Fifty-nine manufacturing businesses employing 2,412 staff across regional NSW have participated in the Minns Labor Government's Lean Manufacturing Pilot Program, which has seen them save time, cut costs and improve profits.
Launched in March 2025, the $800,000 program forms part of the NSW Government's commitment to strengthen the state's manufacturing industry.
In regional NSW, the manufacturing sector generates $38 billion in sales and employs 84,000 workers, reinforcing the need for continued support to strengthen and future-proof the industry.
Lean manufacturing is an internationally recognised business management process that focuses on continuous improvement, reducing waste and achieving better results through process efficiencies.
It helps businesses make simple, cost-effective changes, without compromising on quality.
Through tailored on-site audits, the program has helped small to medium-sized manufacturers identify practical ways to implement lean manufacturing principles and improve their operations.
This could include identifying and cutting wasteful processes, improving quality control methods optimizing resources and improving productivity.
Lean systems also allow companies to adapt quickly to market changes, supply chain disruptions, or customer needs.
Many Fabrication and Engineering - Gunnedah
Minister for Regional NSW Tara Moriarty recently visited Gunnedah-based Many Fabrication and Engineering, which reported a positive experience and improvements to its operations as a result of the Lean Manufacturing Pilot Program.
Many Fabrication and Engineering has a staff of 45. Through the audit, it identified the need to improve how it collects and uses operational data to make better decisions, both day-to-day and in the long term.
With better information, the business can identify where targeted improvements are needed and develop evidence-based plans and strategies to address them, thereby becoming more competitive.
Ant Packaging in the Northern Rivers
Another success story is process mapping conducted during the audit at Ant Packaging in the Northern Rivers, that identified several areas for improvement.
By implementing clearer visual controls, for example developing verification steps to ensure previous job specifications are saved accurately in the system, Ant Packaging will reduce errors. This is expected to save the business 1,620 hours and $56,000 a year.
These outcomes reflect the experience of many participating businesses, with feedback consistently highlighting the professionalism of the audit teams and the practical value of their advice. Ninety-five per cent of program participants said they were satisfied with the audit process and found the recommendations relevant to their business needs.
Value stream mapping and team engagement were among the most impactful tools, helping businesses visualise inefficiencies and align staff around improvement priorities.
Minister for Regional NSW and Western NSW Tara Moriarty said:
"The Lean Manufacturing Pilot Program has shown what's possible when we give regional manufacturers the tools and support to improve how they operate.
"Across the 59 participating businesses, we've seen strong engagement, clear outcomes and a real appetite to build lean manufacturing principles into everyday operations.
"Programs like this are about more than saving time and cutting costs, they're about strengthening the capability of regional businesses and ensuring they're better positioned to meet future challenges."
Member for South Coast, Liza Butler said.
"It's great to see Nowchem, a proud South Coast business, partnering with the Minns Government to enhance productivity, create jobs and drive investment.
"Access to tailored business management support is a vital way the NSW Government is helping regional businesses-like those in the Shoalhaven-build a stronger, more dynamic local economy."
Member Elect for Kiama, Katelin McInerney said:
"Giving local businesses like Nowchem the opportunity to have their manufacturing processes reviewed through Lean methodologies is a game-changer.
"Lean Manufacturing helps identify inefficiencies, reduce waste, and streamline operations-ultimately boosting productivity and competitiveness.
"By partnering with the Minns Government, Nowchem is not only enhancing its own performance but also contributing to a stronger, resilient manufacturing sector across the South Coast."
Operations Manager, Many Fabrication and Engineering in Gunnedah and program participant Katie Many said:
"We were motivated to take part in the Lean Manufacturing Pilot Program because we recognised the need to pause and review how we operate, with the goal of doing things better and easier for everyone in our team.
"The program was extremely beneficial. It provided the structure and time to analyse our operations in detail, something that often gets overlooked when you're immersed in the daily grind.
"One of the immediate changes was the creation of clearer internal communication pathways to support continuous improvement. We also began developing more robust systems for capturing operational data to inform decision-making.
"We're grateful for the opportunity to be part of this initiative. This program has sparked renewed energy and purpose within our team, and we're excited to build on that momentum."
Managing Director, Ant Packaging in the Byron Shire and program participant John Clark said:
"We've always been committed to continuous improvement and when the opportunity to participate in the Lean Manufacturing Pilot Program came up, we saw it as a chance to challenge ourselves and take a fresh look at how we work.
"The audits provided valuable external insight and the support from the program gave us the tools and structure to turn those insights into practical actions.
"Since completing the pilot, we've already started implementing clearer visual controls, improving communication across shifts and introducing more structured daily problem-solving. These changes are small but powerful, and they're already making a difference to efficiency and team engagement.
"We're grateful to have been part of this pilot and would recommend the program to other manufacturers looking to future-proof their operations. It's helped us reset our focus and reinforced the value of continuous improvement as a daily habit, not a once-off project."
Operations Supervisor, Nowchem in Shoalhaven and program participant Melanie Miller said:
"The program and audit were extremely beneficial to our business. They provided a structured, outside-in perspective that helped us pinpoint several key areas for improvement.
"For example, we've begun reviewing our fill weight ranges to minimise overfilling and reduce material waste. We also identified opportunities to improve planning and scheduling to reduce congestion in shared work areas - ensuring team members have sufficient space to carry out tasks efficiently without getting in each other's way.
"One of our key takeaways from the program was the value of structured problem-solving and cross-functional collaboration. It highlighted the importance of involving team members at all levels to identify root causes and develop sustainable improvements."
HR and Finance Manager, SM Electrical Manufacturing in Lake Macquarie and program participant Stacey Taylor said:
"Our business has experienced rapid growth over the past five years and during that time, we have not had the opportunity to step back and review our processes for inefficiencies.
"Lean principles were entirely new to us before this experience, but the audit has brought them to the forefront of our thinking. We are now much more mindful of how we can improve our processes and continuously seek out ways to work smarter and more efficiently."
"We found the whole experience extremely positive and eye opening. It gave us a fresh perspective on how we approach our operations and we are confident that if we dedicate time to implementing some of the recommendations, we will begin to see tangible benefits."
