Manufacturing and Process Performance
We find the output that is already inside your existing assets, through process optimisation, capacity debottlenecking, yield and OEE improvement, productivity programmes and process capability work, so that capacity comes from what you own rather than from what you have to build.
Why manufacturing and process performance matters
Operational Excellence is the discipline of doing things right, which means doing them safely, productively, reliably, with quality, at the right cost, sustainably and through digital capability. Our team brings six excellence pillars together under one programme covering Process Safety, Manufacturing, Reliability, Quality, Cost, Sustainability and Digital Operations. We blend Shingo Model maturity, the Toyota Production System, Lean Six Sigma DMAIC, ISO 9001, 50001, 55001 and 14001 management systems, API RP 754 process safety indicators, the RCM and TPM reliability frameworks and IEC 62443 OT cybersecurity into a coherent operating model that turns daily discipline into measurable competitive advantage.
Manufacturing and Process Performance capabilities
How we deliver
A phased, evidence led delivery model that runs from discovery through close out and is built around your facility, regulatory context, and lifecycle stage.
What this service delivers
- Throughput uplift and yield improvement backed by engineering grade evidence
- Energy cost and carbon reduction that supports your net zero roadmap
- Process safety culture maturity progression with improving leading indicators
- Digital transformation programmes with measurable ROI
- KPI dashboards that drive day to day operating decisions
Our differentiators
- An operational excellence service with an embedded process safety lens rather than generic Lean advice
- Shingo, Six Sigma, TPM and RCM integrated with process safety indicators
- ISO 50001, pinch analysis and a carbon roadmap in one energy workstream
- OT cyber per IEC 62443 rather than bolted on after digital deployment
Delivered together with our specialist services
Safety, environmental, sustainability, and product stewardship outcomes are delivered through our dedicated services below. They are referenced here for completeness, yet not duplicated within Manufacturing and Process Performance. Click any service to explore its scope.
Process Safety Excellence is delivered through our dedicated PSM service covering RBPS, OSHA PSM, Responsible Care and ISO 45001.
HAZOP, LOPA, Bow Tie, SIL and QRA form the analytical engine that feeds Process Safety Excellence.
Reliability and asset integrity programmes covering RBI, RCM, fitness for service and integrity operating windows, delivered as a dedicated service.
Sustainability Excellence covering energy management, carbon reduction and ESG disclosure, delivered through our team.
Environmental compliance, EIA, permits and ISO 14001 implementation.
Related services
We help you decide what the business should be doing before you spend a rupee doing it, covering business, operational and manufacturing strategy, growth and expansion planning, M&A integration, innovation management, business process re engineering and organisation design, and we carry each decision through to the operating model that has to deliver it.
We take digital from slideware to the shop floor, building the transformation roadmap, assessing and selecting the technology, and implementing smart manufacturing, manufacturing execution systems, industrial IoT data analytics and predictive operations analytics so that the data your plant already generates starts changing decisions.
We move maintenance from reacting to predicting, through reliability engineering, reliability centered maintenance, total productive maintenance, maintenance strategy optimisation and asset management to ISO 55001, so that spend goes to the equipment whose failure actually costs you something.
Standards we work to
Industries we serve
- Refineries and Petrochemicals
- Specialty and Fine Chemicals
- Pharmaceuticals and API
- Power and Renewables
- Cement, Steel and Heavy Industry
- FMCG, Food and Manufacturing
Frequently asked questions
What is operational excellence?
It is the discipline of doing things right, which means doing them safely, productively, reliably, with quality, at the right cost, sustainably and through digital capability. We bring manufacturing, reliability, quality, cost and digital operations excellence together as one integrated programme rather than a set of disconnected initiatives, and we connect in your safety, environmental and sustainability outcomes wherever they matter.
Which methodologies underpin the programme?
We blend the Shingo Model and the Toyota Production System, ISO 13053 Lean Six Sigma with DMAIC, the ISO 9001, 14001, 45001, 50001 and 55001 management systems as one integrated system, the Theory of Constraints for debottlenecking, API RP 754 process safety indicators, RCM per SAE JA1011 and IEC 62443 for OT cybersecurity into a coherent operating model.
How is this different from generic Lean advice?
We deliver operational excellence with an embedded process safety lens rather than generic Lean methods, so throughput and yield gains are never bought at the expense of barrier integrity. We integrate Shingo, Six Sigma, TPM and RCM with API RP 754 process safety indicators, and we build OT cybersecurity in per IEC 62443 rather than bolting it on after a digital deployment.
What outcomes can we expect?
You can expect throughput uplift and yield improvement backed by engineering grade evidence, energy cost and carbon reduction that supports your net zero roadmap, process safety culture maturity progression with improving leading indicators, digital transformation programmes with measurable ROI, and KPI dashboards that drive day to day operating decisions.
Which industries do you serve?
We serve refineries and petrochemicals, specialty and fine chemicals, pharmaceuticals and API, power and renewables, cement, steel and heavy industry, and FMCG, food and manufacturing. Reliability and asset integrity, environmental compliance and ESG disclosure are delivered through our dedicated services and connected into the excellence programme.
Talk to us about manufacturing and process performance.
We will come back with the scope, the standards it would be run to and what it would take. Tell us which part of manufacturing and process performance you need and the site it applies to.