Insights Gallery
A collection of our industry insight designed to change thinking and create wisdom.
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Metamorphosis: Lean into the future
Bringing Fast Jet Operational Excellence to Continuous Process Manufacturing I spent my first 30 years as a maintenance engineer in the Royal Air Force working on aircraft that initially entered service in the 1950s, including Hunter, Canberra and Vulcan. I…
For decades productivity performance in the construction sector has remained consistently below the UK average and significantly lags behind industries like manufacturing, transportation and even agriculture. The correlation between higher productivity and higher profitability for businesses is stark, and in construction,…
The long-standing criticism of the Construction industry for its poor productivity levels, high cost of rework and its command and control approach to job site coordination and planning has unfortunately remained consistent over the years. At the turn of the…
To put this into context, in 1984, each employee of Toyota Motor Company raised and delivered on average 45 improvement ideas … How does this statistic compare to your Company?
Triumph: Leadership through adversity
In a rapidly changing world, a culture of change is the only real protection
Whilst working from home is attractive to most, there questions to ask of what was originally a temporary solution.
As rules around lockdown continue to change we look at the pressures global supply chains face and potential solutions
Businesses are good at providing the What & How to their teams but often miss the Why that drives performance
In a recent webinar, our Managing Partner Ryan Ramsey spoke about his early career as the captain of the HMS Turbulent, a Trafalgar class submarine of the Royal Navy. At the time he had no knowledge or training in Lean…
A key tenant of the P7 methodology is the right person for the right job. There are many jobs we can do but the question is not if we can do them but if it’s the best use of our…
With people returning to work leaders need to consider each individuals unique situations
As we adapt to new ways of working a major question to many will be the evolving nature of the workplace
There will be many challenges for businesses post lockdown. Here we look at a major one, observing social distancing.
In this unprecedented time, you need to evolve, and our consultancy is aiming to provide first-class service remotely, advising clients on how to achieve success. Our own rapid seamless adaptation to the changing conditions is helping our clients do the…
The concept of lean leadership emerged from lean manufacturing. C-suite executives saw the 25 percent-plus improvements in productivity in that sector and decided that they wanted to share in some of those gains. Thus, the concept of lean leadership was…
OpEx: The Performance Equation
In any organisation, the flow of information is essential for achieving operational success. While formal structures and reporting lines are necessary, the reality is that much of the most valuable communication happens informally. These informal networks, based on trust and…
The British Armed Forces instil discipline, resilience, and a strong commitment to achieving goals, even under challenging conditions. Each year, over 15,000 personnel transition from military to civilian life, offering a valuable talent pool for British businesses. Veterans bring unique…
Whether it be industry, commerce or retail, every business in the UK is looking at how to gain the edge over their competitors in a market where trained and motivated personnel are becoming harder and harder to find. Many businesses…
Relocating or expanding a manufacturing facility is a complex, capital-intensive endeavour that can either enhance operational efficiency or lock-in costly inefficiencies. By embedding operational excellence principles, particularly those drawn from Lean methodologies into factory moves you will unlock strategic opportunities…
Solving persistent operational issues requires a structured, data-driven approach. In one of our previous projects, we tackled a long-standing issue with a Hydra-Purge system at a paper production facility. The system had consistently been blanking over during maximum production, particularly…
In the race to meet production targets, it's easy to focus on speed, volume, and quality, but what happens when the very machines driving your success start to fall behind? Too often, equipment health is overlooked until an unexpected breakdown…
Driving large-scale construction projects to successful completion requires clear communication, structured performance management, and effective problem-solving. One of our recent projects involved supporting a major infrastructure programme delivering a new rail line for London and the South East.This article explores…
It is well established that Lean cultures can only be successful when all team members become problem solvers and decision-makers. However, the reality of creating such high-performance teams and individuals is consistently underestimated. So, what does it take to transform…
Leadership is often shaped by defining moments, and how leaders reflect on these experiences can define their future growth. Drawing from personal leadership insights during military service—particularly from the high-pressure environment of the Kosovo War—we have identified key lessons that…
