Muti Nayyar Consultant
End-to-end manufacturing transformation — from Lean culture and precision process engineering to smart automation. One expert. Measurable results.
Muti Nayyar is a Chartered Mechanical Engineer (CEng MIMechE) with over 15 years of hands-on experience leading manufacturing operations across PE-backed, NHS Tier 1, and high-volume industrial environments.
Unlike traditional consultants who advise from a distance, Muti embeds directly into your operation — building CI cultures from scratch, leading long-tenured teams through change with empathy, and delivering measurable P&L impact.
The philosophy is simple: stabilise before automating. Optimise the process first. Then unlock the full power of smart automation.
From initial diagnosis to full-scale transformation — no hand-offs, no gaps, no long retainers.
Embed 5S, Standard Work, Visual Management and daily problem-solving rituals — built to sustain themselves long after the engagement ends.
Replace manual processes with intelligent automation — only once the underlying process is stable. Fast payback, reduced downtime, reliable throughput.
FMEA-led error proofing, supplier quality controls, and data-driven corrective action frameworks closing the loop between field performance and manufacturing.
Line balancing, capacity planning, maintenance strategy and flow engineering — turning bottlenecks into throughput and firefighting into proactive control.
Design and deploy ERP systems built around error-proof processes — ensuring accurate data across finance, supply chain and production planning from day one.
Step in as Interim Operations Director or Head of Engineering — driving transformation from day one with deep sector knowledge and zero ramp-up time.
Optimise the process first. Then automate it.
The MN Consultants PrincipleThis is the single most important metric in any manufacturing operation. Revenue generated per labour hour tells you whether your floor is a profit engine or a cost centre. Most operations directors cannot give you this number on the spot. If yours is below £150, there is almost certainly hidden capacity waiting to be unlocked.
Every engagement follows a proven four-phase sequence — never rushing to automation before the foundations are solid.
Deep-dive into your current state. Process mapping, waste identification, data analysis and team interviews to pinpoint where value is leaking — and why.
Build standard work, visual controls and quality foundations. Unstable processes must be fixed before automation is introduced — or you automate the chaos.
Apply Lean tools to eliminate waste, reduce changeover times, improve flow and unlock hidden capacity across people, equipment and materials.
Now automate — with clear ROI, correct process sequencing, and a stable foundation that is ready. Smart automation delivering fast payback and sustained results.
Tier 1 NHS fire door supplier. ISO 9001 & 14001 compliance, 1,000+ door recall management, 12% productivity uplift through embedded Lean methodology.
PE-backed multi-site pump manufacturer. RFT improved 70% → 99.8%, £700K cost-of-poor-quality eliminated across four production sites.
Modular assembly output tripled from 1 to 3 units/day. £3.5M CAPEX automation project delivered on time and within scope.
High-volume joining systems for national and international OEM customers. £272K annual savings secured; automated assembly lines directed end-to-end.
Subsea pipeline tool development. ATEX Zone 1 certification, 1,000-bar pressure test rig design, HAZID/HAZOP leadership and FEA stress analysis.
Post-acquisition operational readiness and integration. CI frameworks embedded, cross-site processes unified, teams aligned to new ownership strategy.
Whether you're preparing for automation, fighting quality issues, or navigating a PE transition — MN Consultants delivers fast, hands-on results. No long retainers. Just impact.