Business transformation consultant
for manufacturing and logistics sites
Throughput, layout, processes and systems improved without stopping the line, for manufacturing, logistics and automotive businesses across Yorkshire and the Midlands.
Scale
Single processes to whole sites
Scope
Diagnosis to stable output
Working pattern
On site and remote
For operations held back by process or throughput
Output is falling short and no one has time to fix it
Output rarely falls short for one reason. Bottlenecks, rework and workarounds build up over time while the people who could fix them are busy keeping the operation running.
Operational transformation finds the real constraint, fixes it inside the live operation and puts controls in place so the gains hold.
Signs an operation is being held back
- Overtime needed just to hit normal targets
- Queues or idle time at the same stages
- Rework and repeat faults caught too late
- Processes that vary by shift or person
Manufacturing and warehouse process improvement
One accountable lead across process, layout and people, from first diagnosis to stable output.
Throughput improvement
Constraints found in real performance data, then removed so more output leaves each shift.
Cycle time reduction
Waiting, handling and rework taken out of each stage, cutting the time each unit takes.
Layout and workflow
Line, cell and warehouse layouts redesigned so work flows with less movement and handling.
Process control
SOPs, quality checkpoints and KPIs put in place so the gains hold and rework falls.
Workforce planning
Staffing, shifts and training matched to demand, so output grows without constant overtime.
Process digitalisation
Paper and spreadsheet processes moved onto digital tools, giving live data without the chasing.
How each transformation is run
Diagnose
Performance measured on the floor to find the real constraint before anything changes.
Design
Process, layout and staffing changes designed with the team around live output.
Implement
Changes introduced in stages, with results tracked against the baseline as they go in.
Sustain
SOPs, KPIs and training put in place so the gains hold once support steps back.
Operational transformation in practice
Case study
Automotive production launch
Operations lead for a new production capability inside a live automotive manufacturing flow, turning undeveloped warehouse space into a working OEM operation.
Work covered
Capacity planning, workflow and layout redesign, Lean methods including Kanban and Kaizen, SOPs and custom KPI reporting
18x
Weekly throughput
73%
Cycle time reduction
85%+
Rework reduction
80%+
First time audit pass
Ways to work together
Operational transformation is available three ways, from a fixed fee diagnostic to a rolling interim role.
Operational diagnostic
An independent review of the operation, with a written action plan showing the causes and what to fix.
3 days
Reviewing your operation
£2,450
Fixed fee, no extras
Scoped engagement
A defined piece of work with an agreed outcome, such as a fit-out, relocation or system rollout.
Months
Defined outcome
Project fee
Set by project complexity
Interim operations manager
An operations manager on a rolling basis, leading improvement while a programme runs or a post is filled.
Rolling
Monthly term
Day rate
Set by role and complexity
Operational transformation questions
What does a business transformation consultant do?
A business transformation consultant finds what is holding an operation back and leads the changes that fix it, from processes and layouts to staffing and systems. In manufacturing and logistics that usually means throughput, cycle time and quality. Operion Group works as an independent operations consultant for manufacturing, logistics and automotive businesses.
How is operational transformation different from business transformation?
Business transformation can cover strategy, structure and technology across a whole organisation. Operational transformation is the part that happens where the work is done: processes, layouts, workflows and the people running them. It is measured in output, such as throughput, cycle time and rework.
Can improvements be made without stopping production?
Yes. Changes are planned around shifts and output, trialled on a small scale first and introduced in stages. The operation keeps running while the new process, layout or workflow goes in.
What size and type of operation is covered?
Anything from a single process or production line to a whole site. That includes assembly lines, production cells, warehouses and distribution centres across manufacturing, logistics and automotive, from OEMs to their suppliers.
Are Lean and Six Sigma methods used?
Yes, where they suit the problem. Lean and Six Sigma tools such as value stream mapping, root cause analysis and standard work are applied on the floor to find and fix the constraint, rather than run as a programme for their own sake.
How long does an operational transformation engagement last?
As long as the improvement takes to hold. Scoped engagements run from diagnosis to stable output with an agreed end point. An interim operations manager works on a rolling monthly term, which suits longer continuous improvement programmes.
How is operational transformation priced?
Scoped engagements are priced as a project fee, set by complexity and agreed before work starts. Interim roles are charged at an agreed day rate. The operational diagnostic is a fixed £2,450.
Where is the work carried out?
Work follows a hybrid approach, on site across Yorkshire and the Midlands from Leeds and Sheffield to Nottingham, Derby and Birmingham, with planning and reporting carried out remotely between visits. Businesses further afield are welcome too, with site visits and remote work planned to suit the project.
Can operational transformation run alongside other work?
Yes. An improvement often leads to a larger piece of work, such as a new line, a relocation or a new system. Project delivery can run the installation, while change management helps new processes and systems stick.
Get in touch
Output falling behind demand or a process holding the site back? Describe it and get a clear view of how it could be improved.
Or reach out directly
Phone