30% Capacity Opportunity: Cross-Site Lean Review at i2 Analytical

Lean process mapping revealed extraordinary efficiency opportunities at i2 Analytical, a growing commercial analytical laboratory business operating across seven sites in the UK. As the business scaled, manual processes and fragmented systems were consuming capacity and limiting growth. They engaged Walker Business Transformation to understand the true efficiency of their Order-to-Invoice lifecycle.

The Challenge

One process in Watford alone had 92 steps, involved 6 different systems and 3 roles, and took over 5 hours per instance. Of those 92 steps, only 10 added direct value. That pattern was repeated across the business.

What We Did

WBT conducted a comprehensive cross-site Lean review, mapping over 200 processes across Laboratory Operations, Customer Services, Logistics, Administration, and Invoicing, all captured using the Engage Process platform.

• Heavy reliance on Outlook and Excel for core operations identified
• Multiple incompatible LIMS platforms mapped across sites
• Widespread duplication and manual data handling documented
• Lack of standardisation at process handoff points identified
• Invoicing dependencies causing regular manual rework uncovered

The Results

• 200+ processes mapped across 7 sites
• Up to 30% of operational resource releasable through redesign and automation
• 92 steps to 10 value-adding steps identified in one single process

A Target Operating Model was designed, unifying CRM, LIMS, and invoicing into a single integrated framework with a strategic roadmap and five prioritised next steps for implementation.

Could your organisation benefit from a similar approach?
Book a free 30-minute diagnostic call with Lee Walker. Call 07736 379911 or email info@wbt.org.uk