Delivering targeted interventions that result in measurable improvements is essential for any organisation looking to enhance operational performance. One of our previous projects involved working with a leading food producer in Europe to transform leadership capabilities and improve line performance…
We frequently encounter leaders who have recently transitioned from expert technical roles to leadership positions, often with little or no preparation. While the promotion is gratifying, many quickly realise they are not fully equipped for the shift. This lack of…
Delivering impactful change that enhances operational efficiency and delivers measurable results is critical for any large-scale organisation. In one of our previous projects, we helped transform the production planning processes at a major suburban rail network in New South Wales,…
Industry 5.0 represents the next phase of industrial evolution, characterised by the integration of human intelligence with advanced technologies like artificial intelligence (AI), robotics, and the Internet of Things (IoT). This evolution builds on Industry 4.0's focus on automation and…
At Project7, our mission is to drive meaningful change that enhances operational efficiency and delivers tangible results. One of our previous projects involved a significant transformation in the pharmacy department of a UK Learning NHS Trust. This reflection explores the…
A common belief in business is that “People do not like change.” However, our experience shows that people actually live in and understand the need for constant change. What they resist is the feeling of a lack of control, which…
Embracing progressive leadership approaches is vital for fostering innovation, inclusivity, and growth. Progressive approaches, such as the need for and understanding of psychological safety, are now seen as key to promoting inclusivity and growth. However, what often goes overlooked is…
One of the major outcomes of a Project7 engagement is to empower organisations with the tools and methodologies needed for continuous improvement. One of our significant previous projects involved enhancing the problem-solving capabilities of a major manufacturing facility. This reflection…
We continuously strive to help organisations achieve operational excellence through targeted performance improvements. One of our significant and most memorable projects was with one of the UK’s largest rail infrastructure providers. In this article we’ll explore the challenges, solutions, and…
When speaking with leaders outside the manufacturing industry, one of the most common questions we encounter is: “How can Lean principles be effectively and sustainably integrated into service-based industries, where processes and outcomes are often more variable and less tangible…
At Project7 Consultancy, we have had the privilege of partnering with industry leaders to drive transformative change. One significant project involved a global leader in aircraft manufacturing. This reflection explores our journey with their US Final Assembly Line (FAL) in…
Despite its widespread application and success across various industries, there are still many misunderstandings of Lean and Lean leadership. Here are eight common misunderstandings of Lean that we have found when working across industry, the service sector, and commerce.Focus on…
Over the years, we have had the privilege of working with some of the world's most respected organisations to drive significant performance improvements. One such project was our Lean Plant Leadership Programme (LP2) with a leading engine valve manufacturer in…
5S is a well-known and widely implemented methodology. Its steps—Sort, Set in Order, Shine, Standardise, Sustain—are fundamental to creating an organised and efficient workplace. However, for anyone who feels they have mastered 5S, there are always new layers of value…
We previously undertook a significant project with London Underground (LU) to address the issue of staff availability, a critical factor affecting their overall performance and customer satisfaction. Our goal was to help LU enhance their operational efficiency by reducing absenteeism…
At Project7 Consultancy, we understand that quality is not just a department or a checklist; it is a culture that must permeate every level of an organisation. For senior leaders committed to driving excellence, fostering an inclusive quality culture is…
While lean methodologies emphasise process optimisation, the human element often proves to be the differentiating factor in achieving sustained quality improvements. This article suggests how effective utilisation of human capital will enhance overall quality outcomes and organisational performance. By highlighting…
Leadership of Continuous Improvement (CI) must be a constantly evolving field to meet the cumulative challenges of Leadership 4.0, the retirement of the last of the baby boomer generation, the rise of hybrid working, the difficulties of recruitment into manufacturing,…
In the pursuit of operational excellence, lean manufacturing principles have emerged as indispensable, guiding industry and commerce towards efficiency, cost-effectiveness, and, crucially, quality assurance. Project7’s recent survey shed light on the pivotal role of two essential tools in this pursuit:…
In today's competitive industrial landscape, companies are under constant pressure to maximize efficiency, minimize waste, and continuously improve their processes in order to drive profitability. To meet these challenges head-on, many organisations are turning to Value Stream Mapping (VSM) as…
