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Mapping out a processs

Case Studies

Case Study: Transforming Expansion Dreams into Reality


Our client aspired to expand its horizons, opening a new office each year in diverse regions. However, this ambitious vision required the establishment of robust business management systems from scratch.


  • Business Manual & Procedures: We collaborated to craft a comprehensive business manual, meticulously outlining procedures and standard work protocols.

  • Cross-Training Matrix: To ensure operational flexibility, we devised a cross-training matrix, empowering all staff members with versatile skills.

  • Strategic Analysis: The implementation of PESTLE analysis fortified their strategic decision-making, enhancing adaptability to external factors.

  • Quality and Efficiency: By introducing the concept of the Cost of Poor Quality, we heightened their awareness of quality control, resulting in improved efficiency.

  • Operational Excellence: Training in 5S methodology and problem-solving techniques paved the way for enhanced operational excellence.


In just six months, our collaborative efforts bore fruit as the company experienced remarkable growth, surging by an impressive 30%. This monumental achievement emboldened them to successfully inaugurate their first new office, marking the beginning of a thriving expansion journey.

Here are some of the key takeaways from this case study:

  • Having strong business management systems in place is essential for growth.

  • Cross-training staff can help to improve efficiency and productivity.

  • PESTLE analysis can help businesses to identify and mitigate risks.

  • The Cost of Poor Quality can help businesses to reduce waste and improve profitability.

  • 5S and problem-solving can help businesses to improve their processes and achieve their goals.

Case Study: Revamping Efficiency From the Ground Up


Initially approached to implement a business management system, our site visit uncovered more pressing concerns, particularly in the realm of Health & Safety. Given the gravity of these issues, our focus shifted to addressing them as a top priority.


  • Health & Safety Priority: We collaborated closely with the factory owners to rectify Health & Safety concerns, ensuring the safety and well-being of all personnel.

  • Holistic Efficiency Enhancement: With the safety aspect addressed, we embarked on a broader mission to enhance the factory's overall efficiency and effectiveness.

  • Waste Reduction: We introduced the factory owner to the seven wastes of business, pinpointing and addressing sources of inefficiency.

  • Optimized Layout: Relocation of equipment was strategically executed to streamline workflow, reducing bottlenecks and enhancing productivity.

  • Lean Principles: The implementation of 5S and leader standard work further bolstered operational excellence.

  • Inventory & Stock Control: We systematically reduced inventory and work-in-progress (WIP), introducing the FIFO (First In First Out) system to prevent wastage due to glue and chemical expiry.

  • Comprehensive Documentation: Essential manuals, including a business manual, supplier manual, and standard operating procedures, were meticulously crafted.

  • Strategic Tools: We introduced tools like PESTLE analysis, Cost of Poor Quality (COPQ), Overall Equipment Effectiveness (OEE), and a Training Matrix to enhance decision-making and process control.

  • Skill Enhancement: Staff members were diligently trained in problem-solving techniques and 5S methodology.


Within a span of just nine months, the factory witnessed a transformative turnaround. Production escalated, quality standards soared, and customers celebrated the newfound punctuality in deliveries, signifying a remarkable journey towards efficiency and excellence.

Here are some of the key takeaways from this case study:

  • A well-implemented business management system can help businesses to improve their efficiency, quality, and profitability.

  • Addressing health and safety issues is essential for the long-term success of any business.

  • The seven wastes of business can be eliminated to improve efficiency.

  • 5S can help to organize and clean up the workplace, which can lead to improved efficiency and productivity.

  • FIFO can help to reduce waste and improve inventory management.

  • Stock control can help to ensure that the right amount of inventory is always available.

  • A business manual, supplier manual, procedures, and standard work can help to improve communication and efficiency.

  • An approved supplier list can help to ensure that the business is working with reliable suppliers.

  • PESTLE analysis can help businesses to identify and mitigate risks.

  • The Cost of Poor Quality can help businesses to reduce waste and improve profitability.

  • OEE (Overall Equipment Effectiveness) can help businesses to measure and improve the efficiency of their equipment.

  • A Training matrix can help businesses to ensure that their staff are properly trained

Case Study: Transforming a Troubled Department


In the heart of a manufacturing company, a particular department had earned a notorious reputation for generating the highest amount of scrap within the organisation. The company's management team turned to us for a solution, and here's how we turned things around:


Optimising Material Usage: On one of their machines, an inefficient practice was in place. When they needed to replace the rolls of raw material, they resorted to glueing the start of the new roll to the end of the old one to pull it through. The excessive overlap amounted to a wasteful 2 meters. We intervened and reduced this overlap to a mere 25 millimetres, drastically cutting down material waste.

  • Sequencing Efficiency: Another machine in the department required cutting materials at varying angles, ranging from 2 to 75 degrees. They followed the order specified on their daily job cards, leading to inefficient material usage. We reorganised the job cards, ensuring they aligned from lowest to highest angles one day and reversed the order the next. This simple change significantly reduced material waste.

  • Recycling Opportunities: The department was discarding a substantial amount of raw material. We collaborated with the laboratory team and inquired if some of this material could be recycled elsewhere in the manufacturing process. The laboratory confirmed that 50% of it was reusable, curbing wastage.

  • Precision Enhancement: On a different machine, a roll had to be cut down from 2 meters wide to approximately 200 millimetres wide and further to 25 millimetres—the required width for the next process. The subsequent team consistently complained that the 25-millimetre width was never accurate enough for their needs. We stepped in and negotiated with the relevant teams, given the unionised company structure. We persuaded the other team to relinquish their role in setting up the machine at no additional cost to the company. We then instructed the team responsible for setup to use extra cutters and go directly to the 25-millimetre width. Initially met with scepticism, we persisted and, after some trial and error, identified a machine issue. A comprehensive examination and replacement of springs that hadn't been updated in over 30 years rectified the problem. This saved time, reduced scrap, and notably improved the quality and precision of the required width.

  • Preventative Maintenance Implementation: Armed with our insights from the spring replacement, we introduced a total preventative maintenance program for all machines across the department. This ensured that the machinery remained well-maintained and in optimal working condition.



The financial impact of these changes was substantial, with the finance director confirming that, within a mere two-month period, the company had realized savings amounting to £3/4 million.

Here are some of the key takeaways from this case study:

  1. Systematic Efficiency: Identifying and addressing inefficiencies in processes can lead to significant cost savings.

  2. Recycle and Reuse: Explore opportunities for recycling or reusing materials within your organization, promoting sustainability and reducing waste.

  3. Team Collaboration: Effective negotiation and collaboration between teams can lead to process improvements without additional costs.

  4. Regular Maintenance: Implementing preventative maintenance schedules is crucial to maintaining the longevity of machinery and preventing production disruptions.

  5. Continuous Improvement: A commitment to continuous improvement in all aspects of operations can yield substantial financial benefits.

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