How do you imagine the future of your organisation? Scaling bigger? Thinking bolder? Evolving faster?
As partners for progress in manufacturing and technology, MTC combines hands‑on engineering expertise and cutting‑edge capability to solve real business challenges - whether that’s increasing output and quality, reducing cost and time‑to‑market, improving safety, or lowering carbon. We’re independent. We’re unbiased. And we work as an extension of your team to diagnose root causes, de‑risk decisions, and deliver practical, scalable change. Whether you want to scale, evolve, innovate, accelerate, or upskill, imagine what’s possible with MTC.
Ready to move from challenge to positive outcomes? Explore the business challenges below to see how we can help and get in touch to speak with our experts about your goals and the fastest route to impact.
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Process
Unlocking productivity through process innovation
Manufacturers face constant pressure to increase productivity, reduce waste, and adapt to changing market demands. Process innovation is about more than incremental tweaks. It’s about fundamentally rethinking how work gets done. At MTC, we understand that bottlenecks, inefficient layouts, and outdated workflows can hold your business back. Our team works alongside yours to map value streams, identify root causes of inefficiency, and implement lean manufacturing principles that deliver measurable results.
Whether you’re looking to optimise factory layout, introduce automation, or embed continuous improvement, we provide hands-on support and digital tools to de-risk change. Our approach combines process mapping, simulation, and real-world trials to ensure improvements are practical and sustainable.
Discover how our Process Innovation & Improvement services can help you optimise productivity, reduce costs, and future-proof your operations and see real-world examples of these results in action through our case studies.
Dufaylite
Dufaylite faced a critical challenge: rising demand and severe bottlenecks on its lamination line threatened growth and customer delivery. Relocating to a larger site seemed inevitable, but the cost and disruption were prohibitive. MTC partnered with Dufaylite to rethink its operations from the ground up. Through detailed process mapping and simulation, we identified inefficiencies in layout and workflow that were limiting throughput. Our team worked hands-on to redesign the factory layout, embed lean behaviours, and optimise material flow. These changes delivered a 400% increase in lamination line output—without relocation. The improvements not only unlocked immediate productivity gains but also created a scalable foundation for future automation and AI adoption. By combining practical engineering with strategic foresight, Dufaylite avoided unnecessary capital expenditure and positioned itself for sustainable growth
Chafer Machinery
Chafer Machinery was struggling with long build times and missed delivery targets, limiting its ability to meet growing demand. MTC stepped in to help streamline operations without major overhead increases. We introduced colour-coded assembly bays, standardised tooling, and visual management systems to improve workflow clarity and reduce wasted time. These changes were supported by lean principles and team engagement workshops to embed continuous improvement. The results were transformative: build hours reduced by 45%, enabling on-time delivery and doubling turnover within two years. By focusing on practical, scalable solutions, Chafer achieved operational excellence and created a platform for future growth—proving that smart process innovation can deliver big results without heavy investment.
Product
Accelerating product innovation for competitive advantage
Bringing new products to market is challenging, especially when faced with design uncertainties, manufacturability risks, and supply chain gaps. At MTC, we help manufacturers turn ideas into reality by providing end-to-end support for product innovation and development. Our multi-disciplinary engineers guide you from concept through prototyping, design for manufacture (DfM), and industrialisation, ensuring your product is ready for scalable, cost-effective production.
We leverage advanced simulation, rapid prototyping, and supplier engagement to de-risk decisions and accelerate time-to-market. Whether you’re developing medtech devices, electro-mechanical systems, or next-generation consumer products, our expertise helps you overcome barriers and unlock growth.
See how our Product Innovation & Development services support new product introduction (NPI), prototyping, and manufacturability.
Cytecom
Cytecom had a breakthrough concept for rapid infection diagnosis but faced significant hurdles in manufacturability, scalability, and regulatory compliance. MTC partnered with Cytecom to transform their low-fidelity prototype into a robust, production-ready device. Our engineers applied design-for-manufacture principles, optimised component selection, and secured a UK-based supply chain to reduce risk and lead times. We leveraged rapid prototyping and advanced simulation to validate performance and ensure regulatory alignment. The result was a scalable solution that accelerated time-to-market and supported better antibiotic stewardship—a critical step in combating antimicrobial resistance. By combining technical expertise with supply chain resilience, MTC helped Cytecom turn an innovative idea into a commercially viable product that improves patient outcomes and strengthens healthcare systems.
