Thermal management products
Scaling to meet rapid growth
+25%production capacity
15 → 10days lead time
−12%unit manufacturing cost
In about 6 months
Find the capacity your plant already has.
Blazdell Consultancy helps manufacturers remove bottlenecks, cut lead times and get orders out on time, using Lean Six Sigma and a practical, data-first approach.
On-time delivery, before and after
Three recent engagements
Sound familiar?
These problems are rarely about effort. They come from constraints, variation and handoffs that nobody can see clearly. That’s what we find, measure and fix.
Demand is outpacing output
Orders are coming in, but capacity isn’t keeping up.
Lead times keep stretching
Customers are waiting longer, and competitors notice.
Too many orders ship late
On-time delivery is slipping and trust is wearing thin.
Overtime is up, output isn’t
You keep adding labour, but throughput barely moves.
Scrap and rework eat margin
Quality losses hide in plain sight and rarely show up as a line item.
Firefighting is the job
Processes depend on individuals, and management is always reacting.
Results that speak for themselves
Read the case studiesEngineered components
Breaking through bottlenecks
+20%throughput
−25%work-in-progress
80 → 94%on-time delivery
Within about 4 months
Electronics, UK and Asia supply chain
Stabilising international supply
−20%supplier lead times
84 → 96%delivery reliability
−18%inventory
Over 6–9 months
Philip’s own venture
Scaling without losing control
$2.5m → $12m+revenue
3×production capacity
+5 ptsgross margin
Over about 5 years
How we work together
Each step is small and low-risk, so you only commit to more once you’ve seen the value.
- 1
Free scorecard
Five minutes online to see where your plant is most likely losing money.
- 2
15-minute call
We talk through your results and your biggest pressures. No obligation.
- 3
Plant Performance Diagnostic
Three days on-site at a fixed fee, with savings opportunities ranked by value.
- 4
Improvement project
A focused DMAIC project with a clear financial target, and controls so the gains last.
The Plant Performance Diagnostic
Three days on one production line or value stream. You get a clear picture of where you’re losing capacity and money, and what it’s worth to fix, written with your own data.
Fixed fee, agreed before we start
Credited in full against an improvement project started within 90 days.
What you receive
- A current-state value stream map of the line
- Baseline data on scrap, rework, downtime and first-pass yield
- Your top 3–5 improvement opportunities, ranked by estimated savings
- A written report and a presentation to your leadership team
Grounded in Deming. Proven on the shop floor.
Our approach is built on W. Edwards Deming’s System of Profound Knowledge, with Lean Six Sigma at its core. We use DMAIC to improve existing processes and DMADV to design new ones.
We work alongside your people. Control plans, clear ownership and follow-up reviews mean the improvements stay in place long after we’ve gone.
Dr Philip Blazdell
Founder. PhD in Materials Engineering, Chartered Engineer and Six Sigma Black Belt, with experience leading businesses and transformation programmes across the UK, Europe, Asia, Africa and the Americas.
Where is your plant losing money?
Take our free 5-minute Manufacturing Waste & Quality Scorecard. You’ll see your score across six areas, plus a practical first step for your weakest two.