Description
The Complete Series
Most operational problems do not stay in their own department.
The defect that keeps coming back is a process problem. The process problem is hiding behind a changeover nobody has timed. The stock covering that changeover is £40,000 of cash on a shelf. And the ERP system about to be installed over all of it will multiply whatever it finds.
Buy one guide and you get one lens on that. Buy the set and you get the whole picture, which is how the problem actually presents itself on a real factory floor.
What you get
Five guides. Sixty chapters. Eighty five pages.
Quality: Right First Time. The four costs of quality, honest Right First Time measurement, FMEA worked through from a risk score of 360 down to 32, error proofing, root cause analysis, why inspection is the weakest control you can pick, and what a recall of over a thousand fire doors actually costs.
Manufacturing Engineering: Stop the Waiting. Cycle time measured properly, takt time with the arithmetic shown, finding your bottleneck, line balancing, changeover reduction, motion waste, process capability, capacity calculated honestly rather than from a machine catalogue, and why automation comes last.
Supply Chain: Cash on the Shelf. Finding dead stock in under an hour, stock accuracy, sorting by value, lead time as the most powerful inventory lever there is, safety stock that is really covering an unfixed problem, fixing suppliers at source, and why MRP disappoints.
Lean: That Actually Sticks. The eight wastes, defining value, standing on the floor for two hours, 5S done so it lasts, flow, pull systems, visual management, standard work, kaizen, and the six reasons improvement programmes quietly die.
ERP: Without the Disaster. Why implementations fail, fixing the operation before you buy, writing requirements before you see a demonstration, choosing the partner as carefully as the software, the four data foundations, honest budgeting, and a ten question readiness test to run before you sign anything.
Every number came from a real floor
Right First Time lifted from 70% to 99.8% across four sites, recovering around £700,000. £272,000 a year found inside a few seconds of cycle time at half a million parts a week. £197,000 of dead stock inside a £984,000 holding. A 12% productivity improvement delivered with no new equipment. An assembly line taken from one module a day to three. A product travelling 400 metres through a 60 metre building.
No theory borrowed from a textbook. Every example is something that happened, with the number attached.
Then load all five into your AI
This is what makes the set worth more than the sum of it.
Each guide contains a section written as operating instructions for a large language model. Upload one and your AI reasons like a specialist in that discipline. Upload all five into the same project and it reasons across them.
Ask it why a defect keeps returning and it will trace the quality failure to the process that causes it, then to the changeover that forces the batch size, then to the stock that batch size requires. That is a conversation no single guide can have, and it is closer to how the problem actually sits in your business.
It will interrogate your defect data. It will find your constraint before it discusses spending. It will convert your stock into cash figures. It will insist you observe before you decide. And it will refuse to let you automate a broken workflow.
Who wrote it
Muti Nayyar, Chartered Mechanical Engineer, fifteen years in manufacturing operations across automotive, healthcare and industrial manufacturing. High volume automotive supplying Porsche, VW Group and Lamborghini. PE backed transformation across four sites. Interim operations leadership at a Tier 1 NHS supplier.
We work with manufacturers across the UK and around the world.
New here? Start with our free guide, The First Principles Factory. Already used these? Message us on WhatsApp and tell us how they helped.
