ThrottlePlan works with businesses to understand what limits output, raises costs or causes quality problems, then helps their teams make the changes. It also provides mechanical design and engineering analysis.
Map the flow of work, materials and information. Identify bottlenecks, rework and problems between departments.
Operations Services
Operational Improvement
Analyse capacity, production planning, quality and cost. Establish the root causes of delays, waste and inconsistent performance, then prioritise improvements.
Data and Reporting
Consolidate Excel files, Access databases and disconnected reports. Resolve inconsistent definitions, reduce manual processing and improve data accuracy.
Implementation and Training
Implement process changes, assign responsibilities and measure results. Train teams in data hygiene, reporting and maintaining the revised processes.
Engineering Services
Design and Development
Design mechanical components and assemblies. Produce 3D models, fabrication and assembly drawings and bills of materials.
Analysis and Validation
Check designs against their loads and service life by calculation and simulation. Plan testing and revise designs using the results.
Design for Manufacture
Review designs for manufacture, assembly and cost. Support their introduction to production and manage engineering change.
Case Studies
Operations
Production Recovery
More than £19m recovered from a forecast £20m loss
Problem
A manufacturing client had underestimated its machining cycle times. Combined with several breakdowns in the manufacturing area, this left the client unable to keep up with its assembly line. Even with overtime and extra shifts, the forecast loss was £20m in sales profit.
Work
Planning was split across three teams in several areas, each using different data and formats. ThrottlePlan replaced these tools with a single planner taken directly from sales demand, identified the bottleneck processes and proposed options for improvement. The production plan was adjusted to maximise utilisation of the bottleneck processes. ThrottlePlan presented the solutions to the C-level team, gained authorisation, then worked with the sales team to gain its agreement.
Result
Production costs for staffing, overtime and consumables increased, but production recovered before sales were affected. The client recovered more than £19m of the forecast loss.
Engineering
Frame Mass Reduction
33% mass reduction, with improved repairability
Problem
A client needed to reduce the mass of one of its main products.
Work
ThrottlePlan analysed several benchmarks and every major component to identify opportunities for mass reduction, weighted by risk and cost. The client approved a new mass-optimised frame design. ThrottlePlan delivered the design with fatigue, load and bolted joint analysis, then completed iterations based on testing feedback.
Result
The frame is now in service. It is 33% lighter and easier for the end customer to repair.
Client details are withheld for confidentiality.
Approach
Assess
Review your objectives, operating data and current processes with the team. Agree the performance measures and scope of the work.
Diagnose
Test potential causes, compare solutions and assess their cost, benefit and feasibility.
Implement
Make the agreed changes with your team, measure the effect and document the revised process.
Experience
Chartered Engineer CEng MIMechE
ThrottlePlan is led by a Chartered Engineer with more than ten years of international experience in mechanical engineering, manufacturing and operations. This has included leading multidisciplinary teams, developing production facilities and managing product data and engineering change.
Results in manufacturing roles include efficiency improvements of up to 12% through lean methods, and KPIs that reduced the time for design changes to reach production by 50%.
The experience also includes building production-scheduling software and using automation and AI tools to support operational work.
Contact
Email a brief description of your business and the operations or engineering problem you want to address.