Applied Lean Consulting

Driving Efficiency in Business
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Welcome to

Applied Lean Consulting

We take Lean principles derived from Manufacturing and apply them across all industry sectors:

  • Manufacturing
  • Service
  • Administration

LEAN is a universal concept!

Tim Scurlock, Director of ALC said…

We’ve just been voted Industrial Process News company of the year 2020 for our pro-active approach, customer service and attention to detail. This initiative is another opportunity for us to engage with our customers (both current and future) during this difficult time.

lean tips

See our Lean Tips section – quick solutions to every day issues!

Lean is a tools and management system that provides:

  • What customers need
  • When they need it
  • In the quantity they need it
  • In the right sequence
  • Without defects
  • At lowest possible cost

Process Efficiency and Effectiveness

What’s the difference and how do you drive improvement?

ALC helps you to deliver quality and service on time, every time.

  • Consistently meet your OTIF (On-Time, In Full) target
  • Reduce your lead time
  • Reduce WIP (Work In Progress)
  • Improve quality (reduce scrap, re-work and customer credits)
  • Improve layout of production, storage and fulfilment to increase pace and reduce waste
  • Implement lean stock control measures to reduce stock-outs and excess stock
  • Improve stock turn, ease cash flow and increase profit
  • Allow your business to grow without moving premises

Zoom Drop-in

Remote working initiative

How can you tell that your company needs Lean… ?


Managers spend most of their time firefighting: fixing problems and reacting to crises


Employees can’t see the link between their daily tasks and the organisation’s strategic goals

Work Practices

Work practices vary across individuals and groups


Delays or quality deficiencies are hidden and easily missed


Widespread frustration within the company at how long tasks take


Feedback from customers shows poor and variable levels of service


There is a lack of customer focus and no clear idea of what customers are looking for


Employees feel stressed, with high rates of sickness and absenteeism


Witch hunts’, finger pointing and a blame culture are endemic. Staff aren’t encouraged to speak up about impending problems

ALC’s “Lean Tips” Series


What do we mean by Turnbacks? A turnback is anything in a series of sequential steps that causes the pace of work to stop or need correction.

They’re usually found in Admin processes and may only cause delay to a process – or might cause knock-on effects and defects further down the value chain.

Contact ALC

for more tips about how to reduce waste in your business.

Examples include:

  • Orders logged by a Sales team with an incomplete or wrong address.
  • Technical drawings required by production, that are received late or with errors.
  • And customer deliveries that can’t be made because of a stock error.

Turnbacks can be really frustrating but tend to occur simply because of poor communication and this is usually at the handoff between teams.

For example, we might map Turnbacks happening in the handoff between Sales and Customer Services, or between Customer Services and Operations…

How do we solve them?

Firstly, record where in your processes your Turnbacks occur. We recommend a simple tally chart to give you a picture of where to focus your efforts.

Then discuss with the appropriate team, creating a Pareto chart of the main culprit areas. From this, you should be able to feed into your standard PDCA problem solving routine and develop the best actions to take.

Turnbacks happen in every business but tackling them in this way will help to limit their affect whilst at the same time re-inforcing your Lean Management processes.

Creating the culture for Problem Solving takes time – but it’s worth it!
Contact us at ALC if you need help – or to learn more Lean Tips…

See all of ALC's

Contact Us

Applied Lean Consulting Ltd.

Horn Street, Winslow, Bucks
+44 (0) 7411 381 887

Locate us on Linked In.

Applied Lean Consulting

ALC works with a select group of associate consultants giving the flexibility to resource larger projects and extended capabilities beyond the ‘standard’ lean intervention.

Whatever your industry, contact Applied Lean Consulting, on a no obligation basis, to find out how to eliminate waste and drive efficiency into your business.

Or if you just want to find out more about “Lean” and how it can save you money, please do get in touch. We would be very pleased to hear from you if you have any questions concerning the application of Lean and Lean process techniques.

ALC Ltd. is an established independent lean process consultancy which commenced practice in July 2011. Automotive Lean Consulting Ltd. is registered in England and Wales (Companies House number: 7695854).