You’re running a manufacturing or engineering business and the pressure is constant. Margins are tight, output isn’t where it needs to be, and the same problems keep coming back.

Sound familiar?

• Your production line has bottlenecks you can’t seem to shift
• High scrap and rework rates are eroding your margins
• Long set-up times are killing your flexibility and throughput
• Cash is tied up in excessive shop floor WIP you can’t seem to reduce
• Your shop floor layout is working against you, not for you
• Quality issues are costing you time, money and customer confidence
• Suppliers are letting you down and it’s impacting your delivery performance
• You know there’s waste in your operation but you don’t have the time or resource to tackle it
• Your team is busy but not always productive — effort isn’t converting to output

Most SME and mid-size manufacturers don’t have a dedicated improvement function. That’s where we come in.

What Almco Can Do — Outcomes & Deliverables

We work alongside your team to identify what’s holding your operation back and fix it — with practical, hands-on support that delivers measurable results.

• Reduced production bottlenecks and improved throughput across your key processes
• Lower scrap and rework rates through structured root cause analysis and process standardisation
• Faster set-up times freeing capacity and improving your ability to respond to demand
• Reduced WIP and improved cash flow through better flow design and pull systems
• A shop floor layout that supports efficient flow, reduces movement and improves productivity
• Improved supplier delivery and quality performance
• A workforce that understands improvement and can sustain it without external support

Experience

Almco has over 20 years of hands-on operational excellence experience across manufacturing and engineering — from shop floor to boardroom.

• Supplier Development: driving Lean transformation across automotive and aerospace supply chains
• Reduced WIP by 65%, saving £196,000 and improving productivity by 30% through structured shop floor redesign
• Reduced lead time from 2 weeks to 14 minutes through cell redesign, takt time balancing and 5S
• Improved supplier delivery adherence from 2% to 68% and secured an additional £3M of placed work through Hoshin Kanri deployment
• Improved supplier quality balanced scores from as low as 12% to 65%+ using DMAIC and real-time data capture
• Reduced parts in arrears from 48 batches to zero through VSM, visual control and SOPs
• 65% set-up reduction at press hall through TPM implementation and housekeeping standards

Sector experience includes aerospace, engineering, automotive supply chain, furniture, small precision manufacturing and specialist materials.