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Would you like to know where you and your business are in your lean journey?

Sempai develops team leaders to create happy and high performing teams who can meet customer schedules, reduce defects and grow a team for a future talent pipeline

Small & large global businesses have worked with us and implemented our proven strategies and have become leaner, more productive and more capable as a result

Our vision is to help the hidden heroes in manufacturing to make the right things better

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A Digital Lean Toolkit built by lean experts to grow lean thinkers

 
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Grow your manufacturing business by increasing the capability of your shopfloor team. Allowing them to be more in control and needing less crisis support from their supervisor 

SempaiGuide is accessed through an App on a tablet. Enabling your team to learn on the job, making instant and measurable improvements without ever having to leave the shopfloor.  

Key features

  • Embedded lean tools

  • Practical on the job learning

  • Personalised for the users skill level

  • Built in kaizen log to enable recording, monitoring and updating improvements

  • Access to a lean expert

Learn lean

Learn

Learn lean skills on the job and on demand. 

Apply

Apply

With built in learn-a-bit do-a-bit to deliver tangible improvements

Get Results

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Measurable improvements to Safety, Quality, Delivery and Costs

Case Studies

 
Case Study 1

How Team Leader Andy used SempaiGuide to increase his lean skills and save his business £3.6k per year (without leaving the shopfloor!)

OVERVIEW

28 year old Andy is a Team Leader working for a

£200m turnover 1st tier global Japanese Automotive Manufacturer

 

He has been a Team Leader for 3 years and has had some previous lean training (classroom based!)

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

APPROACH

  • Using our "Work & The 7 Wastes" Module on the shopfloor, Andy learned how to Identify and Eliminate the 7 Wastes

  • He worked with one of his operators to improve a job they had to do 6 times per day

  • This job was wasting 1 hour per day

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RESULTS

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Cycle time Reduction

The first time Andy used the module he identified & eliminated 11 wastes to reduce the cycle time from 7 mins to 1.5 mins

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Cost Saving

The 78% cycle time reduction saves £3,600 per year in labour cost

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Skills increase

From his new found skills Andy quickly chose his next improvement area, a tricky operation causing quality problems

SempaiGuide allows Team Leaders to learn relevant techniques on how to improve their areas, delivering improvements, without leaving the shop floor

CONCLUSION
Case Study 2

How Team Leader Derek used SempaiGuide to increase his lean skills and save his business £2.4k per year (while doing his usual job)

OVERVIEW

Derek is a Team Leader working for a

£15m turnover electrical components group

He is a very new Team Leader and had no previous lean training

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

APPROACH

  • Using our "Work & The 7 Wastes" Module on the shopfloor, Derek learned how to identify and eliminate the 7 wastes

  • With guidance from SempaiGuide he decided to improve a task that affected many lines

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RESULTS

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Cycle time Reduction

The first time Derek used the module he identified & eliminated 9 wastes to reduce the cycle time from 89 secs to 40 secs

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Cost Saving

The 55% cycle time reduction saves £2,400 per year in labour cost

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Skills increase

After using SempaiGuide on the shopfloor when he got a little time, Derek's Work & The 7 Waste skills increase by 43%

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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.

CONCLUSION
Case Study 3

How Operations Leader Lee used SempaiGuide to find more issues, earlier, as he patrolled his patch

OVERVIEW

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

He has been an Operations Leader for 1 year and has no previous lean training in this area.

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

APPROACH

  • Using our "Patrolling Your Patch" Module on the shopfloor, Lee sharpened his eyes through videos/animations/photos and performed 6 layered patrols.

  • SempaiGuide automatically assessed his BEFORE and AFTER

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RESULTS

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Less Problems

Lee found 81% more abnormalities on his patch across People, Safety, Environment, Quality, Delivery and Cost

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Cost Saving

His team are happier and giving more kaizen ideas.  Several accidents and defects have been avoided.

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Skills increase

After a few weeks of using SempaiGuide on the shopfloor Lee's eyes have become much sharper and attuned to specific SEQDCP risks.

SempaiGuide gives shopfloor leaders the skills to control their patch, as well as improve it. "Patrolling Your Patch" is one of 4 key control skills in SempaiGuide

CONCLUSION

How Lean Are You?

Ever wondered how lean you and your business is? Take our "How Lean Are You?" Scorecard and receive a personalised results report.

 

It takes just 5 minutes

It's completely free

Customised report

We're Trusted By

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