Muti Nayyar Consultant
15 years of hands-on manufacturing leadership across PE-backed businesses, NHS Tier 1 suppliers, and high-volume industrial environments. Not advisory distance — embedded presence.
Muti Nayyar is a Chartered Mechanical Engineer (CEng MIMechE) with over 15 years of hands-on experience leading manufacturing operations across PE-backed businesses, NHS Tier 1 suppliers, and high-volume industrial environments.
Unlike traditional consultants who advise from a distance, Muti embeds directly into your operation — working alongside your teams, not above them. He builds Continuous Improvement cultures from scratch, leads long-tenured workforces through change with empathy, and delivers measurable P&L impact every engagement.
Educated at two of the UK's leading engineering institutions — an MSc from Cranfield University and a BEng from Coventry — and with a career spanning healthcare, automotive OEM, fluid systems, oil & gas, and modular construction, the breadth of sector experience is rare. The depth of impact is rarer still.
The philosophy has never changed: stabilise before automating. Optimise the process first. Then unlock the full power of smart automation — on a foundation that is genuinely ready to receive it.
Before anything changes, you must be able to see it clearly and repeat it reliably. Standard work, visual controls, and quality foundations come first — always. A process you cannot stabilise, you cannot improve. A process you cannot improve, you should never automate.
Once stable, apply targeted Lean tools to reduce waste, shorten changeover times, improve flow, and unlock hidden capacity across people, equipment and materials. Most operations discover 15–40% of recoverable value in this phase alone — without capital expenditure.
Now — and only now — introduce intelligent automation. With clear ROI, stable process sequencing already in place, and a foundation ready to receive technology. Smart test rigs, cobots, and automated assembly that pay back within 12–24 months and sustain their gains.
Led a full Lean transformation at a Tier 1 NHS fire door supplier, managing a 1,000+ door product recall whilst simultaneously embedding 5S, Standard Work and ISO 9001/14001 compliance systems. Achieved a 12% productivity uplift through structured CI methodology with a long-tenured workforce.
Embedded as Operations Director across four production sites for a PE-backed multi-site pump manufacturer. Improved right-first-time rate from 70% to 99.8%, eliminated £700K of cost-of-poor-quality, and built cross-site CI frameworks that unified previously siloed operations.
Tripled modular assembly output from 1 to 3 units per day through line rebalancing, standard work implementation and SMED-driven changeover reduction. Led a £3.5M CAPEX automation project end-to-end — delivered on time and within scope.
Directed automated assembly lines for high-volume joining systems serving national and international OEM customers. Secured £272K in annual savings through process optimisation and capacity planning. Managed supplier development and penalty charge avoidance (£45K).
Led development of subsea pipeline tooling for extreme-pressure environments. Designed a 1,000-bar pressure test rig, achieved ATEX Zone 1 certification, and led HAZID/HAZOP sessions. Applied FEA stress analysis to ensure structural integrity under demanding operational conditions.
Chartered Engineer status is the highest professional recognition in UK engineering — awarded only to engineers who demonstrate sustained competence, commitment to best practice, and leadership in their field. MIMechE membership with the Institution of Mechanical Engineers requires rigorous assessment of both technical and professional skills.
Cranfield University is consistently ranked among the world's leading postgraduate engineering institutions, specialising in advanced manufacturing, aerospace, and industrial engineering. An MSc from Cranfield represents graduate-level mastery of engineering theory, methodology, and applied research — underpinning every technical recommendation made in the field.
An undergraduate degree in Mechanical Engineering from Coventry University provided the technical foundation — thermodynamics, materials science, stress analysis, manufacturing processes and design — upon which 15 years of practical leadership has been built. Theory grounded in hands-on application from day one.
Qualified and experienced in ISO 9001 (Quality Management Systems) and ISO 14001 (Environmental Management Systems) — having implemented, audited, and maintained compliance across multiple production sites. Practical knowledge, not certificate-only. Systems designed to be self-sustaining beyond the engagement.
Stabilise the process. Optimise the process. Then automate it.
Muti Nayyar · CEng MIMechE · MN Consultants