Struggling with output, capacity or delivery? Find out what's holding your operation back — in one focused day, at no cost.
I identify the constraints limiting your manufacturing performance, pinpoint lost capacity and prioritise the improvements that will make the biggest difference to output, delivery and cost.
The approach
We combine practical shop-floor analysis with proven lean tools to give you a clear picture of your current performance, where the bottleneck is and what to do next.
The methodology
A focused, one-day diagnostic to identify capacity constraints, establish baseline performance and deliver a prioritised plan to improve throughput, delivery and productivity.
Establish the baseline
Output
Current-state value stream map, lead-time picture and initial bottleneck hypothesis.
Quantify the losses
Output
Performance baseline, quantified gaps and evidence-based view of the constraint.
Investigate capacity loss
Output
Activity profile, principal capacity losses and opportunities to increase throughput.
Turn insight into action
Output
Concise report, baseline dashboard, priority actions and next steps.
The one-day schedule
Every hour is purposeful. By the end of the day you have evidence, analysis and a clear picture of what to do next.
Opening meeting,objectives & tour
Confirm business priorities, product mix, demand, shifts, delivery issues and known constraints. Site tour and familarisation.
Current-state VSM and process walk
Map flow, capture key data and identify potential constraints and baseline throughput.
Seven-measure QCDS diagnostic
Review actual results, targets and trends. Identify where losses affect good-output capacity.
Validate the bottleneck and baseline
Check queue build-up, starvation, blocking and available operating time. Select the constraint for detailed observation.
Bottleneck activity sampling
Observe and record how time is used at the constraint (including normal operating conditions and product mix).
Analysis and opportunity quantification
Calculate activity proportions, assess recoverable capacity and identify root causes.
Report preparation and in-person feedback
Present findings, baseline and prioritised actions to the management team.
The seven measures (QCDS)
We assess seven key operational measures, looking at how they work together to impact overall performance.
Delivery schedule adherence
Actual vs planned output and delivery
Non-right-first-time (NRFT)
Defects, rework and scrap
People productivity
Output relative to labour input
Value added per person
Value created relative to workforce
Overall equipment effectiveness (OEE)
Availability, performance and quality losses
Stock turns
Consumption or cost relative to stock
Floor space utilisation
WIP density and usable capacity
What you'll receive
Not a thick deck of slides — a focused document you can act on immediately.
Current-state VSM
Material flow, process times, queues, WIP and lead-time observations.
Baseline performance dashboard
Seven measures showing actual performance, targets, gaps and data limitations.
Bottleneck analysis
Identified or provisional constraint, supporting evidence and impact on throughput and delivery.
Activity sampling results
Breakdown of observed time, principal losses and potential recoverable capacity.
Prioritised improvement plan
Actions ranked by throughput impact, business benefit, implementation effort, cost and risk.
How we prioritise opportunities
We'll distinguish between immediate actions, short-term projects and longer-term capital or engineering changes.
Throughput impact
How much additional good output?
Delivery impact
Improve schedule adherence, overtime or lead time?
Quality impact
Reduce defects, scrap or rework?
Financial benefit
Labour, overtime, material or working capital.
Ease of implementation
Time, cost, resources and risk.
The result
Free — no obligation
Get in touch to arrange your free Manufacturing Bottleneck & Delivery Assessment. One day. No cost. Clear answers.
Book your free assessment