UNCOVER THE HIDDEN WASTE COSTING YOUR FACTORY HUNDREDS OF THOUSANDS
Most factories are running flat-out.. but still bleeding profit through unseen waste, downtime, and rework.
In one focused session, we’ll walk your floor, expose the biggest leaks, and turn them into high-value improvement projects your team can sustain.
See where your profit is hiding, and how to recover it.
Limited factory partnerships available each quarter.
Start With a
Gap Analysis
Walk the floor, pinpoint the biggest leaks, and create a short list of high-value improvement projects.
Train Your
Team Hands-On
We build capability where it counts, on your live production lines, so improvements stick long after training ends.
Deliver
Measurable Savings
Most factories uncover £100K–£500K in waste reduction and see productivity climb 15–20%.
⭐⭐⭐⭐⭐
“Aaron is one of the most dedicated professionals I have ever worked with. His dedication to the companies he works with is unparalleled and he always goes above and beyond to add real world benefits for the companies he works with.
He is results driven and has a refreshing and sometimes humorous approach to training and mentoring.
I would highly recommend putting Aaron to the test, you won’t regret it, and you will definitely see a return on investment.”
Craig Blaney
Non-executive director with the Public Health Agency
CAFRE College Advisory Group (CAG)
Former Deputy Mayor of North Down & Ards Borough Council
MOST FACTORIES THINK THEY’RE RUNNING AT FULL CAPACITY,
FEW REALISE HOW MUCH PROFIT THEY’RE LEAKING EVERY DAY
Listen, if you’re reading this, it’s because you already know your operation’s under pressure. Orders are growing, shifts are full, and from the outside, everything looks busy.
But behind the numbers, downtime’s creeping up, changeovers drag, and people spend more time firefighting than improving.
You’re full of ideas but find yourself buried in problems, reacting instead of leading, chasing yesterday’s issues instead of building tomorrow’s results.
You keep hearing, “We just need more people,” or “We need new equipment.”
But the truth is, most of the waste is already hidden in your process, you just can’t see it clearly yet.
What you need isn’t another quick fix or a poster on the wall.
You need a structured, proven way to uncover what’s really holding you back, and a system that helps your team fix it for good.
“Trust me, I’ve been there, and I know how to fix it.”
SO YOU’VE TRAINED YOUR STAFF, FIXED THE OBVIOUS ISSUES…
AND THE PROBLEMS KEEP COMING BACK
Most factories have already tried to get things under control.
You’ve trained and retrained staff, updated SOPs, maybe even invested in new equipment and for a while, it helps.
But then the same bottlenecks return. Downtime creeps up. Firefighting has become the norm.
Because what’s really happening isn’t a lack of effort.. it's waste hiding in your process: time, motion, inventory, and defects that no one’s been able to clearly see or stop.
Sure — a few fixes might have made things better for a while.
But none of them built what you actually need: a clear, measurable process that removes waste for good and gives your people the tools to keep it gone.
Is This Right for You?
This approach is ideal if you:
Run or manage a factory that’s constantly firefighting to hit output targets
Want to uncover and measure waste you can’t yet see
Need your team to take ownership of continuous improvement
Want measurable results and sustainable change not theory
Believe that the right structure and coaching can transform performance
This is NOT for you if you:
Think the issues will disappear with more manpower or overtime
Want another short-term initiative with no accountability
Aren’t ready to make measurable improvements on the floor
⭐⭐⭐⭐⭐
“Aaron is a skilled operational manager with good cross functional experience. Through this experience he has managed to improve business integration in a business that experienced rapid growth. This is something that not all but some operational managers succeed in doing. A key point of difference with Aaron is that, as well as successfully integrating key business functions, he introduced and imbedded lean manufacturing into the business taking the whole team on this journey and empowering individuals at all levels to take direct responsibilities for their areas of control.”
Tariq Habib
Finance Director, Yorkshire Premier Meat
BY THE WAY, I’M AARON
A few years ago, I was in the same position you might be in right now — running at full tilt, juggling shift patterns, chasing output, and wondering why the numbers never quite added up.
We were busy every single day, but profit wasn’t moving. Downtime crept in. Problems kept coming back.
I knew the effort was there, what was missing was structure.
Then I figured it out. It wasn’t about working harder.
It was about seeing the waste that was hiding in plain sight and building systems to keep it gone.
At Finnebrogue, we scaled from a small regional operation into one of the UK’s largest food manufacturers.
