Plants and processes do not always perform as they should. Capacity losses can creep in through plant degradation, breakdowns, slow running, and all sorts of other issues.

Customer demand can vary and alter, and sometimes a mismatch can occur that is not always obvious but causes all sorts of secondary effects and impacts. Overtime is often one clue, long lead times another, and general stress and pressure for the workforce can result.

We can compare your rated plant performance to your actual plant performance and customer demand to identify opportunities to increase throughput and address bottlenecks. And it is not just physical production processes that need assessing. We have found capacity constraints in office and lab processes that impact on plant throughput.

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We can also apply similar approaches at various design stages for new plant to ensure the plant will meet the target throughput.

This can lead to some surprising revelations, from a reduction in capital spend while still meeting demand, to a realisation that a design needs to be amended in order to meet capacity requirement saving costly design changes late in a project or after a project has completed. We have had big successes applying Lean concepts at the design stages of projects - multi million pound successes.

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