Client success story

SIMULATION AND MODELLING

Scaling Manufacturing 45X with Simulation​

CLIENT:

METAL FABRICATION COMPANY​

The challenge:

A metal fabrication company needed to scale production of a proprietary product from 600 to 26,000 units—a 45-fold increase. The goals were to:​

Maintain onshore manufacturing​

Inability to model complex job routings and resource constraints.​

Reduce per-unit cost with increased volume.​

The Solution:

Developed a simulation model that captured the entire production flow—from raw material intake to finished goods

Identifying constraints and bottlenecks​

Testing optimisation scenarios – testing worker allocation strategies, shift pattern changes, equipment upgrades, and storage capacity adjustments​

Using data to design the future state; factory layout, optimise resource allocation, and plan capital investments​

THE IMPACT:

LMAC’s data-led transformation enabled the business to:​

Enable precise ROI calculations for capital investments​

Virtually experiment with different strategies before making real-world changes​

Confidently Plan for Scalable Growth

Capabilities Deployed

Data-driven simulation modelling

Process reconfiguration​​

Data-driven problem solving

Workflow optimisation​

“

Using simulation, we’ve moved away from guesswork and towards evidence-based decision making. It’s given our team a clear view of what changes will truly deliver impact — from shift patterns to capital investments. This model is now shaping how we plan improvements across the wider business.