NSW lean manufacturing pilot unlocks savings for regional manufacturers

The NSW Government has announced that 59 manufacturing businesses across regional NSW have participated in its Lean Manufacturing Pilot Program, enabling them to save time, cut costs and improve profits.

Launched in March 2025, the $800,000 program forms part of the NSW Government’s commitment to strengthening 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 futureproof 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 onsite 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, optimising resources and improving productivity.

Lean systems also allow companies to adapt quickly to market changes, supply chain disruptions or customer needs.

“The Lean Manufacturing Pilot Program has shown what’s possible when we give regional manufacturers the tools and support to improve how they operate,” said Minister for Regional NSW and Western NSW Tara Moriarty. “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.”

“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,” said Katie Many, Operations Manager, Many Fabrication and Engineering in Gunnedah. “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.”

“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,” said John Clark, Managing Director at Ant Packaging in the Byron Shire. “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 futureproof 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.”

Image credit: iStock.com/Tashatuvango