Services

Lean Manufacturing Consulting

Improve flow, cut waste and ship on time—every day.

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Proven Expertise in Driving Lean Manufacturing

With decades on the plant floor, we’ve helped teams remove waste, balance flow, and build standard work that sticks. Our lean manufacturing consultants work shoulder-to-shoulder with operators and leaders to stabilize processes and lift performance that lasts. The result: faster flow, less WIP, better quality, and predictable delivery.

  • Thousands of client-focused projects improving flow, OEE, and lead time
  • Powered by 60 experienced experts across operations, planning, quality and maintenance
  • Generated hundreds of millions in hard savings and capacity release
  • 90% referral-based practice, reflecting client trust and outcomes

Empowering Your Business with Tailored, Results-Driven Solutions

We combine proven Lean methods with your culture and challenges to design the simplest system that works—and that your team owns.

  • Experienced leadership teams coaching from floor to board room
  • Customized solutions for High Mix/Low Volume and repetitive production environments and repetitive environments
  • Seamless integration with your team to attain lasting results
  • Measurable improvement gains realized in GM and operational metrics 
  • Knowledge transfer so improvements continue long after we leave.

How We Get Results

Understand

  • Rapid scan of goals, KPIs, behaviors, and routines
  • Baseline flow, OEE, quality, delivery, and inventory
  • Identify bottlenecks and high-impact opportunities

Fix

  • Remove barriers to flow by eliminating waste, closing gaps, and aligning processes
  • Increase velocity and reduce variation by implementing TAKT, Flow and Pull
  • Leverage standard work and problem solving to fix real issues root cause

Sustain

  • Leader standard work with a simple review cadence
  • Visual Management System to support continuous improvement
  • Coaching so teams own the system and improve it

Service Offerings

Operational Excellence

  • Develop and Deploy operational excellence Operating System
  • Lean
  • Waste Elimination
  • Takt, Flow, Pull
  • Value Stream Mapping
  • Lean for Engineer to Order/single purpose
  • Visual Management & Control System
  • Six Sigma
  • Quality Management Systems
  • New Product Development
  • Strategy Deployment
  • Rapid Business Transformation

Supply Chain Management

  • Supply chain strategic planning
  • Supply base performance improvements
  • Distribution architecture design and implementation
  • Modelling
  • What-If analysis
  • Sales & Inventory Operations Planning
  • Tactical supply chain problem solving and corrective action

Acquisitions & Integrations

  • Pre-LOI Support
  • CIM review and impression
  • Operational due diligence
  • Full-Potential Identification
  • Rapid value capture
  • 100-day implementation planning
  • Full integration planning and execution
  • Transformation of operations to lean/CI culture
  • Pre divestiture operations analysis/sale readiness

Leadership & Change Management

  • Leadership development and executive coaching
  • Organizational design
  • Transformational design
  • Strategy development and deployment
  • Communications planning and execution
  • Building high performance teams

Program & Project management

  • Strategy alignment in project identification
  • Structured approach
  • Lean Six Sigma tools to drive out waste
  • Proprietary program and project management tool sets
  • Lean project management processes
  • Integration of lean techniques in PM
  • PDCA methodology
  • Embedded project leadership

What We Deliver

Operating system

  • Daily Management System (KPIs/visual boards; tiered huddles & escalation)
  • Goal deployment (strategy → daily work)

Lean standard work & flow

  • Value Stream Mapping; TAKT / Flow / Pull
  • Standard work library; SMED (quick changeover)

Quality & problem solving

  • A3 / PDCA coaching; loss analysis; visual controls
  • Kaizen events (as needed)

Rollout & governance

  • 90-day rollout with milestones, owners, checkpoints
  • Review cadence, sustain audits, skills matrix & cross-training

Lean Manufacturing Consulting Case Studies

Precision assembly (HMLV)

Situation

Throughput constrained by frequent changeovers

Action

SMED events, standard work, visual management

Results

Changeover −32%, Throughput +12%, OTIF +6 pts

Complex assembly line

Situation

Low OEE and recurring quality issues

Action

Loss analysis, A3 coaching, first-piece verification

Results

OEE +7 pts, Scrap −15%, Rework −10%

Avionics supplier

Situation

Micro-stops and unstable delivery

Action

Daily management boards, escalation path, line balance

Results

Micro-stops −20%, OEE +8 pts, OTIF +6 pts

Frequently Asked Questions

Is Lean just projects and events?

No. We build daily routines so Lean becomes how work runs—not a side project.

How fast will we see results?

Most sites see measurable improvement in 4-8 weeks.

Will we need additional headcount or capital to gain the results?

Typically, no. We work with your current team and equipment to optimize it before recommending additional resources.

Lean Manufacturing Consulting Insights

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Ready to make Lean the way your plant runs?

Get a quick, practical plan for your first 90 days.

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