Lean Six Sigma for manufacturers.
We help plant and operations leaders find hidden capacity, remove bottlenecks and make delivery performance predictable, with results measured in money, not just metrics.
When demand outpaces output
Growth is good news until the factory can’t keep up. Adding people, machines or shifts is expensive, and often unnecessary.
- Map the end-to-end process to find the real constraints
- Release capacity at the bottleneck before investing in more
- Align sales forecasts, purchasing and production capacity
When lead times and late deliveries hurt customers
Long, unpredictable lead times erode trust and hand business to competitors.
- Measure where orders actually wait, and why
- Introduce clearer production planning and scheduling
- Set daily delivery KPIs with clear ownership
When overtime rises but output doesn’t
Extra labour that doesn’t move throughput is a sign that work is being lost somewhere in the process.
- Separate root causes from symptoms with Six Sigma tools
- Redesign workflow around the main constraint
- Reduce work-in-progress so work flows instead of queueing
When scrap and rework eat your margin
The cost of poor quality is often invisible in management reports, yet it can be one of the biggest drains on profit.
- Put a money value on scrap, rework and quality losses
- Find and remove sources of process variation
- Build control plans so problems stay fixed
When suppliers let you down
Inconsistent supplier performance ripples through your whole operation.
- Introduce supplier scorecards on delivery, quality and responsiveness
- Improve forecasting and communication with partners
- Right-size inventory once supply is reliable
When growth turns into firefighting
As businesses scale, processes that relied on individuals start to break.
- Build a scalable operating model with clear responsibilities
- Establish management rhythms, KPIs and capacity planning
- Strengthen handoffs between sales, engineering, procurement and operations
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.
Where we’ve worked
Our experience spans advanced and technology manufacturing, from factory floors to international supply chains across the UK and Asia.
- Thermal management products and electronics components
- Industrial products and engineered components
- Electronics and outsourced manufacturing
- Technology products and international manufacturing
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.