• Who We Are
    • Who We Are

      Project7 is a specialist global performance improvement consultancy geared to provide Lean inspired solutions across our client’s complete asset and service value streams.

      About Project7

      Project7 Consultancy empower people to operate to robust processes and deliver extraordinary performance.

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      Our People

      Leadership and followership needs to be balanced correctly. We make both succeed as one.

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      Our Partnerships

      We are proud to collaborate with some exciting and innovative organisations to provide holistic solutions to our clients.

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  • What Sectors We Serve
    • What Sectors We Serve v2

      Project7 operates with a global footprint and provides universal Lean inspired solutions which transcend language, culture and industry. 

      Infrastructure Design & Build

      Encouraged by an industry with the ambition to improve, we deliver solutions to transform construction productivity.

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      Manufacturing & Operations

      We understand what it takes to become manufacturing best in class and we have the ingredients to replicate success.

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      Maintenance, Repair & Overhaul​

      Helping the wheels of industry keep moving, we provide Lean inspired solutions to unlock efficiency within MRO environments.

      Read More
  • How We Help Our Clients
    • How We Help Our Clients v2

       At Project7, we build close business relationships with shareholders, customers and employees at all levels, with decades of experience solving our client’s most challenging pain points.

      Our Capabilities

      Our knowledge has become our capability through decades of solving our client’s most challenging problems.

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      Our Training Offerings

      When organisations stop learning, they stop growing. Our Lean training programmes break existing paradigms and teach organisations how to see.

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  • Our Impact
    • Our Impact v2

      We are proud to share and celebrate our impact on our clients and the wider industry.

      Client Success

      Our client’s success and our own are inextricably linked.

      Explore Case Studies

      Our Insights

      Leadership and followership needs to be balanced correctly. We make both succeed as one.

      View Insights
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    • Infrastructure Design & Build
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    • Our Capabilities
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  • Who We Are
    • Who We Are
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    • Our Impact v2
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logologo
  • Who We Are
    • Who We Are
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    • What Sectors We Serve v2
  • How We Help Our Clients
    • How We Help Our Clients v2
  • Our Impact
    • Our Impact v2
  • Contact

   

  • Who We Are
    • Who We Are
  • What Sectors We Serve
    • What Sectors We Serve v2
  • How We Help Our Clients
    • How We Help Our Clients v2
  • Our Impact
    • Our Impact v2
  • Contact

Insights Gallery

A collection of our industry insight designed to change thinking and create wisdom.

What are you interested in?

Metamorphosis: Lean into the future

cranes-darker

Debunking the 5 Myths of Construction Productivity

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,…

Read More
railtunnel

How to Reduce Construction Rework Costs

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…

Read More
p7-car

Lessons the Construction Industry Can Learn from Lean Manufacturing

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?

Read More
defence-level1-2

Achieving TPM Excellence,the Fast Jet Way

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…

Read More
cranes-darker

Debunking the 5 Myths of Construction Productivity

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,…

Read More
railtunnel

How to Reduce Construction Rework Costs

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…

Read More
p7-car

Lessons the Construction Industry Can Learn from Lean Manufacturing

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?

Read More
defence-level1-2

Achieving TPM Excellence,the Fast Jet Way

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…

Read More
cranes-darker

Debunking the 5 Myths of Construction Productivity

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,…

Read More
railtunnel

How to Reduce Construction Rework Costs

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…

Read More
p7-car

Lessons the Construction Industry Can Learn from Lean Manufacturing

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?

Read More

Triumph: Leadership through adversity

Rail-level1-3

Looking Beyond Lockdown: Part 1 – Social Distancing

There will be many challenges for businesses post lockdown. Here we look at a major one, observing social distancing.

Read More
p7-group

What to do when your business is struggling

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…

Read More
P7-

Lean Leadership

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…

Read More
Understanding how giving our teams a 'Why' not just a 'What' improves performance

Planning & Diversifying: Protection Against The Unexpected

In a rapidly changing world, a culture of change is the only real protection

Read More
Stack of papers

Questions Working From Home Needs To Answer

Whilst working from home is attractive to most, there questions to ask of what was originally a temporary solution.

