Services
Lean work that gets to the root, not the surface.
Every engagement is built around your specific value stream and your specific losses. But the six capabilities below represent the full scope of what we do — and how we combine them to drive compounding results.
End-to-end lean deployment
Lean Transformation
We partner with your leadership team to design and deploy a comprehensive lean operating system — from value-stream mapping and flow design to pull systems and standard work. Not a one-time workshop. A transformation that lasts.
What We Do
- Current-state value-stream mapping and waste quantification
- Future-state design and transformation roadmap
- Pull system design (kanban, FIFO lanes, supermarkets)
- Standard work development and cascade
- Daily management system implementation
Typical Outcomes
- 25–40% lead-time reduction
- WIP reduction of 30–50%
- On-time delivery improvement of 15–25 points
Maximizing equipment effectiveness
Operational Excellence & OEE
OEE is more than a metric — it's a diagnostic lens. We unpack availability, performance, and quality losses at the machine level, then deploy targeted countermeasures: SMED for changeover reduction, TPM for reliability, and structured problem-solving to eliminate recurring defects.
What We Do
- OEE baseline assessment and loss-tree analysis
- SMED (Single-Minute Exchange of Die) workshops
- Total Productive Maintenance (TPM) deployment
- Autonomous maintenance training and standards
- OEE dashboard and escalation cadence design
Typical Outcomes
- OEE improvement of 15–25 percentage points
- Changeover reduction of 50–80%
- Unplanned downtime reduction of 30–45%
Building the CI muscle across your workforce
Continuous Improvement Culture
Lean tools without a culture of improvement are just tools. We build capability at every level — from the shop floor to the leadership team — so your organization can sustain and accelerate gains long after our engagement ends.
What We Do
- Kaizen event facilitation (3–5 day blitz events)
- Gemba walk programs and leader standard work
- A3 problem-solving capability building
- 5 Whys and root-cause analysis training
- Tiered daily accountability systems (Tier 1–4)
Typical Outcomes
- CI ideas per employee: 5–10x increase in 12 months
- Frontline problem-solving capability within 6 months
- Sustained gains 12 months post-engagement
Targeting the 8 wastes across your value stream
Waste Elimination (Muda)
Muda is everywhere — in the motion of your operators, the inventory stacked on your floor, the overprocessing baked into your procedures. We map it, quantify it, and systematically eliminate it using the proven TIMWOODS framework.
What We Do
- Structured waste walk and quantification workshops
- TIMWOODS mapping across the value stream
- Motion and ergonomics analysis
- Overproduction and inventory reduction programs
- Process redesign to eliminate overprocessing
Typical Outcomes
- 20–35% floor space reclamation
- Inventory turns improvement of 2–4x
- Labor productivity gains of 15–25%
Where discipline meets clarity
5S & Visual Management
5S is not housekeeping — it's the foundation of standard work and the bedrock of visual control. When everything has a place and every place is marked, abnormal conditions are visible in seconds.
What We Do
- 5S deployment (Sort, Set in Order, Shine, Standardize, Sustain)
- Shadow board and visual control design
- Standardized work instruction (SWI) development
- Andon system design and implementation
- 5S audit system and scoring cadence
Typical Outcomes
- 5S audit scores above 85% within 90 days
- Defect detection time reduced by 60–70%
- New operator onboarding time cut by 40%
Eliminating constraints, accelerating flow
Supply Chain & Throughput
Bottlenecks steal capacity. Hidden in your scheduling logic, your supplier lead times, or your batch sizes — they cap your throughput ceiling. We apply the Theory of Constraints and lean flow principles to find the true constraint and subordinate everything else to it.
What We Do
- Constraint identification and exploitation planning
- Inventory positioning and buffer strategy
- Supplier development and lead-time reduction programs
- Heijunka (level loading) and scheduling redesign
- S&OP and production planning improvement
Typical Outcomes
- Throughput improvement of 15–25%
- Supplier lead-time reduction of 30–50%
- Schedule attainment improvement of 20–30 points
Start the Conversation
Ready to see what's hiding in your value stream?
Every engagement begins with an operations assessment — a structured Gemba walk where we observe your current state, quantify your key losses, and map the opportunity. No commitment required. If the numbers make sense, we talk scope.