Lean Manufacturing


Companies must develop and manage production networks that are lean and flexible enough to operate cost-effectively. The key challenges include increasing the efficiency of shop-floor operations, managing networks, improving overall equipment effectiveness, and aligning the objectives of manufacturing with other functional areas.

However, the root causes of poor quality and low manufacturing productivity often can be traced back to processes that happen long before the product hits the shop floor. They include product line complexity, product design, scheduling, and sourcing.


Maintaining high quality and low costs is crucial for manufacturing businesses today. Bagley’s approach helps companies in topics ranging from strategic decisions regarding setting up manufacturing operations to specific production site and line improvement.

Companies must have a focus on production excellence, minimizing costs, increasing efficiency, improving quality, and delivering measurable improvements in all areas of manufacturing. They must take a holistic approach, addressing strategic challenges, core processes and capabilities, performance management, and cross-functional alignment.

What We Do

While our approach varies depending on the client’s situation, our overall framework addresses strategic questions that impact production cost, quality, flexibility, service levels, and control. This includes a clear understanding of the current and future product portfolio, what should the company "make vs. buy" based on core capabilities and needs, and what should the future footprint and capacity plan look like.

Bagley deploys a battery of tools and initiatives that can be described in three groups: improvement enablers, shop floor improvement, and overhead streamlining.

Our broad-based diagnostic tools include comparisons with best practices and assessments of the potential of lean manufacturing techniques. We identify changes that will reap the largest payoffs and the best methods of achieving them. We then help clients implement improvements, ranging from product line complexity reduction to manufacturing practices that dramatically enhance productivity.

  • We help our clients streamline production processes, optimize the shop floor using proven lean techniques, boost efficiency and utilization, reduce costs, increase flexibility, and ensure knowledge sharing and consistency across all operations.
  • We help clients decide which products to make and which to buy. We take into account competitive differentiators, core competencies, the supply chain, target markets, cost structure, and sourcing options.
  • We help companies build optimized production networks that can reduce total manufacturing costs and deliver major improvements in resource utilization, asset productivity, and output.