DFMA SPECIALISTS
Lean Manufacturing
AI & Computer Vision QC
Digital Twin Platforms
CONSTRUCTION 4.0
DIGITAL ENABLING
BUILT FOR THE
PRECAST INDUSTRY.
NOT ADAPTED FOR IT.
Most management consultancies apply generic lean frameworks to manufacturing clients. Lean Precast Solutions is different. LPS was built specifically for precast concrete producers by a team that spent 21 years working exclusively inside one.
That means our advice is grounded in the actual constraints of precast production — bed scheduling, rebar placement, steam curing cycles, crane sequences, and the commercial pressure of every day a product sits in the yard.
We bring Construction 4.0 tools — DfMA, Digital Twins, AI-powered quality control — to an industry that needs them, in a language the industry understands.
21+
Years in Precast
Services Designed
for Precast Producers
From initial lean assessment to full AI deployment — every service is
scoped around the specific realities of precast concrete manufacturing.
Carbon & Compliance
Management
Carbon Tracker® — our specialist tool for EPD compliance and embodied carbon management, built specifically for the EN 15804 requirements of precast producers.
35+
Years in
Construction
Richard
Kowalski
Co-Founder — Lean Manufacturing, DfMA & Strategy
Richard spent over 35 years in the construction industry, 16 years working exclusively inside O’Reilly Precast, one of Ireland’s leading manufacturers, introducing Tekla Structures 3D modelling and developing a standardised DfMA solution for Aldi retail stores. That production floor experience is the foundation of LPS’s lean, DfMA, and Construction 4.0 service lines.
O’Reilly Precast
16 years working exclusively inside a major Irish precast manufacturer
Tekla Structures
Introduced 3D BIM modelling to precast production in 2005
DfMA
Standardised DfMA solution for Aldi retail infrastructure across Ireland
Carbon Tracker®
Developer of LPS’s specialist embodied carbon monitoring framework based on a digital twin
PhD
Digital Twins
Scott
Sheenan
Co-Founder, PhD — Digital Twins, Production & AI
Scott brings over 10 years of precast production planning and management, combined with doctoral research in digital twin applications for predictive maintenance in construction — research that directly underpins LPS’s Digital Twin and AI Quality Control services. He bridges the gap between academic rigour and factory-floor implementation.
PhD Research
Digital twin applications in predictive maintenance and construction
Production Planning
10+ years managing precast production scheduling and operations
Digital Twin Lead
Leads LPS’s Digital Twin and AI Quality Control service delivery
DAC.digital Partner
Works directly with DAC.digital on Computer Vision and AI agent deployment
Not a Generalist
A Specialist
Generic management consultants apply the same frameworks to every manufacturer. We apply 21 years of precast-specific knowledge.
Industry-Only Focus
We work exclusively with precast concrete producers. No divided attention, no learning curve at your expense.
Production Floor Experience
Advice grounded in actual manufacturing — bed scheduling, rebar logistics, curing cycles, yard management.
Technology Without the Jargon
AI, Digital Twins, and Computer Vision translated into business outcomes, not technology theatre.
Senior-Level Engagement
You work directly with the principals — an experienced practitioner and a PhD-qualified specialist. No handoffs to generalist junior staff.
Ready to Reduce Waste and Modernise Your Precast Operation?
From the Blog
How Lean Thinking Keeps Precast Plants Profitable When Margins Get Tight
If Your Precast Plant Feels Like Controlled Chaos, You’re Not Alone Elements sitting for days waiting on steel or a crane. Molds tied up because one batch is off-spec. Yard full of finished pieces that can’t ship because the paperwork isn’t done. Everyone running flat out and you still miss the odd delivery date. Most…
Digital Transformation in Precast Manufacturing: Why Your Expensive Software Isn’t Working
We’ve all been there. The sales presentation was impressive. The demo looked slick. The ROI projections made perfect sense on paper. So, you signed the contract, rolled out the new system, and waited for the transformation to start. Six months later, you’re standing on the production floor, and something feels off. The new ERP system…
The Hidden Costs Draining Your Precast Concrete Business
Every day in precast plants across the country, managers walk past the same problems without realizing they’re watching profits disappear. It’s not dramatic equipment failures or catastrophic quality issues that sink margins, it’s the accumulation of small inefficiencies that nobody thinks to question. When “Normal” Operations Cost More Than They Should Picture this: A crew…