Efficiency soared. Output multiplied. And those improvements helped our sites become a national benchmark for lean performance.. earning me the UK & Ireland Plant Manager of the Year award.
(Proof: you’re here now reading this).
Since then, I’ve helped over 50 manufacturers do the same, uncovering hidden losses, training their teams to take ownership, and turning constant firefighting into calm, measurable control.
I’m not a consultant who just talks theory. I’ve lived it.. every shift, every line, every metric.
That’s exactly what we’ll do together: uncover the waste your factory can’t yet see, train your people to remove it, and build the systems to keep it gone.
OVER$15M+
Savings identified across
client factories
50+
Manufacturers transformed over the
past 3 years
15-20%
Average improvement in
productivity
THIS APPROACH MAKES IT EASY TO TURN CHAOS INTO CONTROL.. AND WASTE INTO PROFIT
If you follow the process, I guarantee you’ll uncover measurable savings and lasting improvements, the same approach that’s delivered hundreds of thousands in results for factories just like yours.
We’ll identify where your biggest leaks are hiding, train your team to eliminate them, and build the systems to keep performance climbing long after I leave.
Limited factory partnerships available each quarter.
⭐⭐⭐⭐⭐
Thanks a million for all your help and support over the past few weeks. It has been a pleasure getting to know you and working with you on the Lean project.
The range of professional services that I provide are quite technical and complex. I was very impressed how quickly Aaron was able to get a grasp of them given that he is predominantly involved in the manufacturing sector. Not only that, Aaron went ‘over and above’ in terms of the improvements that he recommended for my business (He even gave me an AI demo which was very much appreciated!). He has provided me with a very clear strategy going forward and now the onus rests on me to execute it.
Aaron is a very pragmatic businessman and it was great to learn so much from him during the Lean project. During our entire engagement he answered all my questions, provided clear advice and was very generous with his time. I would have no hesitation in recommending Aaron to any business looking to improve their operations.
Dermot McCole
EVERYTHING YOU NEED TO UNCOVER WASTE AND BUILD A SELF-SUFFICIENT TEAM
Gap Analysis Day
A focused on-site session where we walk your floor, pinpoint the biggest inefficiencies, and create a short list of high-value improvement projects.
● Real data, real issues not theory
● Immediate visibility of hidden waste
● Action plan you can start on day one
Hands-On Lean Training
Your team learns by doing not in a classroom.
We combine short, practical lessons with live problem-solving on your own production lines.
● Yellow Belt-level lean skills
● Real savings identified during training
● Confidence to apply tools independently
Fractional Coaching
Ongoing on-site support to drive projects forward, track performance, and embed a culture of continuous improvement.
● One or two days per week on-site
● Project accountability and performance tracking
● Sustainable progress over the long term
Measurable Results & Ongoing Support
You don’t just get training you get a system that stays.
We measure every improvement and make sure your team can maintain it without constant external help.
● Proven productivity gains of 15–20%
● Typical savings between £100K–£500K
● Clear roadmap for continued growth
WHAT WE’LL BUILD TOGETHER
(Step by Step)
Phase 1: Diagnose & Discover
On-Site Gap Analysis Day
We walk your floor together, uncovering hidden waste across time, motion, inventory, and defects.
Identify your biggest cost leaks and downtime drivers
Quantify the savings potential (often £100K–£500K)
Build a short list of high-value improvement projects
Phase 2: Train & Transform
Lean Yellow Belt Implementation
Your team learns by doing solving real problems on the production line while mastering lean fundamentals.
Hands-on workshops, not slide decks
Immediate improvement projects tracked in real time
Develop confident, capable team members who own the process
Phase 3: Embed & Sustain
Fractional Coaching & Continuous Improvement
We turn short-term wins into lasting change through ongoing on-site coaching and performance tracking.
One or two days per week dedicated support
Clear roadmap and KPIs to keep results measurable
Build a self-sufficient culture that runs without firefighting
Phase 4: Measure & Scale
Results Review & Long-Term Roadmap
We review outcomes, calculate verified savings, and outline your next 12-month improvement plan.
Real productivity data and ROI tracking
Sustainable lean system your team can maintain independently
Proven 15–20% improvement in overall productivity
⭐⭐⭐⭐⭐
“Aaron has an uncanny ability to not only train people in the tools of Lean Manufacturing & operational excellence, but he also does this whilst engaging your people and creating a culture of continuous improvement that lasts long after his training is done.”
