Case Studies
Results across
complex environments
01
Manufacturing
Manufacturing · Pharmaceuticals
Production Line Reliability: From Chronic Stoppages to Sustained High Performance
A Kaizen program on a pharmaceutical production line delivered step-change reliability improvements within 12 weeks.
The Challenge
A leading European pharmaceutical network was suffering from fragmented supply chains across Europe, with tier-1 suppliers operating independently and no visibility across sites or regions.
The Approach
Mapped supplier landscape across 7 countries with 54 sites; designed shared IMS and rolled out hub-and-spoke structure.
The Result
23% cost per unit reduction; supplier consolidation from 22 to 8 key suppliers (cost neutral); throughput +31%
18 month engagement
02
Electronics
Manufacturing · Electronics
56% Lead Time Reduction in 12 Weeks
An electronics equipment manufacturer struggling with long assembly lead times that were limiting output and responsiveness to demand.
The Challenge
Assembly lead times of 14+ weeks were creating customer dissatisfaction and constraining growth. Root causes were fragmented scheduling, excess WIP and unbalanced workstations.
The Approach
Value stream mapping, workstation rebalancing, pull scheduling and targeted WIP reduction sprints across the assembly floor.
The Result
Lead time reduced from 14 weeks to 6.2 weeks (−56%) within 12 weeks of engagement start.
03
Mining Equipment
Mining Equipment Manufacturing · 4-Year Engagement
Building a Continuous Improvement Culture: Capability, Maintenance and Real Results
A four-year partnership that developed improvement capability at all levels and transformed maintenance from reactive to high-performing.
The Challenge
A mining equipment manufacturer had a maintenance function operating almost entirely in reactive mode, with no structured improvement capability and high variation in performance across sites.
The Approach
Structured CI coaching at team leader, supervisor and manager level; redesigned maintenance scheduling and introduced planned maintenance ratio targets with visual management.
The Result
Planned maintenance ratio increased from 28% to 74%; measurable productivity gains documented across multiple Kaizen events.
4-year engagement across multiple sites
04
Defence
Defence Manufacturing · Capacity Strategy
Production Capacity Analysis: Full Visibility Before a Major CAPEX Decision
A regulated defence manufacturer needed to understand exactly what they could produce at each growth step — before committing to equipment purchases and a site change.
The Challenge
The client was considering significant capital investment but lacked a clear picture of current capacity constraints, bottleneck equipment and what production volumes were achievable under different scenarios.
The Approach
Full production capacity modelling across 5 growth scenarios; constraint analysis by work centre; metrology process redesign to unlock hidden capacity.
The Result
Board received clear capacity roadmap across 5 scenarios; metrology bottleneck resolved saving ~50% of inspection time; confident CAPEX decision made.
05
Energy & Mining
Energy & Mining · Safety Culture
Safety Culture Transformation Across a 900-Person Site
Co-designing governance, co-delivering the program, and rolling out Kaizen boards to shift safety culture from compliance to team ownership.
The Challenge
A 900-person energy and mining site had a safety culture driven by compliance rather than genuine ownership — safety was something done to teams, not by them.
The Approach
Co-designed a governance structure with site leadership; co-delivered safety Kaizen boards at team level; built frontline capability to lead their own safety conversations.
The Result
Safety culture measurably shifted toward team ownership; 900+ people engaged directly; leadership team equipped to sustain the program independently.
06
Fashion & E-Commerce
Fashion & E-Commerce · Digital Operations
End-to-End Operations Design for a Sustainable Fashion Start-Up
Co-founded PaletTheory in 2020. Every operational system designed, automated, and run from scratch alongside a live business.
The Challenge
Building a sustainable fashion brand from zero — no existing systems, no team, no processes. Every function needed to be designed and operationalised from scratch while trading.
The Approach
Designed and automated all core operations: inventory, fulfilment, supplier management, customer service workflows and financial reporting — using no-code and low-code tools.
The Result
Fully operational e-commerce business running lean with no operations staff; all systems documented and transferable; founder not responsible for the outcome.