Success Stories
MXL software has been used to help clients evaluate options and develop proposals for capital investment projects with great success!
Real Results from Real Factories
See how manufacturers use Wolfwyse factory modelling to find bottlenecks, optimize plans, and make better decisions.
FoodAI-Optimised Scheduling Delivers 13.5% Throughput Increase
“The model showed us exactly which tanks were causing bottlenecks—and the AI-optimised schedule eliminated 80% of our labour excess hours.” — Production Manager The Challenge A vinegar manufacturer was struggling to get full value from their production assets. The operation spanned milling, mashing, fermentation, and bottling—each stage with its own constraints and interdependencies. Storage tanks […]
PharmaInhaler Assembly: 12% OEE Improvement Through Value Stream Modelling
“The model showed us exactly where we were losing time and money and proved the business case for new equipment before we committed to it.” — Plant Manager The Challenge A pharmaceutical manufacturer operating five inhaler assembly and packing lines knew their operation had inefficiencies—but couldn’t pinpoint exactly where value was being lost or quantify […]
FoodMilitary Ration Pack Assembly: £4M Saved Before Breaking Ground
“The interactive factory model identified £4 million in cost savings compared to our initial spreadsheet-based solution.” — Operations Director The Challenge A UK defence contractor was planning a new assembly and packing facility for military ration packs. The operation would involve three assembly and packing lines handling over 100 different components—from main meals and snacks […]
FoodPickles Manufacturer Cuts Labour Costs 30% by Consolidating to 5-Day Production
The Challenge A mid-sized pickles and condiments manufacturer was operating continuous 24/7 production to meet demand. Management suspected there was significant hidden capacity, but lacked the tools to prove it. Key questions remained unanswered: Could they consolidate to 5-day operations without missing orders? How would changeovers and tank utilisation be affected? What was the true […]
HealthcareWarehouse Automation: 50% ROI from Scenario-Modelled Investment
“We tested ten investment scenarios from £700k to £7M—the model showed us exactly which option delivered the best return.” — Logistics Director The Challenge A healthcare company’s warehouse operation was under pressure. Labour costs were rising, product range was expanding, and the existing manual processes couldn’t scale. Automation was the obvious answer—but at what level […]
PharmaReady Meals Factory: 15% Cost Reduction Through Lean Design and Automation
“The model let us test every scenario before committing to the design—we achieved 15% cost reduction and a 3-year payback on a £16.5 million investment.” — Operations Director The Challenge A food manufacturer producing potato-based ready meals across multiple sites faced rising costs and inconsistent yields. Existing facilities had evolved over decades, accumulating inefficiencies in […]
FoodThree Factories to One: How Scenario Modelling De-Risked an £18M Consolidation
“We tested every scenario before moving a single piece of equipment—the model showed us exactly how to consolidate three factories without disrupting supply.” — Supply Chain Director The Challenge A biscuit manufacturer was operating three factories across different locations, each with its own overhead structure, workforce, and logistics arrangements. Senior management knew consolidation could unlock […]
HealthcareBlending, Bottling & Packing: Modelling a New Line from Concept to Commissioning
“The model guided us from initial concept through to commissioning—we knew exactly what capacity we’d get before the equipment arrived.” — Engineering Director The Challenge A healthcare manufacturer had identified a market opportunity for a new range of high-margin mouthwash products, but their existing blending, bottling, and packing operation was already running at capacity. To […]
FoodChocolate Packing: Optimising Product Allocation Across European Factories
“For the first time, we could compare product costs and capacity across all our European factories—and make allocation decisions based on data, not assumptions.” — European Operations Director The Challenge A confectionery manufacturer with multiple European factories needed to understand the true performance and cost structure of their chocolate processing and packing operation. With six […]
FoodAI-Optimised Scheduling Delivers 13.5% Throughput Increase
“The model showed us exactly which tanks were causing bottlenecks—and the AI-optimised schedule eliminated 80% of our labour excess hours.” — Production Manager The Challenge A vinegar manufacturer was struggling to get full value from their production assets. The operation spanned milling, mashing, fermentation, and bottling—each stage with its own constraints and interdependencies. Storage tanks […]
FoodMilitary Ration Pack Assembly: £4M Saved Before Breaking Ground
“The interactive factory model identified £4 million in cost savings compared to our initial spreadsheet-based solution.” — Operations Director The Challenge A UK defence contractor was planning a new assembly and packing facility for military ration packs. The operation would involve three assembly and packing lines handling over 100 different components—from main meals and snacks […]
FoodPickles Manufacturer Cuts Labour Costs 30% by Consolidating to 5-Day Production
The Challenge A mid-sized pickles and condiments manufacturer was operating continuous 24/7 production to meet demand. Management suspected there was significant hidden capacity, but lacked the tools to prove it. Key questions remained unanswered: Could they consolidate to 5-day operations without missing orders? How would changeovers and tank utilisation be affected? What was the true […]
FoodThree Factories to One: How Scenario Modelling De-Risked an £18M Consolidation
“We tested every scenario before moving a single piece of equipment—the model showed us exactly how to consolidate three factories without disrupting supply.” — Supply Chain Director The Challenge A biscuit manufacturer was operating three factories across different locations, each with its own overhead structure, workforce, and logistics arrangements. Senior management knew consolidation could unlock […]
FoodChocolate Packing: Optimising Product Allocation Across European Factories
“For the first time, we could compare product costs and capacity across all our European factories—and make allocation decisions based on data, not assumptions.” — European Operations Director The Challenge A confectionery manufacturer with multiple European factories needed to understand the true performance and cost structure of their chocolate processing and packing operation. With six […]
PharmaInhaler Assembly: 12% OEE Improvement Through Value Stream Modelling
“The model showed us exactly where we were losing time and money and proved the business case for new equipment before we committed to it.” — Plant Manager The Challenge A pharmaceutical manufacturer operating five inhaler assembly and packing lines knew their operation had inefficiencies—but couldn’t pinpoint exactly where value was being lost or quantify […]
PharmaReady Meals Factory: 15% Cost Reduction Through Lean Design and Automation
“The model let us test every scenario before committing to the design—we achieved 15% cost reduction and a 3-year payback on a £16.5 million investment.” — Operations Director The Challenge A food manufacturer producing potato-based ready meals across multiple sites faced rising costs and inconsistent yields. Existing facilities had evolved over decades, accumulating inefficiencies in […]
HealthcareWarehouse Automation: 50% ROI from Scenario-Modelled Investment
“We tested ten investment scenarios from £700k to £7M—the model showed us exactly which option delivered the best return.” — Logistics Director The Challenge A healthcare company’s warehouse operation was under pressure. Labour costs were rising, product range was expanding, and the existing manual processes couldn’t scale. Automation was the obvious answer—but at what level […]
HealthcareBlending, Bottling & Packing: Modelling a New Line from Concept to Commissioning
“The model guided us from initial concept through to commissioning—we knew exactly what capacity we’d get before the equipment arrived.” — Engineering Director The Challenge A healthcare manufacturer had identified a market opportunity for a new range of high-margin mouthwash products, but their existing blending, bottling, and packing operation was already running at capacity. To […]