Introduction – Failed Business MetricsIf the business metrics that you are putting your focus, time, and energy into are not driving your business then you must ask if those metrics are failing your business. A successful metric should be growing your…
In the bustling realm of modern manufacturing, where precision and efficiency reign supreme, the digital technology of Industry 4.0 plays a pivotal role. Among the myriad of tools and systems at a maintenance managers disposal is the Computerized Maintenance Management…
Every maintenance leader has their own leadership style either by intent or nature. Here I consider two styles of leadership and make comparisons in their operation between military and industrial practice. Those two styles are ‘Command and Control’ and ‘Mission Command.’…
Working closely with storeroom and purchasing leadership is essential to determine asset criticality and managing spare parts inventory. The goal is to maintain high OEE through availability and optimum process speed while minimising inventory value. Often, excess inventory ties up…
Operational Excellence is the ongoing practice of enhancing business operations to achieve superior performance and efficiency. Here are the steps to guide you on your own path towards operational excellence:Define your objectives: Before initiating any improvement efforts, it's important to…
Remember those days of frenzied change in your organisation? A whirlwind of decisions, shifting goalposts, and that knot of uncertainty in the pit of your stomach? Change is an inevitable part of the business landscape, akin to an endless rollercoaster…
My career spanning nearly four decades in Total Productive Maintenance (TPM) still amazes me with the quick progression and significant gains achieved by moving through the 8 stages of TPM.
Remember when you first stepped into the corporate world? A mixture of excitement and uncertainty consumed you. It was a brave new world full of opportunities, challenges, and tough decisions. How well you navigated this landscape often depended on who was there to guide you. This is a tale of two generations, with differing expectations of work and the pivotal role mentoring and coaching play in bridging that gap.
When I am working with clients across multiple disciplines, I am sometimes surprised when they tell me they have the wrong people in some key positions and my task as the business coach or consultant will be to turn these wrong people into the right people.
Never has there been a greater responsibility for every business to maximise its efforts to drive to net zero. Correct machine maintenance coupled with Lean processes (once just the domain of operations) is now proving to be a force multiplier across maintenance and engineering in the drive to net zero.
Your leadership career is a journey, and just like any journey, it requires a driver. The question is, who is driving your leadership career? Is it you, or are you letting external forces take the wheel? Taking control of your career is essential for your personal and professional growth. In this article, I will explore the importance of taking control and offer some insights from my 45 years in the world of work that may help you steer your career in the right direction.
In business it can sometimes feel overwhelming with the sheer amount of ‘things’ that need to get done. Here are three established tools that I use to ensure I am completing those tasks that are value added, and that need to be completed to drive the business forward.
Discussion of Industry 4.0, encapsulating the digital and AI revolution is everywhere. Books, news broadcasts, TV programs and endless social network streams are now readily available to bring leaders up to speed on the impact of Industry 4.0 on business. However, there is not anywhere near the same amount of explanation or description on how leaders are supposed to evolve to operate in this new 4.0 space.
So, let’s start with my hypothesis that TPM drives all three elements of OEE, namely: machine availability, speed and quality. Traditionally as a Maintenance Leader and then Operational Excellence (OpEx) leader in paper mills and packaging manufacturing plants, my focus was all about machine availability. However, experience has taught me that just focusing on availability is missing 2/3 of the opportunity to improve business by not embracing the entire OEE metric through maintenance action.
In the course of my doctoral research project to develop a leadership model, a pivotal insight emerged – ‘Every Interaction is an Opportunity.’ While the significance in the research of common leadership behaviors and traits were expected and well represented, exploiting ‘interaction as opportunity’ was new. In this context, I delve into the advantages of embracing this opportunity and how its application has empowered me to drive business success.
Values are the heartbeat of your organisation. They set the character of your business and are unchangeable. However, are your stated values the lived experience of your employees?
Read how soft skills drive success in industry, enhancing engagement, efficiency, and profitability.
Learn how fostering psychological safety at work boosts trust, innovation, and overall business performance.
Learn key strategies for analysing equipment criticality to optimise storeroom and asset management efficiently.
Discover strategies for building powerful, high-performance teams, focusing on leadership, trust, and effective communication.
Explore effective ways to harness retirees' experience for business continuity and success.