Industrial Products – Light Fittings Manufacturer

Operating Strategy

Business Challenge
Design and implement an Operating Strategy which will position the company to penetrate new European markets.


  • Our client recognized substantial opportunities to increase sales of both standard products and “architect specified” products for specialist applications.
  • This required a complete redesign of the production operations and logistics / distribution approach.


  • Master Plan’ established, using Lean principles of Cellular Manufacturing, Pull Systems and IPTs (Mini-Businesses).
  • Organisation re-designed centred around four ‘mini-businesses’
  • Facility layout redesigned to enable ‘straight line flow’ for all products, and the set up for the four ‘mini-businesses’.
  • New paint plant, press brake, assembly lines and flexible manufacturing system were specified, procured and installed.
    Distribution logistics network featuring four hubs with distribution networks.

Key Achievements & Value Delivered

  • Response times dramatically reduced – standard products delivered within 48 hours of order.
  • 300% increase in overall stock-turns.