Client Results & Case Studies

Explore how Project7 has helped clients in manufacturing, MRO and infrastructure improve operational performance, build leadership capability and deliver lasting change. MRO examples include rail and aerospace maintenance. The library also retains evidence from healthcare and service operations. Each case study explains the challenge, our approach and the results reported.

Manufacturing & Operations

Operating systems, plant leadership, production flow and practical improvement.

Rail manufacturing and engineering

3 European hubs12 working days. One improvement roadmap

Global rail manufacturer: 3P Diagnostic

Evidence from 25 interviews, process assessments and direct observation helped prioritise engineering improvements across three European hubs.

Read case study

Food manufacturing operations

£2m+savings opportunities identified

Hilton Food UK: 3P Diagnostic

A focused People, Process and Performance diagnostic identified improvement opportunities and avoided £1.5m of planned capital expenditure.

Read case study →

Illustration of food-manufacturing colleagues learning at a visual performance board

£74,000+average benefit per delegate from their first project

Manufacturing Excellence Academy: Building Capability in Food Manufacturing

A global food manufacturer combined immersive learning, live workplace projects and coaching, with reported ROI above 20:1 in earlier Academy cohorts.

Read case study →

Lean Plant Leadership Programme

A common operating system across 14 plants helped a global automotive manufacturer improve overall equipment effectiveness by 31%.

Read case study

Achieving Operational Excellence

Developing operational excellence in manufacturing.

Read case study

Enterprise Wide Operating Model Deployment

Deploying a common operating model across an enterprise.

Read case study

Lean Leadership & Line Performance Improvement

Connecting Lean leadership with production-line performance.

Read case study

Creating a High-Performance Culture

Developing a culture that supports high performance.

Read case study

Organisational Design and Appointments

Organisation design and appointments across BVT Surface Fleet shipbuilding operations.

Read case study

Practical Problem Solving and Kata Coaching

Practical problem solving and Kata coaching.

Read case study

Agile Product Design & Engineering

Agile approaches to product design and engineering.

Read case study

17%Production increase over 12 months

Axalta Montbrison: Removing a Production Bottleneck

Targeted problem solving at a coatings manufacturing site combined equipment changes with practical operating routines to improve throughput and reliability.

Read case study

45%Reported productivity increase

Axalta Jiading: Unlocking Waterborne Production Capacity

Better planning, material availability and leadership routines helped a coatings manufacturer increase productivity and make production more predictable.

Read case study

54%Reduction in material waste

Adelie: Reducing Food Manufacturing Waste

Standard work, visual material control and short interval reviews helped a food-to-go manufacturer reduce waste and improve coordination across shifts.

Read case study

18 hoursAdditional production capacity per month

WestRock: Increasing Pulper Conveyor Capacity

A focused Six Sigma investigation solved a decade-old material-feed problem and released additional production capacity within routine planned downtime.

Read case study

3 daysTo solve a five-year problem

WestRock: Solving a Persistent Hydra-Purge Throughput Loss

Data-led problem solving challenged an accepted equipment diagnosis and unlocked throughput through a simple, low-cost process modification.

Read case study

60+Supplier beneficiaries reached

Sharing in Growth: Developing Lean Leadership Across Aerospace Suppliers

Project7 helped Sharing in Growth develop consistent Lean leadership capability across UK aerospace suppliers, connecting strategy, daily management and coaching behaviours.

Read case study

62% → 98%Reported CPI averages: Ship 1 to Ship 3

BAE Systems: Improving Performance Through Workforce Ownership

Clear measures, leadership coaching and schedule-based working helped a naval fabrication workforce take greater ownership of delivery and cost performance.

Read case study

150+Active product lines in scope

Vion Enfield: Designing the Delivery System Before Capital Commitment

Enterprise value-stream analysis gave food-manufacturing leaders a shared view of their delivery system before major relocation, design and capital decisions.

Read case study

Adelie: Building Daily Production Control with Short Interval Reviews

Short interval control gave food-manufacturing teams a common view of performance and a practical routine for acting on issues during the shift.

Read case study

How we help in this sector →

Maintenance, Repair & Overhaul (MRO)

Rail and aerospace MRO: maintenance performance, asset reliability, engineering governance and capability transfer.

Structured Continuous Improvement

Four-step knowledge transfer combined Lean Academies with hands-on coaching: 260 managers completed the Academy and over 210 Lean workstreams were established.

Read case study

Transforming Scheduled Maintenance Performance

Improving scheduled maintenance processes and performance.

Read case study

Fleet Management Transformation

Fleet management and operational transformation.

Read case study

Engineering Management Office Transformation

Engineering governance and operating-system development at Transport for London.

Read case study

Lean Tools and Leadership Coaching

Practical Lean tools and leadership coaching.

Read case study

Outstations Performance Improvement

Improving performance across outstation operations.

Read case study

Central Line Depot Visual Performance Management

Visual performance management in a rail depot.

Read case study

Portfolio Level Resource Optimisation

Resource availability and reliability improvement at London Underground.

Read case study

World Class Production Planning

Production planning and visual management for Sydney Trains Major Works.

Read case study

58%Increase in train-operator availability

London Underground: Improving Workforce Availability Through Visual Management

A tailored visual management system helped London Underground’s Network Business Services function make performance visible, reduce training delays and release operational capacity.

Read case study

55%Reduction in ballast stockpile

Network Rail: Reducing Ballast Inventory Through Value-Stream Analysis

End-to-end supply-chain analysis and depot-level visual management helped Network Rail reduce inventory and build a clearer, more consistent planning system.

Read case study

51%Reduction in Short Notice Change

Network Rail Wessex: Improving Planning and Reducing Late Change

A shared planning process helped Network Rail’s Wessex route reduce late change, improve compliance and bring greater control to infrastructure work delivery.

Read case study

90Senior managers trained

DB Cargo: Turning Lean Leadership Learning into Operational Results

A tailored Lean Learning Academy combined practical learning with workplace projects and coaching, helping senior managers lead continuous improvement.

Read case study

Bombardier: Strengthening Aerospace Service-Centre Performance

An operating-system programme helped Bombardier’s international service-centre teams connect leadership routines, workflow visibility and frontline improvement.

Read case study

50%Reported productivity increase

Network Rail: Improving Track Maintenance Through Standard Work

A practical standard-work approach helped rail maintenance teams reduce variation, remove over-processing and improve the consistency of track repairs.

Read case study

50%Reduction in customer complaints

Network Rail South East: Connecting Teams Through Visual Performance Management

A structured visual-management deployment connected maintenance teams and leadership around shared measures, clearer responsibilities and practical problem solving.

Read case study

6 centresDesigned and deployed

TfL Engineering: Strengthening Delivery Through Tiered Visual Management

Tiered visual performance management helped TfL Engineering connect safety, resource allocation and programme delivery through a common governance rhythm.

Read case study

How we help in this sector →

Infrastructure Design & Build

Programme control and team performance in complex construction.

Creating High Performing Teams in Complex Construction

Visual performance management connected nine stations and 11 shafts and portals, aligning teams, decisions and critical milestones.

Read case study

How we help in this sector →

Healthcare & Service Operations

Further examples of Lean improvement in complex service environments.

Pathology Service Improvement

Applying improvement methods to pathology services.

Read case study

Pharmacy Service Improvement

Applying improvement methods to pharmacy services.

Read case study

What could this look like in your organisation?

Tell us where performance needs to improve. We can discuss the challenge and a practical next step.

Discuss your challenge →