REDUCE INEFFICIENCIES AND IMPROVE PRODUCTION FLOW IN    MANUFACTURING OPERATIONS 

Our Zero Muda approach helps manufacturing operations reduce costs, eliminate non‑value‑adding processes, and secure safer, faster and more consistent material flows from goods-in, through each production step, to final despatch.
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Typical Challenges in Your Sector

Manufacturing operations run under constant cost pressure and shifting demand, so even small inefficiencies can quickly impact margins, quality and delivery performance.


Typical sources of inefficiency include:

  • Rising handling costs per pallet and per unit moved
  • Seasonal and unpredictable demand creating peaks, idle time and excess stock
  • Quality issues and product damage leading to scrap, rework and customer complaints
  • Safety risks around high-traffic areas, mixed equipment and pedestrian interfaces
  • Bottlenecks, queuing and imbalanced flow between production, storage and dispatch
  • Process and picking errors that slow throughput, increase costs and impact performance
  • Labour shortages making it difficult to staff critical processes and shifts

Many of these issues link back to the 7 types of waste in manufacturing – directly impacting cost, safety, sustainability and operational efficiency.

The Zero Muda Approach for Manufacturing Operations 

By applying a Zero Muda approach, businesses identify and reduce waste across people, processes, and equipment, improving performance where it matters most.

Manufacturing operations can achieve:

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Lower cost-per-move

Optimised travel routes and layouts reduce labour, fuel and energy waste.

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Improved production flow

Streamlined processes, reduced double-handling, and more efficient material movement.

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Safer, standardised operations

Clear routes and consistent travel patterns reduce risk in busy production and warehouse zones.

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Better space utilisation

Storage layouts match product velocity, reducing search time and unnecessary travel.

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Improved quality and reduced damage

More stable handling and controlled movement minimise product damage and process errors.

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Lower emissions and energy usage

Reduced idle time, fewer unnecessary movements, and smarter charging across production and internal logistics.

Our Solutions, Delivered Through a Zero Muda Approach

Zero Muda is delivered through Toyota Material Handling's complete range of solutions.

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Consultancy Approach

We assess operational challenges, workflows, downtime, and cost-reduction opportunities. Using our lean thinking approach, we support you to reduce waste that drives greater efficiency, sustainability, and long-term value.

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Automated Solutions

Streamline and standardise workflows for higher throughput, combat labour shortages, improve safety, reduce damage and achieve greater accuracy by introducing automation solutions into your handling operations. 

 

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Energy & Sustainability Solutions 

We help optimise fuel and energy usage through smarter fleet choices, including electric options, to reduce operating costs and environmental impact. 

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Fleet, Safety & Performance Management 

Through fleet management technology and advanced safety systems, we provide better visibility of your operation — helping reduce costs, improve safety, and increase productivity. 

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Reliable Material Handling Equipment 

We specify the right equipment for your operation, from counterbalance and reach trucks to VNA, powered pallet trucks, and tow tractors. 

Real Results in Manufacturing 

Toyota Material Handling's Zero Muda approach has helped manufacturing businesses significantly reduce inefficiencies across their operations.

 

Histon Sweet Spreads

  • Cut down trips between lines from 6 per hour to 1 per hour
  • Noise reduction due to introducing quieter tow tractors 
  • Reduced idle movement and handling waste
  • Improved energy efficiency by optimising fleet usage and warehouse flow
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Encirc (The Park)  

Warehouse automation is delivering measurable benefits for high-volume operations, as shown by Encirc (formally The Park), one of the UK’s largest independent wine bottling and storage facility. By implementing Toyota automated trucks and shuttle systems, the business has improved throughput, reduced labour dependency and operating costs, and increased storage efficiency, creating a safer, more scalable operation built for future growth.

 

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29 automated reach trucks

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Moving 1.2 million pallets annually

 

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1.6 million in annual savings

Frequently Asked Questions
What is Zero Muda?

Zero Muda is a lean-thinking approach that helps organisations identify and remove waste across their material handling operations, improving efficiency, safety, and performance. It means Zero Waste. 

How does Zero Muda apply to Manufacturing?

Zero Muda helps manufacturers remove waste from their operations by improving material flow, reducing handling, and creating safer, more efficient factory layouts.

How do we get started?

Fill in the form below and a member of the team will be in touch. If you're not sure which solution you require and would prefer a consultation, please select the 'consultant' option. 

Start your journey to achieving operational efficiency.