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.

Industrial Products – Component Manufacturer

Manufacturing and Supply Chain Excellence

Business Challenge

Deliver radical operational performance improvements in order to win new orders and transform market perceptions

Our client, a leading supplier of pumps and motors to major civil aerospace manufacturers, was faced with the challenge of how to remain competitive in an environment where customers were demanding better responsiveness, quality, delivery and prices


  • As a first step, a small joint team was mobilised to review current operations and determine potential improvement opportunities, including a number of “quick wins” to create early benefits and effectively make the programme self-funding.
  • The team then progressively tackled all elements of the manufacturing and supply chain processes, deploying lean techniques, strategic sourcing, and other operational excellence principles

Key Achievements & Value Delivered

  • 95% improvement in delivery performance
  • 100% improvement in delivery quality
  • 60% reduction in product lead time
  • Maintenance of output levels with a 25% reduction in workforce
  • Securing of largest order for three years with principal customer