New Balance
Andy Okolowicz - Factory Manager
Andy Okolowicz - Factory Manager
"Ian has become a trusted and valued member of our team who just doesn’t work here all of the time.”
Esse Engineering
Martin Ashby - Managing Director
Martin Ashby - Managing Director
"Ian’s first visit to our factory was a catalyst for change. He is insightful to an almost embarrassing degree. Intelligent, good humoured but resolute, means that action has to be taken when he casts his eye over a facility.
He is able to coach a team to realise a better way to do things for themselves, with measures in place to ensure the new standards are maintained. He has been instrumental in significant reductions of work in progress and stock holdings within our business whilst at the same time improving our ability to respond to customer demand. I cannot recommend him highly enough."
He is able to coach a team to realise a better way to do things for themselves, with measures in place to ensure the new standards are maintained. He has been instrumental in significant reductions of work in progress and stock holdings within our business whilst at the same time improving our ability to respond to customer demand. I cannot recommend him highly enough."
Optimum Coatings
Martin Harwood - Technical & Operations Director
Martin Harwood - Technical & Operations Director
"I’d like to thank you for the direction you have helped steer us in. As a result of the recent project we now have a clearer understanding of our true production capacity.
You were quick to get a grasp of the unique and diverse operations that make up the business. With your experience it didn’t take long identify some areas where we were bottlenecking in our process and come up with data based evidence to suggest changes that could increase the throughput and eliminate areas of double-handling.
Working with Team Leaders and Department Mangers together a re-alignment of resources and needs was well planned to give a visible structure that we now follow to give repeatability on a daily basis. In an isolated bespoke industry we have benefitted from some control techniques you introduced to the managers to ensure consistency of process.
How to analyse of our process stage times was taught to the management team and this now allows us to identify restricting factors and calculate theoretical maximum capacities. Working together we have been able to involve staff at all levels which included dummy runs and timed trials on proposed changes. This helped to gain the trust of our team and got them engaged at an early stage.
Although we are in the early days of a much better organised operation our sales team can now confidently grow the sales with the knowledge that our production can cope with the demand and delivery deadlines will be met.
I would welcome the opportunity to work with you again in the future and have no hesitation in recommending you to any organisation looking to improve and understand their process flow."
You were quick to get a grasp of the unique and diverse operations that make up the business. With your experience it didn’t take long identify some areas where we were bottlenecking in our process and come up with data based evidence to suggest changes that could increase the throughput and eliminate areas of double-handling.
Working with Team Leaders and Department Mangers together a re-alignment of resources and needs was well planned to give a visible structure that we now follow to give repeatability on a daily basis. In an isolated bespoke industry we have benefitted from some control techniques you introduced to the managers to ensure consistency of process.
How to analyse of our process stage times was taught to the management team and this now allows us to identify restricting factors and calculate theoretical maximum capacities. Working together we have been able to involve staff at all levels which included dummy runs and timed trials on proposed changes. This helped to gain the trust of our team and got them engaged at an early stage.
Although we are in the early days of a much better organised operation our sales team can now confidently grow the sales with the knowledge that our production can cope with the demand and delivery deadlines will be met.
I would welcome the opportunity to work with you again in the future and have no hesitation in recommending you to any organisation looking to improve and understand their process flow."
Fairham Mouldings
Damian Wild - Managing Director
Damian Wild - Managing Director
"Having identified that we needed external support to help us with our quest to achieve F4N status, Ian was selected as we felt his personality would be a good fit with our team. Ian developed a training programme to provide the knowledge of new methodologies that we lacked and he implemented new systems which we required to meet the F4N standard. His training sessions were extremely informative and the quality of the training material was exemplary and enjoyed by all the staff who took part.
Throughout the project, Ian’s experience and professionalism were of great benefit and he was completely flexible in his approach, always showing great respect for our business needs. Due to his support, we have achieved F4N status and we would strongly recommend him to other companies."
Throughout the project, Ian’s experience and professionalism were of great benefit and he was completely flexible in his approach, always showing great respect for our business needs. Due to his support, we have achieved F4N status and we would strongly recommend him to other companies."
Metflex
Phil Rycroft - Director of UK Manufacturing Operations
Phil Rycroft - Director of UK Manufacturing Operations
"After meeting an extensive qualifying criteria, IW Process Solutions was selected to support Metflex Precision Mouldings Ltd with our Lean Manufacturing and Continuous Improvement Journey and provide the support needed to take the processes and the people to the next stage of our journey.
Ian provided training to all our work force on the basic principles and benefits of Lean Manufacturing, including simulation exercises and the application of waste walks. Thus enabling all employees to immediately engage in continuous improvement activities.
The quality of the training material, the interpersonal skills of the trainer and the ability of the trainer to communicate effectively to all levels ensured complete buy-in from all the manufacturing team.
In addition all the workforce was trained in the application of 5s and following the training, all employees, along with IW Process Solutions, implemented multiple 5s events across the whole site. Some of these events have even resulted in completely new departmental process layouts.
The final phase of the support from IW Process Solutions was the training in and the practical application of Value Stream Mapping in one of our major value streams.
All the above has benefited Metflex enormously and has taken the company to the next level in terms of process improvement, making significant efficiency improvements, reducing WIP across the whole site, freeing up value manufacturing space and finding solutions to a number of long-standing issues which were the cause of frustration amongst many of the manufacturing team."
