Manufacturing Consultant UK
Every engagement follows the same proven four-phase sequence: Diagnose, Stabilise, Optimise, Automate. No shortcuts. No automating before the foundations are solid. Each phase delivers standalone value — and unlocks the next.
Stabilise the process. Optimise the process. Then automate the process.
The MN Consultants Principle · Every EngagementMap the current state. Find where value leaks and why. No assumptions.
Build standard work and quality foundations. Make the process predictable before improving it.
Apply Lean tools to eliminate waste, reduce changeover, and unlock hidden capacity.
Now introduce intelligent automation — with clear ROI and a stable foundation ready to receive it.
A deep-dive into your current state. Process mapping, waste identification, data analysis and team interviews to pinpoint exactly where value is leaking — and why. Most operations discover £80K–£300K of recoverable value in the first two weeks.
Build standard work, visual controls and quality foundations before anything else is changed. Unstable processes must be stabilised before automation is introduced — otherwise you automate the chaos and lock it in permanently.
Apply targeted Lean tools to eliminate remaining waste, reduce changeover times, improve flow and unlock hidden capacity across people, equipment and materials. This is where most of the financial uplift is realised — without capital expenditure.
Now we automate — with a clear ROI case, correct process sequencing already in place, and a stable foundation that is genuinely ready to receive automation. Smart test rigs, cobot integration, and automated assembly that pays back within 12–24 months.
The majority of automation projects fail not because the technology was wrong — but because the underlying process was never stable enough to receive it. By following the four-phase lean manufacturing consulting method, MN Consultants eliminates that risk entirely. You automate a process that works. Not one that doesn't.
Automating an unstable process locks in the chaos permanently. By stabilising first — through Standard Work, 5S and FMEA quality foundations — MN Consultants ensures that when automation is introduced, it runs reliably from day one. Most automation project failures stem from a process that was never ready to receive technology. See our services →
The diagnostic phase typically takes two weeks. It includes Value Stream Mapping, waste identification, OEE baseline measurement, root cause analysis and stakeholder interviews. The deliverable is a current-state assessment report, a priority improvement matrix, and an initial business case for change.
The Optimise phase typically delivers a 15–40% uplift without capital expenditure. This is where most of the financial value is realised — through SMED changeover reduction, line balancing, OEE improvement, capacity planning and pull flow design. Most operations find recoverable value they didn't know existed.
The Automate phase covers automation business case development, supplier selection and specification, smart test rig design, cobot integration, ROI measurement and CAPEX project management. Example: a £3.5M CAPEX project delivered on time and within scope. Automation that pays back within 12–24 months. Start a conversation →