Read More
HGV

How Covid-19 Has Forced Change On Global Supply Chains

As rules around lockdown continue to change we look at the pressures global supply chains face and potential solutions

Read More
Understanding how giving our teams a 'Why' not just a 'What' improves performance

The Leadership Trilogy: What, Why & How

Businesses are good at providing the What & How to their teams but often miss the Why that drives performance

Read More
BVT-Surface-Fleet-Organisational-Design-and-Appointments-Banner

Leading By Letting Go

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…

Read More
banking-level1-1

How Facilities Management lends itself to Lean Thinking

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…

Read More
p7-meet

Looking Beyond Lockdown: Part 3 – Every Employee Is Unique

With people returning to work leaders need to consider each individuals unique situations

Read More
People working around a table

Looking Beyond Lockdown: Part 2 – Are Your Premises Needed?

As we adapt to new ways of working a major question to many will be the evolving nature of the workplace

Read More
Rail-level1-3

Looking Beyond Lockdown: Part 1 – Social Distancing

There will be many challenges for businesses post lockdown. Here we look at a major one, observing social distancing.

Read More
p7-group

What to do when your business is struggling

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…

Read More
P7-

Lean Leadership

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…

Read More
Understanding how giving our teams a 'Why' not just a 'What' improves performance

Planning & Diversifying: Protection Against The Unexpected

In a rapidly changing world, a culture of change is the only real protection

Read More
Stack of papers

Questions Working From Home Needs To Answer

Whilst working from home is attractive to most, there questions to ask of what was originally a temporary solution.

Read More
HGV

How Covid-19 Has Forced Change On Global Supply Chains

As rules around lockdown continue to change we look at the pressures global supply chains face and potential solutions

Read More
Understanding how giving our teams a 'Why' not just a 'What' improves performance

The Leadership Trilogy: What, Why & How

Businesses are good at providing the What & How to their teams but often miss the Why that drives performance

Read More
BVT-Surface-Fleet-Organisational-Design-and-Appointments-Banner

Leading By Letting Go

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…

Read More
banking-level1-1

How Facilities Management lends itself to Lean Thinking

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…

Read More
p7-meet

Looking Beyond Lockdown: Part 3 – Every Employee Is Unique

With people returning to work leaders need to consider each individuals unique situations

Read More
People working around a table

Looking Beyond Lockdown: Part 2 – Are Your Premises Needed?

As we adapt to new ways of working a major question to many will be the evolving nature of the workplace

Read More
Rail-level1-3

Looking Beyond Lockdown: Part 1 – Social Distancing

There will be many challenges for businesses post lockdown. Here we look at a major one, observing social distancing.

Read More
p7-group

What to do when your business is struggling

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…

Read More
P7-

Lean Leadership

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…

Read More

OpEx: The Performance Equation

analysing_equipment2

Analysing Equipment Criticality for Optimal Storeroom Asset Management

Learn key strategies for analysing equipment criticality to optimise storeroom and asset management efficiently.

Read More
high_performance2

Building Powerful Teams: Strategies for High Performance

Discover strategies for building powerful, high-performance teams, focusing on leadership, trust, and effective communication.

Read More
retiring_talent2

Saving Your Business, Capturing Retiree’s Experience!

Explore effective ways to harness retirees' experience for business continuity and success.

Read More
Seasons Greetings

Season’s Greetings

As 2024 comes to an end, we want to take this moment to thank you for being part of an incredible year.

Read More
Meet The Team John Powell

Meet the Team – John Powell

The strength of our team at Project7 lies in the diversity of skills, experiences, and dedication that each member brings to the table. John Powell, our Alliance Director, is a perfect example of this. His passion for building connections, overcoming…

Read More
Process Confirmation in a Lean Culture

The Importance of Process Confirmation in a Lean Culture

Process confirmation is a cornerstone of Lean manufacturing, ensuring that processes operate as designed and deliver consistent results.

