Make Lean Stick: Consulting Practices That Deliver Measurable Results

Chosen theme: Lean Manufacturing Consulting Practices. Step into the gemba with us for practical, people-first guidance that turns Lean theory into everyday habits, measurable wins, and a resilient culture of continuous improvement.

Foundations of Lean Manufacturing Consulting

Before tools, we confirm purpose: customer need, business urgency, and constraints. We create a shared problem statement that leaders sign, operators respect, and everyone can test. Tell us your current challenge to co-create a clear mission.

Foundations of Lean Manufacturing Consulting

We walk the line, observe cycles, talk with operators, and follow material and information flow. Photos, time studies, and respectful questions reveal truths spreadsheets hide. Want a fresh set of eyes on your process? Invite us to observe.

Value Stream Mapping That Drives Action

We gather cross-functional voices, customer data, and recent run histories. Sticky notes, tape, and courage replace assumptions with flow reality. Comment your biggest handoff headache, and we’ll suggest a way to visualize it tomorrow.

Value Stream Mapping That Drives Action

Cycle times, changeover patterns, uptime, and queue depths are captured live at the gemba. No blaming—only flow facts. This honesty invites ownership. Share a photo of your process board, and we’ll highlight one improvement opportunity.

Scope the Kaizen Without Chaos

We right-size goals to fit a five-day cadence: clear targets, safe boundaries, and measurable outcomes. The secret is pre-work. Drop your event idea, and we’ll help shape a scope that protects production while enabling learning.

Coach on the Floor, Not from Slides

Facilitators model problem solving at the machine: PDCA, A3 thinking, and respectful challenge. Leaders practice asking better questions, not giving faster answers. Tell us your biggest coaching gap, and we’ll share a script to try tomorrow.

Capture Wins and Standardize Immediately

We document changes with photos, revised SOPs, and short training videos. A visible before-and-after inspires replication across shifts. Subscribe for our kaizen storyboard template that makes success easier to spread.

5S as a Cultural Lever, Not Just Tidiness

We tag and remove clutter while narrating the cost of searching, reaching, and rework. Teams feel the time they win back. Share a photo of your bench or cell; we’ll suggest one Sort action with measurable benefit.

5S as a Cultural Lever, Not Just Tidiness

Shadow boards, floor lines, and labeled kits reflect real work, not designer dreams. Operators co-create visuals they will maintain. Comment with a recurring missing-tool pain, and we’ll propose a simple visual safeguard.

Takt Time with Demand Variability

We compute takt against realistic demand bands, not wishful averages. Buffers, pitch boards, and visual pacing help operators win each hour. Share your demand pattern, and we’ll recommend a practical pacing experiment.

Right-Sized Supermarkets

We set min/max levels using consumption data, replenishment times, and variability. Simple cards, bins, or e-kanban close the loop. Tell us your worst stockout, and we’ll outline a supermarket fix you can trial this week.

Heijunka for Uneven Demand

We level mix and volume to reduce changeovers and stress. The result: smoother flow and fewer firefights. Subscribe for a heijunka box guide and a story of a client who halved expedites in two months.

Separate Internal from External

We film changeovers, time each step, and move preparation outside the stop window. Simple carts, pre-staging, and clear roles cut minutes fast. Share your average setup time; we’ll suggest one externalization to try next run.

Design Fixtures and Kitting That Flow

Color-coded kits, mistake-proof clamps, and one-turn fasteners remove friction. Operators help design ergonomic motions that stick. Comment with a fiddly adjustment, and we’ll brainstorm a low-cost fixture tweak to eliminate it.

Measure Impact Beyond Minutes

We track OEE, lead time, batch size, and schedule adherence to prove business value. Wins feed the next SMED wave. Subscribe for our SMED storyboard to keep momentum visible and irresistible.

Sustainment: Hoshin, Metrics, and Daily Management

We align breakthrough objectives with line-level targets and resources. Conflicts surface early, not at quarter-end. Share your top priority, and we’ll suggest a measurable, frontline-aligned indicator to anchor it.