Padraig McEneaney
CEO, Celtic Pure
⭐⭐⭐⭐⭐
When the Lean process began, I wondered if it might be a waste of time, but within the first few minutes I realised it was not. Aaron gave me a completely fresh perspective on how we operate. He highlighted areas I was already aware of but provided a different take and a practical, structured approach to addressing them.
Throughout the programme, Aaron demonstrated excellent knowledge of Lean principles and, more importantly, an ability to apply them effectively within our business. His style was clear, engaging, and always relevant to the challenges we face.
Although I have not yet implemented all of Aaron’s recommendations, several have already been put into action, and I am developing a strategy to introduce the others.
I would highly recommend Aaron Lynn to any business looking to gain genuine insight into their operations and make meaningful improvements.
Daniel Barrett
HERE’S EXACTLY WHAT YOU’LL GET WHEN WE WORK TOGETHER
On-Site Gap Analysis Day
We’ll walk your floor together, identify the biggest leaks, and turn them into a short list of high-value improvement projects.
You’ll get immediate visibility on where waste is hiding — and exactly what to do next.
Hands-On Lean Yellow Belt Training
Your team will learn lean tools through live production challenges, not PowerPoint slides.
They’ll fix real problems, track results, and build confidence to keep improvements going on their own.
Live Improvement Projects
Each team applies what they learn directly to your production line — often uncovering £100K–£500K in savings during training.
Fractional Lean Coaching
One or two days per week of on-site support to keep projects moving, measure performance, and embed a culture of continuous improvement.
Performance Roadmap & Review
A structured plan that outlines savings achieved, tracks ongoing improvements, and sets the next phase of your lean growth strategy.
You’ll walk away with:
A clear roadmap for improvement
A capable team that can spot and remove waste
Measurable results and sustainable progress
PS – I only work with a small number of factories at a time so I can stay hands-on.
If you’re planning ahead for next quarter, now’s the time to start.
You Have My Promise
Why This Approach Delivers Real, Measurable Results
There are hundreds of consultants and trainers who talk about Lean.
Most will walk your site, run a workshop, and leave you with a binder full of slides that never reach the shop floor.
That’s not what I do.
My approach is built on practice, not theory the same systems that scaled Finnebrogue into one of the UK’s largest food manufacturers and have delivered measurable savings for over 50 factories since.
You get a partner who stays hands-on until the results are proven and sustainable.
Aaron's
System
Typical Consultancy
On-site gap analysis walking the floor with your team
Real-world training applied to your live production challenges
Trackable savings and productivity metrics
Fractional coaching until your team can run independently
Continuous improvement culture that sustains itself
⚠️ (Rarely achieved)
Aaron's
System
Typical Consultancy
On-site gap analysis walking the floor with your team
Real-world training applied to your live production challenges
Trackable savings and productivity metrics
Fractional coaching until your team can run independently
Continuous improvement culture that sustains itself
⚠️ (Rarely achieved)
I only take on a small number of factories at a time — because I’d rather deliver proven, lasting results than surface-level workshops.
⭐⭐⭐⭐⭐
“Thank you very much for taking us through the LEAN Process.
We have learned a lot and are ready to start on the recommendations.
It was an absolute pleasure meeting you and I will be recommending you to other businesses, you know your stuff!!
Thank you very much and hopefully our paths cross in the future.”
Orla Gallagher
Here's My Guarantee to You
When we work together, I guarantee two things:
You’ll uncover measurable savings in your factory — often between £100K and £500K.
You’ll leave with a trained, capable team who can keep finding and fixing waste long after I’ve left the building.
This isn't theory.
It’s the same continuous improvement framework that’s delivered over £15 million in verified savings across multiple factories.
Your commitment plus our training and coaching equals guaranteed results.
GIVE ME 3 MONTHS
By the end of our time working together, you’ll have:
A clear factory performance map showing where waste exists and how to remove it.
A team who can measure, report, and sustain improvement without constant supervision.
A live performance dashboard tracking productivity and profitability.
A culture of continuous improvement that doesn’t fade when the consultant leaves.
Questions I Always Get
Q:
We’ve done Lean before, and it didn’t stick. How is this any different?
A:
We hear this a lot. Most Lean programmes fail because they’re event-based, a few days of workshops and then everyone slips back to old habits.
Optimise isn’t an event, it’s a system built to last.
Think of it like learning to drive, you don’t just study the theory, you have a co-pilot beside you who’s been there, done it, and guides you until you’re competent on your own.
