Front line · lean manufacturing & Lean Six Sigma
Lean manufacturing that works in a small factory
Lean doesn’t need a corporate program, consultants in suits or a wall of posters. It needs someone on the floor fixing real problems with your team, and making sure the fixes stick.
Practical lean, not theory
Paul is a degree-qualified manufacturing engineer and Lean Six Sigma Master Black Belt with more than 20 years in Australia and overseas. The tools are the same ones large manufacturers use, scaled to a business where the owner still knows every job.
- Waste removal: waiting, double handling, searching, rework, over-processing and excess stock.
- 5S and workplace organisation so tools and materials are always where they should be.
- Standard work so every job is done the same way, whoever does it.
- Root cause problem solving for faults that keep coming back.
- Set-up and changeover reduction so you can run smaller batches.
Solving the problem nobody could fix
For one processing client, Paul solved a fault that had beaten every earlier attempt, adding more than $350k to the bottom line.
Building your team’s capability
We coach your supervisors and operators as we go, so they can keep improving after we leave. Where it suits, we run lean training and mentor your own improvement people through their first projects.
Common questions
+Is lean only for large manufacturers?
No. Small manufacturers often see faster results, because decisions are quick and everyone can see the change.
+Do you provide Lean Six Sigma training?
Yes, as part of an engagement: practical training and coaching for your team on real projects in your business.
Find out what's keeping you on the floor
A free 30-minute call is the first step. We'll talk through your operation and whether a factory review makes sense.