LEAN Manufacturing Improvement Consultants

We help people reduce costs – Improve Process, Productivity, Profits and Cash Flow.

Lean Methodology


  • Reduction of Waste.
  • The Reduction of Costs.
  • Improvement of  Process, Productivity, Production.


  • Deals with “CHANGE”  optimization of complex processes or systems: Development – Improvement – Implementation – Process Control – Standardization…
  • Deals with Factory Process Layouts – Process Methods – Product Build Time – Machine Down Time – Product Build Quality – Scrap and Rejects – Tooling Issues – Materials Organisation – Written Procedures – Manning Levels – Analysis and Synthetics of Production Data…


LEAN 6 Sigma:  Methodology:  Turning ideas into reality.

  • Define- The Root Cause, Benefits to the customer, Benefits to the company.
  • Measure- Aspects of the current process and collect relevant data.
  • Analyse- The data to verify root causes.
  • Improve- The process based on data collected.
  • Control- The process. Create Standard Operating Procedures.


Seven Wastes:  Reduction of Non-Value Operation.

  • Transportation- Excessive movement of product between operations.
  • Inventory- Over Stocked Materials sat on a shelf collecting dust.
  • Motion- Movement of the body. Reaching, Bending, Walking.
  • Waiting- People Idle not producing. Waiting for parts or people.
  • Over Production- Making too many or too much, parts not required.
  • Over Processing- Too many operations in the process. End-to-End.
  • Defects- Re-Works, Repairs due to a build, drawing, machining error.
  • Resources- People. The 8th Waste…

5S Cell Improved Lean-line

5S: ( Housekeeping )

  • SORT. What is needed, Remove what is not needed.
  • SET.Organise What is Needed.
  • SHINE. Tidy Area and Keep Clean.
  • STANDARDIZE. Organise Process, Reduce Variation.
  • SUSTAIN. Maintain with Process Controls.


Organisation of Materials, Create ORDER from DISORDER

  • Optimise Stock Levels
  • Management of Stock Levels
  • Reduce Pick and Put-away time
  • Controls that Improve Cash Flow


SMED:  Tool change, m/c set-up, Reduction of time wasted

  • Single Minute Exchange of Dies:
  • Reduction of Changeovers
  • Reduction of Machine Set Up Time
  • Increased Production and Productivity

Crushed in machine

Total Planned Maintenance:- Prevention not Repair.

  • To Improve Machine Uptime
  • To Keep Machines Hitting Targets
  • To Increase Production and Productivity
  • To Increase Sales from Global Business Growth

Continuous Improvement

Visual Management Control: Key Performance Indicators

  • Production Target / Achieved
  • Quality Yield Numbers
  • Downtime Pareto
  • Rejects Pareto