That’s what we do, we stay in the passenger seat until your team can confidently drive continuous improvement themselves.
Q:
What kind of return on investment can I expect?
A:
Every project we run is measured in savings and performance improvements, not feel-good posters.
Our clients typically see:
- 10–20% improvement in productivity,
- Significant reductions in downtime and waste,
- Smoother communication and fewer production headaches.
We track progress weekly through KPIs, so you can literally see the value growing in real time.
Q:
How much does it cost?
A:
It depends on your goals and the level of support you want, but most projects are heavily subsidised through Enterprise Ireland or Local Enterprise Office funding, sometimes up to 90% funded.
In most cases, the savings we unlock cover the investment many times over.
We’ll always make sure the cost makes sense before we begin.
Q:
We’ve already got a busy operation, how can we take on another project?
A:
That’s exactly why we exist.
Most factories are already firefighting daily issues. We help you break that cycle by bringing control, structure, and visibility.
Instead of adding more work, we remove the chaos so your managers can breathe again and make better decisions.
Q:
Is this just training, or do you actually help us implement it?
A:
We do both.
Training gives people knowledge, consultancy embeds that knowledge into the way your factory runs.
Our role is to coach your team on the job, so improvements become part of their daily habits, not another forgotten course.
Q:
Who delivers the training and support?
A:
You’ll work directly with experienced factory professionals who’ve run production sites and delivered real results, not consultants who’ve only read about Lean.
We’ve lived the same pressures you face and know what works in the real world.
Q:
How long does it take to see results?
A:
You’ll see impact within weeks.
Most Lean programmes run for 6–8 weeks, and results are visible as early as the second session, whether that’s reduced changeover times, better team communication, or clearer shift performance.
For larger Lean Plus projects, we embed deeper cultural and structural change that lasts.
Q:
What happens when you leave? Will it fade away again?
A:
Not with us.
Our goal is to make your team self-sufficient, capable of sustaining the system long after we’re gone.
We don’t just deliver training, we build internal competence, routines, and visual systems that keep momentum alive.
Q:
How do you measure success?
A:
We don’t rely on opinions or theories.
We measure everything, OEE, downtime, labour utilisation, yield, and communication flow.
Your results are displayed on visual boards and digital dashboards, so the whole team can see progress every day.
Q:
Do you work only with large companies?
A:
No. We work with everyone from small family-run sites to major multi-site manufacturers.
Lean is about thinking differently, not having a huge budget. We scale our approach to fit your size and your goals.
Q:
What makes Optimise different from other Lean consultants?
A:
We’re not outsiders with PowerPoints, we’re operators who’ve led factories through chaos and built real-world systems that work.
Our focus is action, accountability, and results you can see and feel on the shop floor.
We don’t speak jargon. We speak your language, throughput, yield, downtime, cost.
Q:
Can you help us go digital too?
A:
Absolutely.
Our sister company, OptimX, connects everything you do in Lean into one digital platform, real-time dashboards, live KPIs, and action tracking.
It’s the next step toward a paperless, data-driven factory.
Q:
What’s the first step to get started?
A:
Book a free discovery call.
We’ll look at your operation, identify opportunities for improvement, and outline how you can access available funding.
No pressure, no jargon, just a clear, practical conversation about your goals.
Q:
How does this help my people?
A:
When chaos drops, stress drops.
Our systems create clarity, everyone knows what success looks like and how to get there.
That’s why our approach not only boosts performance but also improves morale, teamwork, and mental health across your factory.
⭐⭐⭐⭐⭐
“I can honestly say, you add significant experience in FMCG, but most importantly you share knowledge gained, develop teams and individuals, which is a true measure of your Value.”
Gary Doyle
Managing director
READY TO GET YOUR FACTORY RUNNING SMOOTHER IN 3 MONTHS?
If you’re tired of chasing the same problems every quarter missed targets, wasted time, low output this is where that changes.
We’ll pinpoint where money’s being lost, train your team to fix it, and build systems that keep your performance climbing month after month.
No shutdowns. No buzzwords. Just measurable improvement that shows up on the bottom line.
Your commitment plus our training and coaching equals guaranteed results.
YOU DESERVE A FACTORY
THAT RUNS ITSELF — NOT ONE THAT RUNS YOU.
You’ve already invested in equipment, software, and training.
Now it’s time to make it all work together.
Let’s turn your factory into a system that runs lean, smooth, and profitably — every single day.
© 2025 OptimX | Need help? Email me directly: [email protected]