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CASE.
STUDIES.

Our Case Study showcase proudly presents real-life success stories and tangible results achieved through our innovative lean solutions and collaborative approach. 
 
We invite you to explore how we have partnered with businesses like yours to overcome challenges, drive growth and flourish from the lean knowledge we have shared.

 


We hope these case studies will inspire you to transform your business with lean. 

CLIENT

INDUSTRY

NO. OF EMPLOYEES

DENSO

AUTOMOTIVE

1000 +

CHALLENGE

DEVELOP A
BUILT-IN
QUALITY 
STRATEGY.

SOLUTION

Over the course of 3 years support we 

  • Devised a JKK (Jikoutei-Kanketsu) Built- in Quality with ownership strategy tied into the business Policy  Deployment 

  • Delivered communication of the strategy 

  • Ran interactive workshops to review and improve mature product quality performance & NPI from  design stage through to launch 

  • We trained 170 key people across Operations, Engineering, Materials, Quality, Finance, Purchasing  functions 

  • Established confirmation activities to support Built-in Quality through NPI and oversaw set-up of an Oobeya room to manage Built-in Quality across functions. 

Our client achieved these results by engaging our consulting service

RESULTS

94%

Quality 

Improvement

170

Key People

Trained

CLIENT

INDUSTRY

NO. OF EMPLOYEES

JCB

CONSTRUCTION

5000 +

CHALLENGE

DESIGN & SET UP A
LEAN ACADEMY

SOLUTION

We led the Group General Manager and his team to design and set up a lean facility with a mini functional  factory.

  • The mini factory within the Lean Academy fabricates and assembles a real product made by the  company. 

  • We defined the Group Lean strategy

  • We designed the training materials and functional factory, delivered practical courses and assessed, recruited and trained Senior Trainers and Trainers. 

RESULTS

3000+

People
Trained

CLIENT

INDUSTRY

NO. OF EMPLOYEES

TOYOTA GROUP 

AUTOMOTIVE

1000 +

CHALLENGE

ACCELERATE
OEE PERFORMANCE.

SOLUTION

In response we:

  • Helped the team to develop a strategy for breaking down the shop and prioritising areas / machines.

  • Identified skills weaknesses at Manager / Cell Leader / Team Leader level and trained them hands on  5s & TPM 

  • Created and trained 6 zone champions 

  • Created visual control kamishibai style 5s / TPM approach to manage and drive improvement

  • Introduced layered audit and confirmation process for 5s / TPM auditing with a kaizen mechanism.

Our client achieved these results by taking our 5s/TPM course

RESULTS

22%

OEE
Improvement

25

Key Machines
Improved

CLIENT

INDUSTRY

NO. OF EMPLOYEES

BECTON DICKINSON

MEDICAL DEVICES

1000 +

CHALLENGE

INCREASE LEAN LEADERSHIP
CAPABILITY OF THE
SENIOR TEAM.

SOLUTION

We put together a 12 month plan for on site, on the gemba coaching for 8 key individuals from the Senior Leadership Team, across all functions from Operations to HR to Engineering. The focus was:


1. To develop a stronger focus on their lean transformation by introducing an external sensei style regular check-in
2. To coach key individuals and provide guidance for lean transformation.


The visits were regular, time-efficient and biased towards dealing with real issues and challenges.
The sessions with each leader combined dealing with short-term issues with reflection on their and their team’s capability and behaviours. This was delivered through a mix of coaching and mentoring (with a little counselling) to develop the individuals themselves, the lean strategy and develop the teams working for them. Gemba walks were at the core of the coaching to overcome barriers and capability issues that were hampering their lean transformation.

Our client achieved these results with our expert coaching

RESULTS

3

Promotions within
6 months

CLIENT

INDUSTRY

NO. OF EMPLOYEES

DENSO

AUTOMOTIVE

1000 +

CHALLENGE

UPSKILL SHOPFLOOR LEADERS IN TPS 
TO DELIVER KAIZEN

SOLUTION

  • We ran assessment centres to assess competencies (hard and soft skills) and lean skills to identify  individual/collective gaps.

