Services

Operational Excellence Consulting

Turn improvement into how your plant runs—every day.

Proven Expertise in Driving Operational Excellence

With decades of experience applying Lean Six Sigma methodologies, we have streamlined countless operations, driving millions in cost savings and measurable performance improvements. The expertise of our operational excellence consultants ensures processes are optimized for efficiency, waste is minimized, and organizations achieve sustainable, long-term success.

Thousands of client-focused projects completed, delivering tailored solutions
Powered by 60 experienced experts with extensive industry and operational excellence experience
Generated millions in tangible cost savings for clients
90% referral-based practice, a testament to client trust and satisfaction

A man wearing a white hard hat and white shirt works on a laptop outdoors, exemplifying operational excellence, with a wind turbine and clear blue sky in the background.

Four people in blue work shirts stand together, closely looking at a clipboard in a workshop. They appear to be having a serious discussion about continuous improvement and Lean Manufacturing Consulting strategies.

Empowering Your Business with Tailored, Results-Driven Solutions

CBS leverages internal expertise and client capabilities to create a best value solution for our clients. We bring:

Experienced leadership teams with balanced skillsets
Customized solutions or processes for every company and challenge
Seamless integration with your people and business culture
Measurable improvement gains in minimal time
Knowledge transfer that ensures ongoing success

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

Stand up a simple management system (tiered huddles, visual boards)
Standard work and problem-solving (A3/PDCA) on live issues
Line balance, changeover reduction (SMED), and flow improvements

Sustain

Leader standard work and coaching cadence
Routine audits and KPI reviews to hold the gains
Capability transfer so teams own the system

Service Offerings

Operational Excellence

Strategy / Goal Deployment
Design For “X”
New Product Development
Quality Management Systems
Prevention
Control
Correction and Learning
Lean 6 Sigma
Develop and Deploy Operating System
Visual Management & Control System
TAKT, Flow, Pull
3P
Rapid Business Transformation
Quote to Cash Analysis
Training for X / KPO Office

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

Operational Excellence Consulting Case Studies

A woman wearing a hard hat and safety vest kneels beside an industrial robot arm in a factory, using a control device. She appears to be inspecting or operating the machinery in a modern Aerospace & Defense Consulting setting.

Operational Excellence: Eliminating Waste and Increasing Shop Capacity

Overview

An industrial equipment manufacturer producing commercial products faced production inefficiencies that limited revenue and impacted profitability.

Challenge

Production capability was constrained and unpredictable

Quality concerns and inconsistent output disrupted deliveries

Operating margins were squeezed by excessive overtime and expediting costs

Lack of efficient product flow across assembly lines

Solution

Conducted a full operations assessment

Applied Lean and Six Sigma practices to improve flow and reduce waste

Implemented new material handling and assembly processes

Established standard practices for line efficiency and team ownership

Trained internal teams to lead future line conversions

Results

50% reduction in hours to produce equipment (initial line)

Output increased by over 100%

Cycle time reduced by 85%

Internal team empowered to continue deployments across additional lines with full conversion planned within 12 months

Two workers in blue uniforms and helmets operate machinery in a brightly lit industrial workshop with colorful wall art. Metal bars and equipment highlight an efficient workspace, ideal for lean manufacturing consulting practices.

Operational Excellence: Enterprise Program with Green & Black Belt Training

Overview

A global manufacturer of systems and sub-systems in the high-tech industry—with over 85 locations serving aerospace and defense contractors—sought to build an enterprise-wide Operational Excellence (OE) program.

Challenge

Needed an OE framework tied directly to business strategy

Wanted a sustainable model to scale across business segments

Lacked a unified approach for training, best practice sharing, and continuous improvement

Required leadership alignment to drive lasting change

Solution

Partnered with leadership to design and model a total OE approach

Launched the program in one business segment before scaling

Adopted the OE model company-wide

Delivered proprietary Green and Black Belt training using a blended method

Embedded Six Sigma projects as part of the deployment

Results

OE process scaled from one segment to full enterprise adoption

Over 300 employees trained in Green and Black Belt methodology

$70 million in savings generated since the program began

Organization now equipped with a repeatable, strategy-aligned improvement engine

Two women in red shirts and yellow safety vests smile and talk while working with cardboard boxes and paperwork in a large warehouse, showcasing the organized efficiency promoted by lean manufacturing consulting.

Operational Excellence: 275% Throughput Increase via Synchronous Scheduling

Overview

A global designer and manufacturer of systems and sub-systems in the high-tech sector—serving aerospace and defense contractors across 85+ locations—needed to dramatically improve throughput and on-time delivery.

Challenge

Unable to meet customer demands on quantity, lead time, and on-time delivery (OTD)

Throughput needed to increase by more than 200%

OTD on key product was 0%

Cost reduction was important, but secondary to throughput

Inventory inefficiencies contributed to production constraints

Solution

Partnered with planning and operations to develop a visual, synchronous scheduling system

Identified and optimized critical process centers and set-ups

Built and implemented production management tools to maintain flow

Ensured synchronization and controlled volumes across production lines

Results

Increased throughput by 275% (from 90 units to 247 units)

Improved OTD from 23% to 97% on same product

Reduced cost of product by 25%

Reduced total inventory by 15%

Frequently Asked Questions

Is OpEx different from Lean?

OpEx makes Lean the way the plant runs—every day. It connects strategy to daily work and keeps improvements from slipping back.

How long does it take?

Most sites see measurable improvement in 4-8 weeks.

How do you make results stick?

We install simple routines—tiered huddles, visual boards, leader standard work—and coach teams while fixing live problems.

Ready to see OpEx on the floor?

Get a quick read on where to start and what to fix first.

Request an OpEx Assessment

Op Ex Deliverables

Higher Throughput & Revenue Capacity
Improved EBITDA & Margin Expansion
Increased On-Time Delivery (OTD)
Reduced Operating Costs

Improved Labor Productivity
Lower Inventory & Improved Cash Flow
Enhanced Customer Satisfaction & Retention

Latest Operational Excellence Insights

Bridging the Gap: Aligning Strategy, Metrics, and Daily Actions for Sustainable Success

As business leaders, we’re all familiar with the importance of having a clear, well-defined strategy. It’s the roadmap that guides our decision-making, resource allocation,…
Breaking through the Roadblocks (Before They Crash Production)

Let’s face it: every business has its problems, its constraints, and its inefficiencies. These issues can be like roadblocks, preventing you from reaching your…