£800k Saving in quality and productivity


We were asked by the  Managing Director of a first tier Japanese automotive supplier to upskill Managers and Supervisors in the principles and tools of TPS - control and kaizen – controlling a shop-floor of 800 people. The aim was to create self-reliance and the ability of supervisors to continuously improve their own areas.


Initially 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 75% shop-floor, 25% classroom centred on real problems and the real process. 


Over 3 years, the 65 individuals generated £800k in savings through scrap, productivity, and inventory – a Return on Investment of 3:1. The training was extended to Engineers, Materials other support functions and was recognised globally as excellent development.


Sempai Consultancy Services

Derbyshire, UK


Tel: 01335 344 098



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