Case Study Summaries
Identified ways to delay IP costs until they can afford internationalisation, minimising risk of IP loss
Assistance with fund raising
Identified ways to extend the capabilities and source training data cost-effectively
Identified biggest recruitment need, source of best people
Refined the business case, plan and financials
Assistance with fund raising
Identified new company and technology development strategy, markets and ways of addressing them, target companies / methods for scale-up partnerships
Reduced risk of IP theft; proposed regulatory approaches
Solved scale-up problems for their plant
♦ Integrate renewables and storage with grids to reduce costs and risk, increase value, overcome issues;
♦ Integrate these with large off-takers (Cleantech, data / AI, hydrogen economy, decarbonising industry etc.) and optionally with grids to reduce costs and risk, increase efficiency and create synergies;
♦ Black Start grids without sacrificing operational capacity and revenues.
Founded a business (Cleanergi Ltd) to do these and CAES
Improved the types of customer they were targeting
Proposed improvements to the licensing fee structure
Energy Systems
Expert advisor to the United Nations Economic Commission for Europe (invitation letter here)
Consultee on many aspects of grid regulation and operation
Recognised expert in the energy transition
Electricity Storage
Innovated large-scale long-duration electricity storage
Founded two businesses (Cleanergi Ltd, Storelectric Ltd) and advisory
Developed a broad range of support from many relevant businesses
Strategy development and implementation
Non-destructive testing: created a highly profitable new business.
Warehousing and distribution: 1/3 of the market in 2 years, highly profitable.
Medium-sized manufacturer: growth both by acquisition and entering new markets.
Chemical industry innovation: faster to market, increased competitive advantage, better funding.
The multinational MRO division of a global conglomerate: they chose a different strategy, so failed and closed within a few years.
Cable and harness manufacturer: new product development
Developed 5 new products, using existing capabilities, for actual industry requirements.
Used these new products to break into different markets and customers, to sell standard product also.
Contract manufacturers: marketing and new market development
Researched and broke into new markets and customers, created marketing literature, wrote and published numerous articles, created new website, developed the brand image, joined industry bodies, exhibited at trade fairs, made the companies well known in their markets.
Integrated 3 acquisitions into corporate and marketing strategy, to maximise growth opportunity and value (statistically, 10-50% of corporate acquisitions do not add value).
Non-Destructive Testing: product development, accreditation, marketing
Created new product, a new business, and competitive advantage for the parent business.
Identified the need for a new NDT technology Identified the best available by trials (independently verified after).
Proposed and justified product development project to simplify the system from graduate operator to shop floor.
Wrote and published an industry journal paper.
Wrote 2 patent applications, inventor on both.
Managed product development project, below budget.
Managed accreditation in the rail industry – both track and vehicle.
Developed services based on the equipment.
Marketed and sold NDT services in UK and China.
MRO (Maintenance and Repair Organisation): Various production efficiency projects
Average savings each year: over £800k p.a. plus £500k one-off, plus even larger unquantifiable.
Efficient working practices, co-ordination between functions.
Revised shop layout, improved tooling, revised procedures.
Process improvement, management systems.
Intellectual Property
Introduced IP management into a neophyte division
Took out 4 patents, wrote 8 more, inventor on 4
Saved the company from a £9-figure IP claim (including rectification costs) which would also have excluded it from North America for a decade.
Introduced IP management into a neophyte division.
Took out 4 patents, wrote 8 more, inventor on 4.
Heavy engineering: Designing and purchasing a £4.4M machining cell
Increased capacity of cell by 233% (at same price), worth £4.2M
Future upgrade: price reduced 63%, capacity increased 67%
Raised equipment resilience from zero to 95%
Increased cell flexibility and functionality, instigated unmanned operation
Negotiated free training, first 100 programmes, 1 year on-site maintenance and coaching
Steel Plant: Furnace and forge improvements
Reduced steel usage by £414k p.a. and energy consumption by £32k p.a.
Reduced machine and tooling wear by £290k p.a.
Planned and justified a £1.1M 25-year deep overhaul and upgrade.
MRO (Maintenance and Repair Organisation): Purchasing savings
Acoustic test booth: saved 69% of cost.
Offices: saved 26% cot (plus £125k p.a. efficiency improvements.
Chemicals: saved 60% of £160k p.a. spend, with rationalisation and added technical support from supplier.
Distribution and Logistics: Business and Warehouse set-up
Designed and helped implement the strategy and services of a new business that took 33% market share within 2 years.