Non-Metallic Motor
Developing the world’s first non-metallic electric motor was an ambitious goal requiring radical innovation in materials and design. MTC collaborated with the client to overcome challenges in thermal management, structural integrity, and manufacturability. Using advanced composites and simulation tools, we validated performance under demanding conditions and optimised production processes for scalability. This pioneering motor delivers significant weight reduction and improved efficiency, supporting sustainability in electrification. Beyond technical achievement, the project demonstrates how material innovation can unlock new possibilities for energy transition and lightweight design. By pushing boundaries in engineering and manufacturing, MTC helped create a product that sets a new benchmark for sustainable mobility.
Sustainability
Driving sustainable manufacturing and net zero transformation
Sustainability is now a competitive advantage, not just a regulatory requirement.
Manufacturers are under pressure to reduce carbon emissions, energy consumption, and waste, while maintaining productivity and profitability. At MTC, we help you embed sustainable manufacturing practices by combining lifecycle thinking, process optimisation, and technology selection.
Our experts support you in decarbonising operations, qualifying low-carbon processes, and building circularity into your products. We use carbon modelling, energy assessments, and supply chain analysis to identify opportunities for improvement and deliver practical solutions that drive both environmental and business value.
Find out how our Sustainable Manufacturing & Net Zero services can help you achieve energy reduction, circular economy goals, and low-carbon process adoption.
Lestercast
Lestercast, a precision casting specialist, wanted to take meaningful steps toward sustainability but needed clarity on where to start and how to prioritise improvements. Working with Lloyds Bank and MTC, the company undertook a Sustainability Line Walk—a structured, on-site review designed to uncover energy-saving opportunities and establish a practical roadmap to reduce greenhouse gas emissions. MTC’s experts assessed processes, equipment, and behaviours, identifying quick wins such as optimising lighting and compressed air systems, alongside longer-term actions like heat recovery and digital monitoring. The impartial advice helped Lestercast set realistic net zero objectives and sequence investments for maximum impact. Early actions, including LED lighting installation, delivered immediate savings, while the roadmap provides confidence for future improvements. By combining technical insight with a collaborative approach, the Line Walk gave Lestercast the tools to move from ambition to action—reducing costs, lowering emissions, and strengthening resilience. As Technical and Operations Manager Martin Whelpton noted, “What we do with the MTC will give us extra information to help us move forward with that process.” This case shows how SMEs can start their sustainability journey with clear, actionable steps that deliver both environmental and business value.
Hydrogen Value Chain Projects
Scaling hydrogen technologies from promising pilots to reliable, cost-effective products demands new manufacturing approaches. MTC supported multiple projects across the hydrogen value chain—focusing on net‑shape manufacturing for complex components and modular storage architectures that simplify production, assembly, and maintenance. Our team combined design for manufacture and assembly (DFMA), advanced joining, and precision processing to reduce embodied carbon and part count, while accelerating throughput. We created qualification plans, performed tolerance stacks and leak-path analysis, and developed supplier tooling and process control to ensure repeatability at scale. Alongside the technical work, we produced techno‑economic models to compare alternative routes and investment sequences, and we validated concepts through representative demonstrators and pilot builds. The result is a set of manufacturable, modular solutions that are easier to industrialise, simpler to service, and more resilient in the face of demand variability—supporting the transition to cleaner energy while strengthening UK supply chains. By de‑risking both product and process, these projects shorten time‑to‑market and provide a clearer path to commercial deployment.
Growth & Scaling
Smart growth and scaling for manufacturing success
Scaling up manufacturing is about more than increasing capacity. It’s about doing so efficiently, without compromising quality or delivery. MTC helps manufacturers grow smart by de-bottlenecking critical processes, sequencing investments, and preparing teams and suppliers for expansion. Our support includes factory re-layout, automation roadmapping, and guidance on funding and partnerships, especially for SMEs.
We work with you to build operational excellence, improve throughput, and ensure your business is ready to meet rising demand. Our practical, sleeves-up approach delivers results that enable sustainable growth and long-term competitiveness.
Learn how our Growth & Scaling services can help you increase capacity, optimise operations, and access funding for expansion.
