Electronics & High Tech – Telecomms Equipment Manufacturer

Lean Manufacturing

Business Challenge
To become the “industry benchmark” for manufacturing excellence in telecommunications equipment.

Our client, a leading manufacturer of telecommunications equipment for both military and civil markets, was faced with a number of operational challenges including the need to significantly reduce costs and production lead times whilst improving both product quality and delivery performance.


  • A short initial phase comprised visits to all manufacturing facilities and the development of a set of performance benchmarks , improvement targets and a comprehensive implementation plan.
  • The second phase developed a “factory within a factory” based on lean principles at the main production site, and was used to rapidly showcase the new ways of working and the associated benefits.
  • The new manufacturing architecture was then rolled out to all sites.

Key Achievements & Value Delivered

  • 80% reduction in inventory.
  • 50% reduction in manufacturing lead time.
  • 100% increase in manufacturing throughput efficiency.
  • Company-wide savings estimated at over £20m in inventory reductions alone.