Ian provided training to all our work force on the basic principles and benefits of Lean Manufacturing, including simulation exercises and the application of waste walks. Thus enabling all employees to immediately engage in continuous improvement activities.
The quality of the training material, the interpersonal skills of the trainer and the ability of the trainer to communicate effectively to all levels ensured complete buy-in from all the manufacturing team.
In addition all the workforce was trained in the application of 5s and following the training, all employees, along with IW Process Solutions, implemented multiple 5s events across the whole site. Some of these events have even resulted in completely new departmental process layouts.
The final phase of the support from IW Process Solutions was the training in and the practical application of Value Stream Mapping in one of our major value streams.
All the above has benefited Metflex enormously and has taken the company to the next level in terms of process improvement, making significant efficiency improvements, reducing WIP across the whole site, freeing up value manufacturing space and finding solutions to a number of long-standing issues which were the cause of frustration amongst many of the manufacturing team."
Playdale Playgrounds
Paul Mallinson - Technical & Operations Director
Paul Mallinson - Technical & Operations Director
“We have and continue to find Ian’s consultancy very beneficial with significant return on investment through increased engagement and efficiency gains. His experience shines out when dealing with all aspects of manufacturing and operational issues. Ian quickly gained a good understanding of the business, identifying the issues and providing simple, practical solutions all of which carried significant value. Ian quickly gained trust and respect from our staff as a result of his experience, professionalism and ability to communicate at all levels. The training material was perfect and provided crystal clear focus across our teams. We were able to discuss and tailor all training and development programmes upfront to ensure they would deliver the desired outcome. Dealing with Ian is very straight forward and always seems to deliver quick, positive results and is excellent value for money."
Lovair
Murray Boyt - Operations Director
Murray Boyt - Operations Director
“Having made several changes in production to introduce a one-piece-flow production method, we were conscious that the key part in delivering this change successfully was to involve a partner to support and bring in accountability for the continuous development of the process.
With many years of hands on experience, a logical thinker and someone who is able to communicate his advice, support and follow up in a clear and succinct manner, Ian was just what we needed.
He was eager to get results out of every visit and didn’t waste any time in getting stuck right in. After very quickly getting an understanding of the current systems and processes as well as data sources, he was able to give valuable guidance on how best to sort the data, make it relevant and implement change based on this.
When you are in the same environment all the time you often get blinded to small things that turn out to be big opportunities. It was great having that extra input to help identify these, and carry out process confirmation whilst working with the staff at all levels, communicating the opportunities in such a way as to achieve good buy-in.
His considered and firm approach made it easy to work with him on a professional level and have those collaborative conversations about new ideas and changes – it wasn’t all one sided.
All in all, Ian sharpened the processes on every visit and this drove our continuous improvement programme which enabled Lovair to meet the growing customer demand.”
With many years of hands on experience, a logical thinker and someone who is able to communicate his advice, support and follow up in a clear and succinct manner, Ian was just what we needed.
He was eager to get results out of every visit and didn’t waste any time in getting stuck right in. After very quickly getting an understanding of the current systems and processes as well as data sources, he was able to give valuable guidance on how best to sort the data, make it relevant and implement change based on this.
When you are in the same environment all the time you often get blinded to small things that turn out to be big opportunities. It was great having that extra input to help identify these, and carry out process confirmation whilst working with the staff at all levels, communicating the opportunities in such a way as to achieve good buy-in.
His considered and firm approach made it easy to work with him on a professional level and have those collaborative conversations about new ideas and changes – it wasn’t all one sided.
All in all, Ian sharpened the processes on every visit and this drove our continuous improvement programme which enabled Lovair to meet the growing customer demand.”
Hi-Tech Steel Services
Steve Wells - Corporate Development Manager
Steve Wells - Corporate Development Manager
“We had been wrestling with problems related to work flow in our 47,000 sq.ft. factory for some time. Then Ian came along and with his structured approach he introduced us to Value Stream Mapping. The results have been remarkable in both understanding and tackling the problems via the pictorial evidence. Our Team is now fully motivated and savings are starting to accrue."
Cleland McIver
Paul Adams - Operations Director
Paul Adams - Operations Director
"It was apparent something wasn't right, we could see that efficiencies' had been reducing. I contacted Ian to discuss his thoughts; to get an opinion from someone outside the business.
From the first meeting Ian's knowledge and insight was obvious; sometimes you just need to see it from another perspective.
A vastly experienced consultant, whom is extremely personable which helps when you are trying to implement changes!! Ian had the team buying in to collective ideas results speak for themselves.
We have only looked at part of the business and already have plans to see how we can improve others.
An insightful and very successful project - I would 100% recommend IWPS.
Thanks Ian"
From the first meeting Ian's knowledge and insight was obvious; sometimes you just need to see it from another perspective.
A vastly experienced consultant, whom is extremely personable which helps when you are trying to implement changes!! Ian had the team buying in to collective ideas results speak for themselves.
We have only looked at part of the business and already have plans to see how we can improve others.
An insightful and very successful project - I would 100% recommend IWPS.
Thanks Ian"
Comfortex Limited
Nathan Beckwith - Managing Director
Nathan Beckwith - Managing Director
"Ian's input, both personally and professionally, has been extremely valuable. His effort and hard work on our behalf has helped us to understand the level of improvement that we can aspire to."