Chafer Machinery
A surge in demand put Chafer Machinery’s assembly operations under sustained pressure. Leadership wanted to scale quickly without diluting quality or inflating overheads. MTC partnered with Chafer to create a robust scaling blueprint grounded in real factory data. We mapped end‑to‑end value streams, quantified true capacity constraints, and designed a flow‑aligned layout supported by supermarkets, kitting, and point‑of‑use tooling. Visual management and standard work stabilised day‑to‑day performance, while tiered meetings and clear KPIs enabled fast issue escalation and resolution. We introduced finite‑capacity planning to level the mix, supported supplier development to protect inbound flow, and trained team leaders to sustain improvements. The impact was decisive: lead times shortened, work‑in‑progress dropped, delivery reliability improved, and the business doubled turnover within two years—without a proportional increase in overhead. Most importantly, Chafer gained a repeatable operating model that scales predictably, making future investments in automation lower risk and higher return.
SME growth journeys
Many SMEs know they must grow but lack a clear, sequenced plan that aligns operations, investment, and skills. For organisations like Label Apeel and Dufaylite, MTC delivered structured growth journeys that start on the factory floor and end with an executable roadmap. We ran discovery sessions and line walks to capture bottlenecks, defects, and planning friction; gathered data on cycle times, changeovers, and utilisation; and used simple trials to prove which levers move fastest. From there, we prioritised a mix of low‑capex improvements (layout, standards, visual controls) and targeted capex (fixtures, test capacity, flexible automation) sequenced against demand profiles. We supported business cases, signposted funding options, and built milestones with measurable outcomes so leadership teams could track ROI and course‑correct early. The outcome is a practical, confidence‑building plan that unlocks near‑term capacity, protects quality, and stages the path to digital and automation—so growth arrives with fewer surprises, stronger cash flow, and better delivery performance.
Skills & Training
Building skills and training for the future of manufacturing
Advanced manufacturing technologies require skilled people to realise their full potential.
MTC delivers apprenticeship programmes, upskilling, and specialist training designed to close skills gaps and support digital adoption. Our training is built around real production needs and delivered at multiple UK sites, ensuring your workforce is ready for the challenges of advanced manufacturing.
We offer pathways for apprenticeships, conversion, and upskilling in areas like robotics, automation, and additive manufacturing. Our hands-on approach combines classroom learning with practical experience, accelerating capability building and supporting long-term business success.
Find out how our Skills & Training programmes can help you build a future-ready workforce.
MTC Training
Technology adoption only succeeds when people are confident and capable. MTC Training delivers apprenticeship pathways and tailored upskilling aligned to real production contexts, covering robotics, automation, additive manufacturing, and digital operations. We start with role‑based competency frameworks and skills gap assessments, then build blended programmes combining classroom, simulator, and on‑the‑job learning. Learners work on live, production‑relevant projects to practice problem‑solving, data‑driven decision‑making, and safe adoption of new technologies. Assessment is continuous and practical, with mentors and industry‑experienced trainers providing feedback and coaching. Programmes are delivered across multiple UK sites with access to industrial‑grade equipment, ensuring training translates directly to the shop floor. Employers benefit from faster time‑to‑competence, higher retention, and measurable productivity gains, while apprentices and upskillers gain nationally recognised credentials and transferable skills. The result is a resilient talent pipeline ready for advanced manufacturing, closing today’s gaps and future‑proofing capability as technologies evolve.
DRAMA Programme
Aerospace suppliers saw the potential of additive manufacturing but faced uncertainty around design rules, qualification, and production economics. MTC’s DRAMA programme accelerated adoption by combining best‑in‑class facilities with digital tools and targeted training. We built end‑to‑end AM process chains—from design for AM and build preparation to post‑processing and inspection—so learners could experience the full journey, not isolated steps. Courses covered material behaviour, parameter selection, support strategies, lattice and topology optimisation, and quality management, underpinned by cost and lead‑time modelling. Suppliers completed readiness assessments, hands‑on builds, and evidence packs to support customer conversations and audits. The programme de‑risked first‑article success, reduced iteration time, and helped participants win work by demonstrating credible capability. Beyond individual companies, DRAMA created a community of practice and reusable training assets that continue to raise the sector’s AM maturity—turning interest into qualified, repeatable production.
Supply Chain
Empowering manufacturing through digital transformation
Digital transformation is about making better decisions, faster, using connected data, automation, and advanced analytics. MTC helps manufacturers build right-sized digital roadmaps, prove value in testbeds, and embed technologies that endure. Our expertise spans digital twins, Industry 4.0, manufacturing data analytics, and adaptive scheduling, enabling you to optimise operations and respond to disruption with agility.
