Lean Manufacturing Consultant — Hands-On, Senior, Results-Driven

Lean is not a workshop. Lean is a way of running an operation. As your lean manufacturing consultant, we work on the floor with your team to remove waste, stabilize flow and build the management system that protects the gains.

What Real Lean Looks Like

Real lean is quiet.

There are no posters, no slogans, no event banners.

Standards are visible at the workstation.

Andon signals are acted on within minutes.

Tier meetings finish in 12 minutes with clear actions.

Supervisors spend most of their day on the floor, not in offices.

That is the operational state we build toward.

Lean Tools We Deploy (When They Fit)

Tools are sequenced based on diagnosis — never deployed as a checklist.

  • Value stream mapping (current and future state)
  • SMED for changeover reduction
  • Standard work and standard work combination tables
  • Kanban and pull systems
  • Heijunka leveling for mixed-model production
  • TPM for autonomous and planned maintenance
  • A3 problem solving for structured improvement

Why Most Lean Implementations Fail

They are launched as a tools program rather than an operating system.

Without daily management, escalation and standard leader work, every gain decays inside 12 months.

We build the management infrastructure first, then layer tools onto it.

Industries We Serve

Automotive, aerospace, FMCG, pharmaceutical, food & beverage, building products, industrial equipment, electronics.

Both discrete and process manufacturing, including high-mix low-volume environments.

Outcomes Clients Expect

10–30% throughput improvement, 20–50% downtime reduction, 30–60% changeover reduction, 25–40% inventory reduction, and a self-sustaining daily management cadence within 6 months.

Frequently Asked Questions

What does a lean manufacturing consultant do?

A lean consultant diagnoses waste in your value stream, redesigns flow, installs standard work and daily management, and coaches leaders to sustain the system.

How much does a lean consultant cost?

Senior lean consulting typically ranges from $15K for a diagnostic sprint to $150K+ for full multi-line transformations.

ROI is usually achieved in the first quarter.

Can lean work in low-volume high-mix environments?

Yes — lean principles apply, but the tools change.

We focus on flow stability, quick changeover and visual planning rather than takt and pull.