Operational Excellence & Transformation

Transformations that actually stick

Most consultancies hand you a framework and leave. We work alongside your people to build the capability, culture, and conviction that makes change permanent.

30+
Years hands-on operational experience
20+
Industry sectors successfully transformed
100%
Knowledge transfer — your team owns it
Sectors served
Aerospace & Defence Automotive Manufacturing Pharmaceutical Food & Beverages Logistics & Supply Chain Energy & Nuclear Software & Technology FMCG

We don't sell methodology. We deliver change.

The consultancy market is full of people who know their frameworks. What's rare is someone who has led transformations through the hard yards — the resistance, the politics, the cultural friction — and come out the other side with measurable, lasting results.

That's what we bring. Not theory applied. Practice proven.

01

Practitioners, not presenters

We have led real transformations inside real organisations — from the shopfloor to the boardroom. Our advice comes from having been in the room when things got difficult.

02

Change that outlasts the engagement

We build internal capability deliberately. Our goal is to make ourselves unnecessary — leaving teams with the skills, confidence, and habits to sustain improvement without us.

03

Commercial models built around you

We don't believe one commercial structure fits every engagement. Whether that's a focused project, a phased programme, or something tied more closely to the results we achieve together — we'll find an arrangement that reflects the scope, the risk, and the relationship.

04

AI-augmented, human-led

We use the latest AI tooling to sharpen our diagnostics and accelerate insight — while maintaining that irreplaceable human judgement in the room when it matters most.

End-to-end transformation capability

From rapid diagnostic sprints to multi-year enterprise transformation programmes — we work at the pace your organisation needs, with the rigour your ambition deserves.

Lean Transformation

End-to-end value stream redesign, waste elimination, and continuous improvement culture building. We focus on operational gains that are visible, measurable, and permanent.

Value streams · CI culture · Kaizen

Agile at Scale

Beyond ceremonies and standups — we help organisations build genuine agility. Adaptive planning, iterative delivery, and the leadership behaviours that make it sustainable.

SAFe · LeSS · Scrum at scale

Leadership Coaching

Transformation fails at the top or not at all. We work with leadership teams on the mindset shifts and behaviours that create the conditions for change to take hold.

Executive coaching · Team effectiveness

Operational Diagnostics

A rapid, AI-assisted assessment of where your operation truly is — identifying the highest-leverage opportunities for improvement before a single resource is committed.

Current state mapping · Gap analysis

Transformation Programme Design

Architecture for complex, multi-year change programmes — combining lean, agile, and change management disciplines into a coherent, phased roadmap your organisation can execute.

Roadmapping · Programme governance

Capability Building

Bespoke training, coaching, and workshop facilitation that transfers real skill — not PowerPoint comprehension. Your people leave able to do things they couldn't before.

Workshops · Certification · Mentoring
Proven results

Real engagements. Real numbers.

A selection of the transformations Sean has led across 30+ years and 20+ sectors. Every number is real. Every result is verified. References available on request.

Contract Manufacturing · Turnaround & Merger

From operational crisis to super-site — a two-factory turnaround in Poland

Called in for a three-day diagnostic of a newly acquired facility in Bialystok, Poland that was in freefall — delivery performance collapsing, OEE overstated by 35 points, key customers escalating and threatening to pull business. What followed was a two-year engagement that transformed the site and completed a full factory merger.

The three-day visit became a two-year turnaround. That's what genuine commitment to results looks like.

99%+ Delivery performance (CLIP) — up from crisis lows of 42%
55→85% OEE improvement across the combined facility
6-9mo From crisis to stable, high-performing operation
2 sites Successfully merged into one super-site — on plan
+ Key customer relationships not just saved — additional business won
Shared Services · Process Improvement

Transforming a customer service desk at a Budapest shared service centre

A high-volume customer service operation serving international distributors was struggling with delayed orders, isolated working practices, and unclear workloads. Team members worked in silos, escalation processes didn't exist, and customer satisfaction was deteriorating. We introduced structured problem-solving, visual management, and team-working disciplines.

60% Reduction in delayed orders
+40% Increase in same-day order completion rate
£12K Annual cost savings from improved processes
Full control Team empowered with clear escalation & problem-solving capability
Medical Devices · Supply Chain Transformation

Revealing 313 days of hidden lead time — then redesigning the system to unlock flow

A medical device manufacturer had never mapped their end-to-end supply chain. Lead times were long, inventory was high, but no one understood why. We mapped current state, designed the future state, and quantified a transformation roadmap — now supporting implementation to make it real.

313 days Current state dock-to-dock lead time revealed
~45% Lead time reduction opportunity identified in future state
50%+ Inventory reduction potential — without increasing risk
Ongoing Supporting client implementation — building internal capability to sustain change
LeanSprint Consulting Founder

Sean Ferneyhough

Founder & Principal Consultant, LeanSprint Consulting

I started my career as a Royal Air Force-trained avionics engineer — learning precision, discipline and the cost of getting things wrong in environments where it truly matters. That foundation shaped everything that followed: 30+ years working inside some of the world's most demanding manufacturing and operational environments, from the shopfloor up.

Before founding LeanSprint, I led large-scale transformation programmes at global blue-chip organisations across automotive, defence, contract manufacturing and industrial sectors — environments where lean wasn't a PowerPoint exercise, it was how you survived. I've held the ops director seat. I've managed the P&L. I know what it feels like when a transformation stalls and the pressure is coming from above.

That's what makes LeanSprint different. When I walk into your business, I'm not bringing theory — I'm bringing three decades of hard-won, hands-on experience across aerospace, automotive, defence, manufacturing, logistics, pharma and beyond. My goal is always the same: get you outstanding results, and make sure your team can sustain them without me.

SAFe 6 Practice Consultant Certified
MSc Manufacturing Engineering Systems & Management
SAFe 6 Practice Consultant (SPC6) certified
30+ years in operations & transformation leadership
Former Royal Air Force Engineering Technician (Avionics)
Unipart Group · Rosti · DENSO · Kautex · Celestica
20+ industry sectors across UK, Europe & globally
Work with Sean directly

AI-augmented. Human-led.

The consultancy landscape is changing. AI is commoditising frameworks and diagnostics — which means the only thing that now truly differentiates expert advice is judgement, relationship, and the ability to make change stick in complex human systems.

We embrace AI as a tool that makes us faster, sharper, and more evidence-driven. But we never mistake it for the work itself. Transformation happens in conversations, in trust, in the moments when a resistant organisation finally starts to move.

AI accelerates our diagnostics
We use AI tooling to analyse operational data and identify patterns faster — arriving at insight in days, not weeks, with more rigour than manual methods alone.
Human judgement leads the change
No AI can navigate a resistant plant manager, read the room in a leadership offsite, or build the trust that makes a workforce adopt new ways of working. That's our work.
We help you use AI well too
Lean and agile principles apply directly to AI implementation — we help clients build internal AI capability using the same value-stream thinking and iterative approach we apply everywhere else.
Let's talk

Ready to build a transformation that lasts?

Whether you have a specific challenge in mind or are just beginning to think about change — let's have a direct, no-obligation conversation about where you are and where you want to be.

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