The world's first systemised Job Change Tool — now live

Built by operators who have run every hot-end position.

The world's first systemised Job Change Tool.

We audit your IS machines, your forehearths, your job changes, your meetings, and your KPIs — then install the system that runs without us.

Vendor-neutral NDA-ready Worldwide

Book a hot-end audit Demo the Job Change Tool

150+

Years of collective hot-end experience on the team

80+

Countries where we have supported container glass operations

1ˢᵗ

World's first systemised Job Change Tool

<90d

Typical payback window on floor engagements

Job change is the single largest controllable source of hot-end downtime and rejects in container glass plants. Cross-shift variance on the same SKU is typically 30–60%. A 1% efficiency lift is worth millions in EBITDA.

Most plants chase it with paper checklists, tribal knowledge, and a vendor sales deck. We fix it from the inside.

— Lean Glass

What we do

Nine practices. One outcome: a plant that runs better.

Pick one. Pick several. Each engagement is led by a senior practitioner with hot-end, cold-end and leadership experience — not a junior with a deck.

Hot End Audit

Independent audit of IS machines, forehearth, hot-end coating, ware handling and pack-to-melt KPIs.

Forming Audit

Section timing, mould equipment, NNPB/BB/PB process control and defect taxonomy linked to root cause.

World's first · Flagship

Job Change Tool

The world's first systemised Job Change Tool — SKU Library · Live Execution · KPI Tracking.

SKU LibraryLive ExecutionKPI Tracking

Job Change Lifecycle

End-to-end methodology — planning, SOP, mould preheat, execution, first ware, stabilisation, post-mortem.

Management Audit

Leader Standard Work, span of control, decision rights, tier 1/2/3 meeting structure, KPI ownership.

Meeting Audit

Daily production, shift handover, gemba walks, KPI reviews, root-cause meetings.

Asset Positioning

SKU-to-line allocation, mould rotation, campaign planning, capacity utilisation, multi-site benchmarking.

Strategic Advisory

Greenfield, brownfield modernisation, due diligence, M&A operational diligence, decarbonisation roadmap.

Digitalisation & Reporting

Live KPI dashboards, hot-end/cold-end data integration, digital audits, real-time defect tracking.

Why vendor-neutral matters

No equipment. No commissions. No conflict.

We don't sell IS machines. We don't sell furnaces. We don't sell inspection equipment. Every other 'consultant' in container glass has equipment to sell. We have findings, methodology, and a system. That's the difference between an audit and a sales call.

Read why vendor-neutral matters

Other consultancies

Sell equipment

Vendor commissions
Tied OEM partnerships
Findings shaped by what they sell
Audit doubles as a sales pipeline

Lean Glass

Independent

No equipment for sale
No OEM commissions
Findings ranked by EBITDA, not invoice
Audit is the product, not the lead-gen

Industries served

Every container glass segment, with the vocabulary your buyer uses.

The same hot end runs different defect profiles, customer specs, and campaign rhythms by industry. We speak each one natively.

Beer bottle manufacturing

High volume, lightweighting via NNPB, returnables, scuffing, campaign discipline.

Wine bottle manufacturing

Flint, antique-green, cuvée colour management; punted bases; weight specs; decoration coordination.

Spirits bottle manufacturing

Ultra-premium, complex shapes, decoration coordination, short campaigns, ultra-low defect tolerance.

Food jar manufacturing

Wide-mouth press-and-blow, twist-off finish precision, vacuum integrity, pack-to-melt focus.

Pharmaceutical glass

USP Type I/II/III, EP standards, vial and ampoule precision, regulatory traceability.

Cosmetics & perfume glass (flaconnage)

Surface decoration, complex finishes, ultra-premium spec, short campaigns, ultra-low cosmetic tolerance.

How we work

Diagnose · Prove · Scale · Sustain.

The same four phases every time. The depth and speed change with your situation — the discipline doesn't.

Diagnose

On-site and remote across forming, forehearth, line coordination. We read your data and walk your floor before we open our mouths.

Prove

Pilot on one line with a crew that helped build the approach. Movement on the number, not a slide.

Scale

Line-by-line rollout with your internal coaches leading. We train the trainers and hold the standard.

Sustain

Dashboards, audits, and coaching cadence that keep the gains. The test is month 12, not week 6.

Outcomes

Six things your floor feels in the first quarter.

You will not need a consultant to tell you whether it's working. The floor will tell you first.

Faster Production

Throughput lifts that show up on the scoreboard, not just the spreadsheet.

Steadier Operations

Fewer jam-ups, shorter stops, less hero-maintenance at 2am.

Lower Defects

Root-cause fixes on the top defect modes — not symptomatic tinkering.

Clear KPIs

One source of truth from operator handheld to VP Operations.

Safer Plants

Digital audits with evidence, escalation that sticks, housekeeping that holds.

Engaged Crews

Standards your crews helped build — so they follow them without a memo.

The work

Every corner of the plant, every shift.

Our practitioners have stood in front of these lines and solved the problems they throw at you. This is where we earn our fee.

Molten glass being formed at the hot end — Forming · forehearth · coating
Hot end

Glass bottles flowing on a production line — Inspection · packaging · pack-to-melt
Cold end

IS machine line in a container glass plant — Operational excellence
Plant floor

Modern container glass IS machine — Section timing · automation · control
IS machines

Client voices

What plant leaders say.

Engagements are typically under NDA — quotes are verifiable on request.

"They walked the floor, talked to our crews, and gave us a plan we could actually run. Changeovers are down 38%, first-hour yield is up 15 points."

VP Operations

Container glass manufacturer, Southeast Asia

"We had six spreadsheets reporting OEE differently. Now we have one dashboard and the debate is about what to fix, not whose number is right."

Plant Director

Beverage glass producer, Europe

"Independent due diligence that looked past the data room. They found two operational risks the seller hadn't flagged — and the deal structure reflected it."

Investment Director

Industrial PE firm, North America

30-minute call with a senior practitioner.

Bring a problem — leave with a direction.

Book a hot-end audit Explore services