Read More
Why Manufacturers Hesitate to Invest in Operational Excellence

Why Manufacturers Hesitate to Invest in Operational Excellence

The paradox of manufacturers hesitating to invest in OpEx highlights the challenges of balancing risk, resources, and long-term planning.

Read More
How to Make 5S Stick

How to Make 5S Stick

5S is more than just a tool for workplace organisation—it is a powerful driver of efficiency, safety, and employee engagement.

Read More
Chris Cooley Project7

Meet the Team – Chris Cooley

At Project7, we focus on building a team of talented experts who deliver a real difference for our clients every day. Among them is Chris Cooley, a Principal Consultant whose dedication, problem-solving skills, and ability to connect with people consistently…

Read More
Internal Networking and Informal Communication in Operational Excellence

Internal Networking and Informal Communication in Operational Excellence

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…

Read More
How to Successfully Integrate Veterans into Your Business

How to Successfully Integrate Veterans into Your Business

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…

Read More
Hire a Veteran

Want to Get the Edge on your Competitors – Hire a Veteran

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…

Read More
Building Operational Excellence into Factory Moves

Building Operational Excellence into Factory Moves

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…

Read More
Hydra-Purge Throughput Improvement Project

Reflecting on Our Hydra-Purge Throughput Improvement Project

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…

Read More
OverallEquipmentEffectiveness

How Autonomous Maintenance Drives Overall Equipment Effectiveness

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…

Read More
Visual Performance Management and Problem-Solving

Visual Performance Management and Problem-Solving

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…

Read More
Drivers of Lean Culture

Problem Solvers and Decision Makers as Drivers of Lean Culture

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…

Read More

Leadership Lessons for Civilian Life

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…

Read More
Lead Leadership Line Performance Improvement

Reflecting on our Lean Leadership & Line Performance Improvement Project

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…

Read More

A Survival Guide for New Leaders

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…

Read More

Production Planning Process Improvement Project

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,…

Read More
Balancing Authentic Leadership in Industry 5.0

Balancing Authentic Leadership in Industry 5.0

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…

Read More
Reflecting on our Pharmacy Service Improvement Project

Reflecting on our Pharmacy Service Improvement Project

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…

Read More
Change Victim or Participant

Change: Victim or Participant?

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…

Read More
Why Hermeneutics Matters in Progressive Leadership

Why Hermeneutics Matters in Progressive Leadership

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…

Read More
Practical Problem Solving Kata Coaching

Reflecting on our Practical Problem Solving and Kata Coaching Project

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…

Read More
Reflection on Standardised Working in Rail

Reflection on Standardised Working in Rail

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…

Read More

Lean Principles for the Service Industry

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…

Read More

Reflecting on our Work for a Global Leader in Aircraft Manufacturing

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…

Read More

Addressing Common Misunderstandings for Effective Lean Leadership

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…

Read More

Reflecting on a Lean Plant Leadership Programme

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…

Read More

A Fresh Perspective on 5S

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…

Read More

Reflecting on our Journey with London Underground

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…

Read More

Quality as an Inclusive Culture

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…

Read More
people over process

Achieving Right First Time Quality in Lean Manufacturing

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…

Read More
accelerating your success

Continuous Improvement Leadership – Accelerating Your Success

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,…

Read More
driving product and service quality

Driving Product and Service Quality Enhancement

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:…

Read More
enhancing profitability

Enhancing Profitability Through Value Stream Mapping

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…

Read More
failed business metrics

Failed Business Metrics

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…

Read More
The CMMS

The CMMS: Where Data Goes to Die – Unleashing the Potential of Your Maintenance Digital Backbone

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…

Read More
the leaders journey

The Leader’s Journey from Command and Control to Mission Command

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.’…

Read More
effective strategies

Effective Strategies for Management of Critical Spare Parts and Stocks

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…

Read More
embarking on the path

Embarking on the Path to Operational Excellence

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…

Read More
change readiness

Change Readiness

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…

Read More
Achieving_TPM_Excellence_the_Fast_Jet_Way

Achieving TPM Excellence, the Fast Jet Way

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.