We support you in connecting data, visualising performance, and implementing AI-enabled planning and factory simulation. Our approach ensures digital solutions are practical, scalable, and aligned with your business goals.
Start your journey with our Digital Transformation Solutions—from strategy and testbeds to roadmaps and implementation.
Albert Jagger
Extended lead times, volatile freight, and single‑source dependency in Asia were eroding competitiveness for Albert Jagger. The business needed to reshore key products without compromising cost or quality. MTC built a total landed cost model that exposed the true economics of overseas sourcing, including logistics, minimum order quantities, inventory carrying costs, and quality escapes. We value‑engineered target parts, identified and qualified UK suppliers, and planned the tooling and process transitions with pilot runs to protect continuity. Robust PPAP‑style production approval, capability studies, and incoming inspection standards locked in consistency. The outcomes were compelling: 20–50% cost reductions across selected product families, sharply improved lead times, lower inventory, and a more agile response to demand changes. With dual‑sourcing resilience and closer supplier collaboration, Albert Jagger reduced risk while enhancing customer service—demonstrating how reshoring, done methodically, can strengthen both performance and profitability.
National Centre for Additive Manufacturing
Long, fragile supply chains for low‑volume spares and complex assemblies create cost, delay, and obsolescence risk. Working through the National Centre for Additive Manufacturing, MTC helped organisations consolidate multi‑part assemblies into single AM components, introduce digital inventories, and establish near‑point‑of‑use production. We ran DFAM workshops to simplify geometries, incorporate features, and remove fasteners; applied lattice and topology optimisation to reduce mass; and built material/process qualification routes aligned to application risk. Scan‑to‑print workflows and validated parameter sets accelerated first‑time‑right outcomes, while inspection plans and traceable data packs supported compliance. By moving from physical stock to print‑on‑demand and relocating builds closer to use, clients shortened supply chains, cut inventory, and improved responsiveness to urgent demand. The approach also mitigates obsolescence by retaining certified digital definitions, enabling sustained support for legacy platforms without costly re‑tooling.
Digital Transformation
Empowering manufacturing through digital transformation
Digital transformation is about making better decisions, faster, using connected data, automation, and advanced analytics. MTC helps manufacturers build right-sized digital roadmaps, prove value in testbeds, and embed technologies that endure. Our expertise spans digital twins, Industry 4.0, manufacturing data analytics, and adaptive scheduling, enabling you to optimise operations and respond to disruption with agility.
We support you in connecting data, visualising performance, and implementing AI-enabled planning and factory simulation. Our approach ensures digital solutions are practical, scalable, and aligned with your business goals.
Start your journey with our Digital Transformation Solutions—from strategy and testbeds to roadmaps and implementation.
Safran
Safran’s complex, high‑mix environment made schedules vulnerable to disruptions—shortages, rework, and priority changes rippled across lines and cells. MTC developed an adaptive scheduling digital twin that connects planning with live shop‑floor data. The model mirrors real constraints, resources, routings, changeovers, and runs rapid what‑if scenarios to re‑optimise when conditions change. Planners get decision support that balances on‑time delivery, WIP, and utilisation, while team leaders gain clear, actionable sequences through intuitive UIs and visualisations. KPI dashboards track throughput, adherence, and bottlenecks to drive daily improvement. The shift from reactive fire‑fighting to proactive control improved schedule stability, reduced expedites, and sped up decision cycles. Beyond performance gains, the twin provides a safe testbed to trial policy changes, batch sizes, shift patterns, buffer strategies, before rolling them out on the shop floor, building confidence and accelerating change.
Eaton
Designing a new smart factory involves high‑stakes choices about layout, automation, and systems integration. Eaton partnered with MTC to de‑risk these decisions using digital factory design and discrete‑event simulation. We built a 3D layout with accurate process times, variability, and resource rules to explore alternative flows, storage strategies, and automation options. Scenarios stress‑tested cycle time, throughput, and labour requirements against product mix and growth projections. We analysed ergonomics, operator walk time, and material handling to right‑size equipment and align work content. Parallel testbeds validated critical technologies—vision systems, collaborative robots, traceability—before procurement. The outcome was a data‑backed roadmap and phased investment plan that optimised performance while preserving flexibility. By resolving trade‑offs virtually, Eaton reduced risk, avoided costly rework, and accelerated implementation—ensuring the new facility is scalable, resilient, and aligned to Industry 4.0 principles from day one.
