • Stock availability/delays for customers & departments
  • £160k unsaleable stock at start of project


  • 4D/5D Analysis & Create SOP
  • Better educate team to understand causes
  • Improve visual management of stock storage
  • Better scanning signage
  • Improve adherence to ISO 14001
  • Toolbox talks embedded
  • Weekly audits in place
  • Correct stock location rate went from 35% to 95% in 3 months

I am incredibly impressed by the impact of our Lean Manufacturing Operative (LMO) training – seen in the exceptional projects presented by our team members. Their commitment to move out of comfort zones and learn key lean principles, not only translates into immediate process improvements and cost savings, but also positions us strongly for sustained continuous improvements in manufacturing. This achievement reflects not only the drive and skills of our team members, but also the benefits available when we engage in lean and waste elimination projects in the Altro business. I am very excited as we continue to work with the LMO team to foster a culture of waste elimination and efficiency. Thank you to everyone involved.”

Paul Hankin

Head of Manufacturing, Altro

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