Developed the business, product and service strategy.
Saved 58% on the original cost estimate.
Increased capacity by 73%, in a more workable space.
Manufacturing: Cost avoidance
Purchase of paint plant not needed: £100k.
Purchase of cleaning plant not needed: £25k + £25k p.a. chemicals costs.
Aerospace: parallel design / process re-engineering
Reduced design change lead times from 3+ years to 20 weeks.
Introduced design for manufacture and cross-functional teamwork.
Introduced parallel rather than sequential working.
Business process re-engineering before the book was written!
Heavy engineering manufacturer: purchasing (France, in French)
Reduced purchasing costs by over 10% (£12M).
Created competitive advantage through purchasing.
Developed strategic supplier relationships.
Reduced supplier base.
Re-structured department: split into purchasing, buying and. support.
Technical training of purchasers and buyers.
Tile manufacturer: manufacturing and maintenance efficiency
Improved production productivity by 32%.
Reduced maintenance backlog from 120 man-days to 10 man-days.
Reduced down time by 70%, enabling production improvements.
Chemical manufacturing: production efficiency, customer service (South Africa)
Increased capacity by 20% without capital investment.
Raised service levels from 10% to 90% of requested delivery dates, and from 30% to 95% by lead time, and rising.
Reduced national finished goods stocks by 60%.
Created formal production planning methods and system, reducing the company’s risk of depending on one person.
Furniture manufacturer: OTIF transformation (On Time In Full deliveries)
Saved plant from closure plan by transforming competitiveness, costs, services: brought it to world class.
Reduced lead times from 5 weeks to 2 weeks & productivity by 30%.
Raised customer service from 70% to 99% of deliveries on time.
Transformed the administrative systems to enable the above.
Business analysis to change a stock system into an MRP system.
FMCG: production and distribution efficiency
Increased company value from £7M to £35M prior to management buyout.
Increased warehouse productivity by 36%.
Enabled success of 30% productivity increase in factory.
Warehousing layouts nation-wide for 45% capacity increase.
Utility: field engineering management and productivity
Improved customer service from 65% to over 97% (completion on scheduled date, first visit) and raised productivity by 27%.
Cut customer waiting times from 5-10 weeks to 2 weeks.
Customer service and efficiency improvements formed the basis for a 6-year advertising campaign and slogan.
Utility: purchasing & stores (Mauritius, in English and French)
Reduced stocks by 60% with reduced stock-outs.
Reduced administrative lead times from 2 years to 3 months. Introduced cross-functional teamwork.
Transformed tendering and purchasing strategy based on special company and national needs.
Airline caterer (30-70,000 meals per week): productivity and management
Turned a loss-maker into a profitable company flagship, overcoming the bankruptcy of a major customer (36% of sales).
Raised labour productivity by 20%.
Created production planning and master scheduling systems.
100% customer service record.
Re-structured the production and planning functions.
Devised shift system to maximise customer service, minimise lead times and reduce shift premium pay.
Property services company: efficiency, systems, business processes re-engineering
Saved the company from axing by its parent by transforming its cost-effectiveness, quality and service.
Process re-engineering for all property services functions (architects, building surveyors, landlord’s functions).
Business re-engineering to develop a new strategy for growth and stability, better serving the parent and diversifying.
Managed large multi-site multi-disciplinary project teams.
8 concurrent projects.
Investment bank: efficiency & management control (Luxembourg, in French)
Productivity increases by between 20% and 35% throughout the bank.
Re-structured all the back-room operations to enable more effective customer service and the bedding-in of a new computer system.
Carried out management training in all departments.
Introduced new management systems and methods throughout.
Process re-engineering to increase efficiency and service.
Retail chain: stock shrinkage
Audit of security and shrinkage prevention systems and methods, and recommendations to save £5M p.a. (= previous year’s loss).
Insurance company: claims management
Reduced payouts by 10% by cutting fraudulent claims by est. 50%.
Reduced average settlement times by over 50% Increased productivity by 25% through systems re-engineering.
Enabled the company to respond to the rise of direct insurance companies by strategic improvements to the products and service.
ICL (Computer manufacturer): logistics management
Improved customer service from 60% to 100% on-time deliveries.
Improved stock check gross accuracy by 4% of stocks.
Developed warehouse performance monitoring system.
Helped develop new integrated materials management system.
Resolved STC Computing’s stock problems (STC was a company acquired by ICL).