  • We devised a 15 day practical hands-on program for 65 Cell Leaders & Team Leaders covering control, 5s,  Standardised Work, Waste, Visual Factory, Data Analysis, TPM, Practical Problem Solving, SMED, Line Balance, Layout, Built-in Quality and Area Benchmarking. 

  • The training was centred on real problems and the real process to develop practical Toyota Production System (TPS) skills

Our client achieved these results with our expert coaching

RESULTS

£800k

Saving in
Quality & Productivity

65

Key People
Trained

CASE STUDY

INDUSTRY

Automotive

TEAM LEADER

Derek

ABOUT

Derek is a Team Leader working for a £15m electrical components group.

Derek has been in Operations working on the shopfloor for a number of years.  He is very new to Team Leading and had no previous lean training prior to using SempaiGuide.

ACTION

  1. Using the 'Work and the 7 Wastes Module", Derek chose an activity to improve.

  2. Using the tools inside SempaiGuide he recorded the existing cycle time of a task.  A task that affected many lines.

  3. Derek learnt how to identify and eliminate the 7 Wastes.

  4. Using his new skills, Derek applied them to his chosen task.

  5. Derek recorded the new cycle time after eliminating the identified waste.​

CONCLUSION

SempaiGuide is proven to work for all types of Team Leader - whether they're new to the role, not reaching their potential or high performing.

sempaiguide case study 55% cycle time reduction
team leader using sempaiguide lean app

"I enjoyed the exercises trying to improve a process, applying it. I saw things I hadn't noticed before."

RESULTS

55%

Cycle Time

Reduction

43%

Skills

Increase

9

Wastes Identified & Eliminated

Our client achieved these results using our SempaiGuide Work & the 7 Wastes Module

Case study patrol lee

CASE STUDY

INDUSTRY

Medical Devices

TEAM LEADER

Lee

ABOUT

Lee is an Operations Leader working for a £300m turnover global medical products group.

Lee has been an Operations Leader for 1 year and prior to using SempaiGuide had no previous lean training.

ACTION

  1. SempaiGuide assessed Lee's first patrol to measure and record how aware and observant he was when patrolling his patch.

  2. Lee used SempaiGuide to learn what issues to look out for when patrolling his patch, to intervene at the right time to avoid the issues becoming problems.

  3. Lee learnt to look out for issues involving Safety, Quality, Environment, Cost, Delivery and People.  

CONCLUSION

SempaiGuide gives Shopfloor Leaders the skill to identify Abonormalities before they become Problems.  Increasing control in the factory.

sempaiguide lean app

"I thought the module was brilliant.  It's amazing how much I picked up about what I should be looking for"

team leader using sempaiguid lean toolkit app

RESULTS

81%

More Abnormalities

Found

Our client achieved these results using our SempaiGuide Area Patrol Module

CASE STUDY

INDUSTRY

Automotive

TEAM LEADER

Andy

ABOUT

Andy is a Team Leader working for a £200m turnover 1st tier global Japanese Automotive Manufacturer

Andy has had exposure to classroom based Lean training in the past.  However, generic Lean lessons meant that he struggled to apply what he had learnt in the classroom directly to his work area on the shopfloor.

ACTION

  1. ​Using the ‘Work and the 7 Wastes module’, Andy learned to identify and eliminate the 7 wastes.​

  2. Andy worked with one of his operators to improve a job they had to do six times per day. ​

  3. Through this improvement Andy was able to save one  hour per day.​

  4. Andy was able to make this saving after just one week of using SempaiGuide.

CONCLUSION

SempaiGuide gives Team Leaders relevant techniques to improve their areas, delivering real-time improvements, without leaving the shop floor.

sempaiguide toolkit app

"Since doing this I've noticed that there are other jobs I can change around. It made me look at things better"

team leader using lean app and learning

RESULTS

78%

Cycle Time
Reduction

11

Wastes Identified & Eliminated

£3.6k 

Labour Cost Saving

Our client achieved these results using our SempaiGuide Work & the 7 Wastes Module

smiling team lean training

IF YOU MAKE PRODUCTS.
WE'LL MAKE A DIFFERENCE.

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