Manufacturing & Advanced Industrials · Operations & Asset Management
Lean Manufacturing & Cost Reduction
Lower your cost per unit by removing waste from manufacturing and assembly, and keep it out
Discuss this serviceWhat it is
Lean Manufacturing & Cost Reduction
Our lean manufacturing work happens on the shop floor. We work with your supervisors, engineers, and operators to remove waste, improve material flow using Value Stream Mapping (VSM), cut changeover times with SMED, and set up the daily routines that keep improvements in place.
- Typical duration
- 8 to 16 weeks of active on-site work
The business problem
Why clients need this
Rising material, energy, and labour costs squeeze margins. Lasting margin improvement comes from removing waste and shortening cycle times across the plant, not from one-off cost drives.
- 01
Excess work-in-progress (WIP) fills the shop floor, ties up working capital, and hides quality problems.
- 02
Long changeovers limit flexibility and push the plant towards large, inefficient batches.
- 03
Cost reduction programmes start well but fade within months without daily management routines.
Our approach
How we deliver it
- 1
Value Stream Mapping (Current & Future State)
Mapping material and information flow end to end to find lead-time bottlenecks and non-value-added steps.
- 2
Focused Kaizen Sprints
One-week sprints on priority lines covering SMED, 5S, line balancing, and cell design.
- 3
Total Productive Maintenance (TPM)
Introducing autonomous maintenance so operators take ownership of basic cleaning, inspection, and upkeep.
- 4
Daily Management Systems (Tier 1/2/3)
Visual boards, hourly output tracking, and structured escalation and problem-solving routines.
Data & AI
How technology strengthens this service
Digital value stream maps and line-balancing simulations let us test layout and staffing options on screen before any machinery is moved.
How we use AI across our workTypical deliverables
What you receive
- Current & Future State Value Stream Maps (VSM)
- Standard Operating Procedures (SOPs) & SMED Standard Work
- Tiered Daily Management System & Visual KPI Boards
- Savings Register with agreed baselines and tracked results
Outcomes
What changes for you
- Shorter manufacturing lead times on the lines in scope, measured against an agreed baseline
- Faster, standardised changeovers that allow smaller batches
- Lower WIP inventory and the working capital it releases
Who it is for
- Discrete & batch manufacturers
- OEM component suppliers
- Export-oriented manufacturing units
- Private equity portfolio companies
FAQs
Common questions
How is this different from lean classroom training?+
Most of our time is spent on the shop floor running live improvement sprints with your teams, with savings measured against a baseline rather than training hours delivered.
How do improvements last after you leave?+
We set up daily management routines and train internal lean champions to run audits and problem-solving after the engagement ends.
Does lean work for high-mix, low-volume manufacturing?+
Yes. In high-mix environments we focus on quick-change fixtures, cellular layouts, and smarter sequencing to reduce changeover time.
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Discuss lean manufacturing & cost reduction with our team
Tell us about your site, plant or network. A senior consultant will reply within two business days.