Warehousing & Logistics
Picking accuracy, shift handovers, HSE compliance.
- •Recurring inventory discrepancies and rework.
- •WMS and spreadsheets that do not talk to each other.
- •Documentation that lags behind the actual operation.
Process redesign
Your operation is leaking margin. Find where, and stop it.
A Lean process audit walks your floor, isolates the root causes of waste, and hands you a prioritised action plan in five days. No retainer. No vendor pitch.
Whether you run a warehouse, a trade fleet, or an aesthetic practice, the symptoms of a broken process look surprisingly similar.
Rising labour costs. Recurring rework. Lost paperwork. Customer escalations that never reach the person who can fix them. The tools change, the language changes - the underlying friction does not. This page is for owners and operations managers who recognise the pattern and want it removed.
Common symptoms
If two or more of these feel familiar, the process is the bottleneck - not the people.
1
Labour costs rise faster than productivity.
You have hired, you have trained, you have automated parts of the workflow - yet the margin keeps eroding.
2
Information lives in spreadsheets, emails and someone's head.
Handovers between shifts, teams or sites break down because nothing is in a single source of truth.
3
Rework, returns and complaints repeat in patterns.
The same root cause keeps producing the same defect, but the team treats every incident as a one-off.
4
Compliance, safety and quality checks are reactive.
Documentation gets done after the fact, in a panic, rather than as a natural by-product of the process.
5
Owners are stuck in operational firefighting.
Day-to-day chaos is consuming the time that should be spent on growth, strategy or simply taking a break.
6
Software no longer fits how the business actually runs.
Workflows have evolved, but the system has not - so the team patches around it with sticky notes, exports and workarounds.
Sector context
Same root causes. Different uniforms.
The Lean toolkit is sector-agnostic. The pain it removes is not. Three operational environments I work in most often:
Trade & Field Services
Job handoffs, quote-to-invoice, mobile teams.
- •Information silos between office, dispatch and the field.
- •Slow quote turnaround and invoice leakage.
- •Compliance paperwork repeated job after job.
Aesthetic & Wellness
Client journey, consent records, treatment workflow.
- •Fragmented booking, marketing and clinical records.
- •Manual reminders, no-shows, and lost follow-ups.
- •Sensitive client data scattered across tools.
Method
Diagnose on the floor. Remove the root cause. Embed the fix.
Lean + Six Sigma, delivered solo, on-site. No theoretical models. No PowerPoint-only deliverables.
01
Observe what actually happens.
I walk your floor, shadow your team, and map the real movement of work, materials and information - not the documented procedure that everyone has stopped following.
02
Isolate the root cause.
Using Lean and Six Sigma diagnostics - value-stream mapping, 5-whys, basic statistical analysis - I separate the symptoms your team has normalised from the underlying constraints.
03
Hand back a prioritised action plan.
Within five working days of leaving site you receive a written report: what to fix, in what order, with the expected operational and financial impact. Yours to execute - retainer is optional.
04
Run a Kaizen sprint to embed it.
For the highest-impact items I return for a focused 1-2 week sprint with your team: small, practical changes in short cycles, measured before and after. No disruptive overhaul, no consultancy theatre.
Deliverables
What lands on your desk after the audit.
No fluff, no 80-slide deck. Documents your operations manager can act on the next morning.
A current-state map of the workflow as it actually runs, with the friction points marked.
Root-cause analysis of the top three constraints holding back throughput, margin or compliance.
A prioritised action plan with sequencing, owner, effort estimate and expected impact for each item.
Quick-win recommendations your team can implement in the first 7 days, without external help.
A clear next step: run it yourself, book a Kaizen sprint, or stop here. No pressure either way.
Engage
Two ways to start. Both end with measurable change.
Lean Process Audit
From £500
A focused, on-site diagnostic. Usually 1-5 days walking your operation, followed by a written prioritised action plan within five working days. No retainer, no obligation to continue.
- On-site observation, mapping and interviews
- Root-cause analysis on top constraints
- Prioritised written action plan
- One follow-up call after delivery
Kaizen Sprint
Scoped
A short, focused engagement to embed the highest-impact items from the audit. Typically 1-2 weeks on-site, working alongside your team. Measured before-and-after on the metrics that matter.
- Daily stand-ups and rapid iteration cycles
- Standard work, training and shift handover redesign
- Visible metrics: throughput, defects, lead time
- Handover documentation your team will actually use
Most engagements start with the audit. The sprint is offered, never pushed.
Get started
Ready to stop losing time and money?
No obligation · Yorkshire-based