Read More
shaping_the_future_of_work

Shaping The Future of Work: The Power of Mentoring and Coaching

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.

Read More
turning_the_right_people_into_the_wrong_people

How to Turn the Right People into the Wrong People

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.

Read More
Maintenance_Lean_Processes_and_the_Drive_to_Net_Zero

Maintenance, Lean Processes and the Drive to Net Zero

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.

Read More
who_is_driving_your_career

Who Is Driving Your Leadership Career?

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.

Read More
getting things done

Getting Things Done.

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.

Read More
meeting the demands of leadership 4

Meeting the Demands of Leadership 4.0

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.

Read More
TPM

The Missing Link Between OEE and TPM

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.

Read More
serverroom

Every Interaction is an Opportunity: Maximising Business Potential

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.

Read More
the journey to operational excellence

The Journey to Operational Excellence

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 More
hard_edge_soft-skills

The Hard Edge to Soft Skills

Read how soft skills drive success in industry, enhancing engagement, efficiency, and profitability.

Read More
psychological_safety2

Psychological Safety in the Workplace

Learn how fostering psychological safety at work boosts trust, innovation, and overall business performance.

Read More
analysing_equipment2

Analysing Equipment Criticality for Optimal Storeroom Asset Management

Learn key strategies for analysing equipment criticality to optimise storeroom and asset management efficiently.

Read More
high_performance2

Building Powerful Teams: Strategies for High Performance

Discover strategies for building powerful, high-performance teams, focusing on leadership, trust, and effective communication.

Read More
retiring_talent2

Saving Your Business, Capturing Retiree’s Experience!

Explore effective ways to harness retirees' experience for business continuity and success.

Read More
Seasons Greetings

Season’s Greetings

As 2024 comes to an end, we want to take this moment to thank you for being part of an incredible year.

Read More
Meet The Team John Powell

Meet the Team – John Powell

The strength of our team at Project7 lies in the diversity of skills, experiences, and dedication that each member brings to the table. John Powell, our Alliance Director, is a perfect example of this. His passion for building connections, overcoming…

Read More
Process Confirmation in a Lean Culture

The Importance of Process Confirmation in a Lean Culture

Process confirmation is a cornerstone of Lean manufacturing, ensuring that processes operate as designed and deliver consistent results.

Read More
Why Manufacturers Hesitate to Invest in Operational Excellence

Why Manufacturers Hesitate to Invest in Operational Excellence

The paradox of manufacturers hesitating to invest in OpEx highlights the challenges of balancing risk, resources, and long-term planning.

Read More
How to Make 5S Stick

How to Make 5S Stick

5S is more than just a tool for workplace organisation—it is a powerful driver of efficiency, safety, and employee engagement.

Read More
Chris Cooley Project7

Meet the Team – Chris Cooley

At Project7, we focus on building a team of talented experts who deliver a real difference for our clients every day. Among them is Chris Cooley, a Principal Consultant whose dedication, problem-solving skills, and ability to connect with people consistently…

Read More
Internal Networking and Informal Communication in Operational Excellence

Internal Networking and Informal Communication in Operational Excellence

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…

Read More
How to Successfully Integrate Veterans into Your Business

How to Successfully Integrate Veterans into Your Business

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…

Read More
Hire a Veteran

Want to Get the Edge on your Competitors – Hire a Veteran

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…

Read More
Building Operational Excellence into Factory Moves

Building Operational Excellence into Factory Moves

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…

Read More
Hydra-Purge Throughput Improvement Project

Reflecting on Our Hydra-Purge Throughput Improvement Project

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…

Read More
OverallEquipmentEffectiveness

How Autonomous Maintenance Drives Overall Equipment Effectiveness

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…

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Visual Performance Management and Problem-Solving

