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

We don’t just diagnose and leave. We work with your people to implement changes that stick.

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.