"Redesigned our plant layout for new equipment installation—no new construction needed.”

“Our Costa Rica branch faced major layout challenges while trying to install a new machining cell. Lean 101 spent some days onsite collaborating with our Operations team analyzing our plant flow and redesigning the layout for a better flow. Without any new construction, we installed the new cell in a way that actually improved the overall plant flow. In addition, Lean 101 spent a weekend training our entire plant associates on Lean Concepts with practical tools.”

“Boosted assembly line capacity by 30%—with no new hires.”

“Our California site was awarded additional product volume, but our plant capacity couldn’t keep up. Lean 101 trained our associates in lean tools for waste identification, waste reduction, and process optimization; later they led a Kaizen workshop to optimize our process flow and uncover improvement opportunities. By rebalancing and optimizing the entire assembly line, we increased capacity by more than 30%—without hiring a single new associate; plus, we improved work station ergonomics for our associates.”

"Lean 101 helped us eliminate a bottleneck so our subassembly line now keeps pace with the main line."

“Our California subassembly line struggled to keep pace with the main line, causing frequent stoppages due to missing parts. Lean 101 facilitated a Value Stream Mapping (VSM) workshop that revealed the bottleneck and guided us through actions to improve workflow. After a short implementation, we broke the bottleneck and our subassembly now runs at the same rate as the main line with the same resources we had before.”

"Lean 101 simplified our performance boards and KPIs, giving team leaders clarity and confidence in daily reporting."

“Our Team Performance Boards were overloaded with KPIs that team leaders didn’t fully understand, leaving them unclear on what truly mattered. Lean 101 helped us analyze our operation to identify the most important metrics at the team level. They simplified the boards and retrained our team leaders, ensuring they were confident and aligned in their daily reporting. Today, our performance boards are simple, clear, and effective."

"30% productivity boost in just three months.”

“Our organization was growing fast and had just launched a new molding line, but we couldn’t reach its full capacity due to recurring issues. With our Lean Coach guidance, we implemented OEE (Overall Equipment Effectiveness) to measure performance and identify the key problems draining productivity. By giving our teams the right KPIs and visibility combined with other Lean 6 sigma tools, they shifted from firefighting to solving root causes. Within three months, productivity increased and sustained by 30%.”

"Cut scrap by 45%—saving $50K per month.”

“Our highest scrap-generating cell was losing more than $50K per month due to weld defects. With our Lean Coach support, we applied problem-solving methods to uncover the real root cause and then, we implemented lean 6 Sigma tools to control process variation. The result was a, overall 45% scrap reduction in the cell, and a 90% reduction for our highest-cost SKU.”

"Reduced tube mill changeovers by 50%.”

“Our tube mill changeovers took more than 7 hours, creating major challenges when additional products were assigned to our line. With our Lean Coach guidance, we ran a SMED workshop to analyze every step, document standards, and improve Changeover sequencing. Engineering, Operations, and Quality teams collaborated on the project, and we ultimately cut changeover time by 50%."

"Restored cell productivity and freed one operator.”

“One of our production cells relied on excessive overtime because it couldn’t keep up with demand—even though it had the capacity per design. With our Lean Coach support, we mapped the process, uncovered the hidden productivity losses, and applied lean six sigma tools to improve and stabilize the process. As a result, we restored productivity and freed up 1 of the 3 operators for redeployment.”

"Closed 20% of our quality KPI gap in six months.”

“Our plant was struggling to meet quality KPIs, constantly reacting to defects instead of preventing them. With our Lean Coach guidance, we identified systemic issues and deployed tools like TPM/OPM, 5S, and Standard Work across the entire site. Within six months, we closed 20% of the quality KPI gap and established a stronger process control.”

"Your Lean Experiencing workshop opened my eyes and empowered me to drive culture change.”

“In my 25+ years with this company, I never truly understood the core objective of Lean manufacturing—until I joined your experiential Lean Simulation workshop. For the first time, I saw lean concepts applied hands-on, in real time with a real process; It opened my eyes, and I now feel empowered to build a culture of process excellence in my plant.”

"Our organization has thrived for more than 100 years, relying on the expertise of our people rather than documented processes. But as we expanded and faced a wave of retirements, serious weaknesses were exposed. With our Lean Coach support, we mapped out and documented our processes, developed training materials for new associates, and standardized global practices to reduce variation. These changes position us to keep growing without pain."

"You helped us to turn our toughest skeptics into Process Excellence ambassadors”

“We invited our plant’s union stewards to participate in your hands-on Lean Simulation workshop. Historically, they resisted process improvements, fearing cost saving initiatives would mean job cuts. After the workshop, they left quietly—but the very next week, the most resistant steward approached our CI team requesting support to implement a list of improvement ideas from his work team. It was a cultural shift we never expected."