What Does a Manufacturing Consultant Do? | Levantar UK

A manufacturing consultant helps factories, production leaders & teams improve productivity, efficiency, and quality.

We do this by;

• Identifying bottlenecks,
• Introducing realistic schedules that can be achieved,
• Redesigning processes to remove and reduce wasted time and effort,
• Coaching leaders so they manage instead of firefight,
• Use analytical techniques and modern digital tools to give you clarity and control.

In short a manufacturing consultant should be both an industrial advisor and hands on problem identifier and solver, focussed on making your factory run smoother, faster and more profitably.

But here's the thing - not all consultants work the same way.

Traditional Manufacturing Consultants:

• Analyse your processes and write detailed reports
• Recommend systems and technology upgrades
• Focus on theory and best practices
• Leave you to implement their recommendations

Hands-On Manufacturing Consultants:

• Roll up their sleeves and work directly with your team
• Train your existing managers to perform better
• Focus on immediate, practical improvements
• Stay until the problems are actually solved

The difference? The first gives you a roadmap. The latter drives the car with you until you reach your destination.

At Levantar, our clients typically see 20–35% output improvements in 2-3 months without adding headcount.

Clients typically see:

• Shorter lead times. e.g. one UK factory cut delivery time by 30% in 3 months.

• Higher throughput and capacity. Factories have been rebalanced, bottlenecks managed to deliver 40% more output.

• Improved quality with fewer defects. Working on the process steps and schedules can deliver 'build as you go' quality with inbuilt inspection.

• Stronger Leaders. Managers shift from firefighting to leading.

• More Profit, Less stress. Costs fall while manufacturing margins rise. Coupled this with the ability to grow the business.

STABLISE

Prevent Your Manufacturing Output From Getting Worse; Make Costs, Quality, Delivery Dates Predictable

OPTIMISE

Making Your Operations As Productive, Efficient & Cost Effective As Possible

GROWTH

Enable Your Manufacturing Leaders & Teams to Deliver Your Business Growth Targets

How We Do It (Our 4-Step Method)

Step 1 — Diagnose the Problems

We start with a Factory Diagnosis Review. It's an assessment to understand your challenges, quickly oversee your processes, KPIs, and bottlenecks. You'll get a report with a time line of improvements listed in orders of what to deal with first. In an order that deals with your biggest challenges first.

Step 2 — Design Better Flow

We re-engineer your scheduling and key workflows. When week in week out you aren't delivering on time, it's likely that your scheduling needs to be reviewed. We find the bottleneck, get it moving. Introduce visual management, and begin helping your team to reduce wasted time and effort. This means utilising some of the tools found in our Lean Manufacturing Consulting Service

We apply the correct tools & techniques for your business. This doesn't mean learning every tool nor that we think you need to copy the automobile production line systems. Most firms don't need all these tools.  

Step 3 — Develop Your Leaders

We train supervisors to run daily huddles, coach their teams, and develop plans to manage their own workload. The majority of Manufacturing Leaders are looking for training and development - 66% according to Make UK. 

Manufacturing Managers are often technically trained but no one has ever told them about the 7 management Hats they wear every day. We have a specific Coaching and Mentoring For Manufacturing Leaders service.

Step 4 — Deliver Measurable Gains

We install routines, dashboards and reviews that sustain improvements month after month.

They Should:

• Have walked in your shoes (actual manufacturing management experience)
• Focus on developing your existing team rather than replacing them
• Deliver measurable results within the first 90 days
• Work hands-on with your operations, not just from an office
• Be available for ongoing support after the main project

You Should Feel:

• Confident they understand your specific challenges
• Relieved that someone else is taking control of the problems
• Optimistic about your operations manager's development
• Clear about what success looks like and when you'll achieve it

Why Finding The Bottleneck is Important. 

Why would a company hire a manufacturing consultant?

To help fix recurring productivity issues, late deliveries, reduce waste, and accelerate growth without relying on overtime or extra staff. The also hire manufacturing consultants because of the experience and external view they can bring.

What problems do Manufacturing Consultants solve?

Common issues we encounter include missed delivery targets, bottlenecks in production, quality issues, skills problems and an inability to grow. We often discover frontline leaders stuck in firefighting mode and factory owners stressed from having to get too involved. All of these can be solved.

How quickly can results be seen?

Most factories notice visible improvements in delivery times in 4-6 weeks, with sustainable cultural change embedded in 2-3 months. Training and coaching manager to wear the 7 Hats of Manufacturing confidently does take longer.

How much will a Manufacturing Consultant cost?

If you're worried about the cost. How much is it worth to get 20% more work out with no extra labour costs? How much is it worth to deliver work on time to your customers? How much is it worth to finally deliver your growth plans without needing new premises or machinery?

How is an Industrial Consultant different from an internal manager?

Managers run day-to-day operations. An industrial consultant brings outside expertise, proven methods, and insights from other industries & sectors to identify problems faster and guide lasting change.

Can a Manufacturing Consultant help with Industry 4.0 or automation?

Yes. Manufacturing experts can often advise on automation, digital workflows, MRP, ERP, IoT and AI solutions. Making sure investments solve the correct problems, align with your business strategy and deliver real returns on investment. Ensuring they don't add more complexity.

Why not just buy new machinery instead of hiring a Manufacturing Expert?

New machines can improve output, they can be more reliable, faster and easier to maintain. If processes and leadership aren’t fixed, you might just be on the path to making mistakes faster. Many times we've improved factory outputs by 20,30,40% without new machinery or staff. Sometimes our insights into new machinery shows it can deliver much greater benefits than had been identified.

Want practical help improving your factory’s performance?

Learn more about our Manufacturing Consultant services here