Visual Performance Management and Problem-Solving

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…

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Drivers of Lean Culture

Problem Solvers and Decision Makers as Drivers of Lean Culture

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…

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Leadership Lessons for Civilian Life

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…

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Lead Leadership Line Performance Improvement

Reflecting on our Lean Leadership & Line Performance Improvement Project

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…

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A Survival Guide for New Leaders

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…

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Production Planning Process Improvement Project

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,…

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Balancing Authentic Leadership in Industry 5.0

Balancing Authentic Leadership in Industry 5.0

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…

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Reflecting on our Pharmacy Service Improvement Project

Reflecting on our Pharmacy Service Improvement Project

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…

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Change Victim or Participant

Change: Victim or Participant?

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…

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Why Hermeneutics Matters in Progressive Leadership

Why Hermeneutics Matters in Progressive Leadership

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…

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Practical Problem Solving Kata Coaching

Reflecting on our Practical Problem Solving and Kata Coaching Project

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…

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Reflection on Standardised Working in Rail

Reflection on Standardised Working in Rail

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…

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Lean Principles for the Service Industry

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…

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Reflecting on our Work for a Global Leader in Aircraft Manufacturing

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…

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Addressing Common Misunderstandings for Effective Lean Leadership

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…

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Reflecting on a Lean Plant Leadership Programme

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…

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A Fresh Perspective on 5S

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…

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Reflecting on our Journey with London Underground

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…

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Quality as an Inclusive Culture

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…

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people over process

Achieving Right First Time Quality in Lean Manufacturing

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…

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accelerating your success

Continuous Improvement Leadership – Accelerating Your Success

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,…

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driving product and service quality

Driving Product and Service Quality Enhancement

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:…

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enhancing profitability

Enhancing Profitability Through Value Stream Mapping

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…

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failed business metrics

Failed Business Metrics

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…

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The CMMS

The CMMS: Where Data Goes to Die – Unleashing the Potential of Your Maintenance Digital Backbone

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…

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the leaders journey

The Leader’s Journey from Command and Control to Mission Command

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.’…

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effective strategies

Effective Strategies for Management of Critical Spare Parts and Stocks

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…

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embarking on the path

Embarking on the Path to Operational Excellence

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…

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change readiness

Change Readiness

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…

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Achieving_TPM_Excellence_the_Fast_Jet_Way

Achieving TPM Excellence, the Fast Jet Way

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.

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shaping_the_future_of_work

Shaping The Future of Work: The Power of Mentoring and Coaching

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.

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turning_the_right_people_into_the_wrong_people

How to Turn the Right People into the Wrong People

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.

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Maintenance_Lean_Processes_and_the_Drive_to_Net_Zero

Maintenance, Lean Processes and the Drive to Net Zero

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.

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who_is_driving_your_career

Who Is Driving Your Leadership Career?

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.

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getting things done

Getting Things Done.

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.

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meeting the demands of leadership 4

Meeting the Demands of Leadership 4.0

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.

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TPM

The Missing Link Between OEE and TPM

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.

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serverroom

Every Interaction is an Opportunity: Maximising Business Potential

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.

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the journey to operational excellence

The Journey to Operational Excellence

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?

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hard_edge_soft-skills

The Hard Edge to Soft Skills

Read how soft skills drive success in industry, enhancing engagement, efficiency, and profitability.

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psychological_safety2

Psychological Safety in the Workplace

Learn how fostering psychological safety at work boosts trust, innovation, and overall business performance.

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analysing_equipment2

Analysing Equipment Criticality for Optimal Storeroom Asset Management

Learn key strategies for analysing equipment criticality to optimise storeroom and asset management efficiently.

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high_performance2

Building Powerful Teams: Strategies for High Performance

Discover strategies for building powerful, high-performance teams, focusing on leadership, trust, and effective communication.

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retiring_talent2

Saving Your Business, Capturing Retiree’s Experience!

Explore effective ways to harness retirees' experience for business continuity and success.

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