Vectus Consulting
Moved forwards.

Concept to commercialisation.

Between prototype and production, things stall. We diagnose what’s wrong and fix it — because good design within a product isn’t optional, it’s what makes it manufacturable, sellable, and profitable.

Start a Conversation What We Solve
6σProcess
Capability
LSSLean
Six Sigma
DfXDesign-Led
Approach
UKBased &
Operated
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Project. Process. Product.
From concept to commercial reality.

What We Solve

Sound familiar? We’ve fixed this before.

These are the situations where clients typically call us. If you recognise one, we should talk.

Product Stuck

“The design works in the lab, but we can’t get it into production.”

We diagnose the gap between your design intent and manufacturing reality — tolerance issues, material choices, process capability — and fix it before you burn more budget.

Typical engagement: 4–8 weeks
Cost Overrun

“Our unit costs are too high and we can’t work out where the margin is going.”

We build a detailed COGS model, identify the cost drivers, and deliver a practical roadmap to hit your target unit economics — often through DfM changes your team hasn’t considered.

Typical engagement: 2–4 weeks
No Senior Expertise

“We need someone who’s actually done this before.”

You get experienced, senior-level capability for the specific problem you need solved — without the cost or commitment of a permanent hire.

Typical engagement: ongoing, a few days per month
Process Failing

“Yield is low, scrap is high, and we’re firefighting every week.”

We run a structured diagnostic using Six Sigma methodology, identify the root causes, and implement fixes that stick — with the data to prove it.

Typical engagement: 4–6 weeks

What We Do

Specific interventions. Tangible outcomes.

Every engagement starts with a clear scope and ends with a deliverable.

i

Tolerance Stack Analysis

GD&T review, statistical tolerance stack-ups, and Cpk target-setting to ensure your design is actually manufacturable.

ii

COGS Modelling & Cost Reduction

Detailed cost-of-goods model at volume. Scenario analysis, cost driver identification, and a practical reduction roadmap.

iii

DfM / DfA Assessment

Design for Manufacture and Assembly review. Changes that reduce cost, improve yield, and simplify production.

iv

Process Capability Study

Six Sigma diagnostic on your production process. SPC data, root cause analysis, and an improvement plan with measurable targets.

v

Make vs Buy Analysis

Structured evaluation of in-house vs outsource. Total cost modelling, risk assessment, and supplier strategy.

vi

Production Transfer & Validation

Moving from development to production. Process design, IQ/OQ/PQ protocols, and capability sign-off.

vii

NPI Stage-Gate Design

New product introduction governance. Stage-gate framework, decision criteria, and review cadence for your organisation.

viii

Regulatory Pathway Planning

CE/UKCA, FDA 510(k), ISO 13485 — regulatory strategy mapped from day one so it doesn’t surprise you at the end.

ix

Supplier Audit & Qualification

Full supply chain assessment. Vendor capability, quality systems, dual-sourcing strategy, and incoming quality specs.

Microfluidic device
Case Study
Medical Device · Life Science

Microfluidic Diagnostic Device — Concept to Launch

Novel microfluidic medical device stuck between design and production. Tolerance issues, no COGS clarity, and no manufacturing strategy. We diagnosed the blockers, fixed the design for manufacture, and led the programme to commercial launch.

6σProcess Capability
↓38%COGS Reduction
On TimeLaunch
Production facility
Case Study
Precision Manufacturing

Production Transfer — Prototype to Volume

Complex electro-mechanical assembly that worked in the workshop but couldn’t be produced at scale. We designed the production process, qualified the supply chain, ran IQ/OQ/PQ, and hit target unit cost before SOP.

12 wkTo SOP
↓22%Unit Cost
Cpk>1.67All Criticals
Vectus gave us something we couldn’t build internally — senior capability that understood our product, our regulatory environment, and the commercial pressure we were under.
VP Engineering
UK Medical Device Company

The Network

Partnered with proven fractional consultants.

When a problem needs more than one discipline, Vectus draws on a network of senior fractional consultants — specialists who have worked together before, share methodology, and deploy fast.

Every associate is independently vetted, carries professional indemnity insurance, and operates under Vectus quality standards.

ME
Mechanical DesignDfM, DfA, GD&T
EE
Electronics & PCBSchematic, layout, embedded
SW
Software & FirmwareIEC 62304, regulated SW
MF
ManufacturingTransfer, validation, scale-up
QR
Quality & RegulatoryISO 13485, CE/UKCA/FDA
PM
Programme LeadershipNPI, governance, delivery

Where We Work

Deep experience across regulated and precision sectors.

Medical Device
Life Science
Precision Manufacturing
FMCG

Where This Can Go

Most relationships start small. Some grow.

A focused engagement that delivers results often leads to something bigger. That’s by design — trust is earned, not assumed.

01Retained AdvisoryOngoing strategic access, a few days per month
02Programme LeadershipFull end-to-end programme delivery
03Multi-Discipline DeploymentCross-functional team from the Vectus network

Why Vectus

The questions you’re already asking.

“Why not hire someone?”
Because you need a specific problem solved, not a headcount.

A hire takes months to recruit and brings one discipline. Vectus deploys this week with the exact expertise your problem needs.

“Why not a large consultancy?”
Because you need someone who’s built products, not slides.

Large firms sell junior teams and methodology. Vectus delivers senior practitioners who have personally solved these problems before.

“How quickly can you start?”
Usually within a week of a scoping call.

A 30-minute conversation to understand the problem. A clear proposal within days. Work starts as soon as you’re ready.

“Do you know our sector?”
The engineering discipline is universal. The regulation isn’t.

Deep experience across ISO 13485, CE/UKCA, FDA 510(k), and nuclear quality standards. The methodology transfers; the regulatory knowledge is specific.

1
Call

30 minutes to understand your problem. No obligation.

2
Scope

Clear proposal with defined outputs, timeline, and cost. Typically within a week.

3
Deliver

Hands-on work, measurable outcomes, and a deliverable you can act on immediately.

Get in Touch

Got a problem? Let’s talk.

Tell us what’s stuck, what’s costing too much, or what expertise you’re missing. If we can help, we’ll tell you how — quickly and honestly.

Phone+44 (0) 7426 922 637
Emailenquiries@vectusconsulting.com
LinkedInJoseph Wheeler
LocationBrighton, England
What happens next

A 30-minute call to understand your problem. If there’s a fit, a clear scope and approach within a week. No obligation.