Productivity Deployment - Ideas Library

Effective problem-solving sits at the core of Lean and Continuous Improvement. Among the many methods available, the A3 approach, developed at Toyota, remains one of the most powerful. It provides a standard one-page structure to capture the full story of a problem: The problem description Current conditions Root cause analysis Improvement options Countermeasures tested and implemented Follow-up plans This simple, visual format helps teams communicate clearly and think logica

If problem-solving sits at the centre of Lean Thinking, then the PDCA (Plan, Do, Check, Act) cycle is the engine that drives it. Also known as the Shewhart or Deming Cycle, PDCA provides a simple but powerful structure for learning and improvement. The cycle works like this: Plan:  Identify an opportunity and develop a clear plan, including success measures Do:  Test the change on a small scale and gather data Check:  Analyse results to understand whether the change delivered

“The artist ought never allow anything to overcome his sense of the main end of art – perfection.” — Michelangelo Among the guiding principles of the Shingo™ Model, Seek Perfection  is one of the most striking. It often prompts the reaction: “Perfection isn’t possible, so why pursue it?” Why Seek Perfection? The answer is simple. Seek Perfection  is the driving force behind daily, incremental improvement. It captures the true spirit of Kaizen. Imperfection is what fuels innov

The word Gemba  is one of the most widely used Japanese terms in continuous improvement. It has no direct English equivalent, but it simply means “the actual place” — the place where value is created. That might be a factory floor, a customer service centre, a design studio or even a client’s site. Why Gemba Matters Taiichi Ohno, often described as the father of the Toyota Production System, developed the concept of the gemba walk to help people step away from their daily rou

Manufacturing organisations face constant pressure to improve productivity, reduce waste, increase reliability and strengthen quality. Lean Six Sigma provides a proven, structured way to achieve these outcomes by combining the speed and simplicity of lean with the analytical rigour of Six Sigma. Our Lean Six Sigma training develops practical, confident practitioners who can lead improvement projects, solve complex problems and deliver measurable results. Why Lean Six Sigma Ma

Sustainable productivity improvement relies on capability, not just tools or short-term activity. Manufacturing organisations need people who understand how to improve processes, solve problems, lead teams and embed better ways of working. The Lean Competency System (LCS) provides a structured, internationally recognised framework for developing that capability. It helps organisations build the skills, behaviours and confidence needed to drive long-term improvement. Why LCS M

Effective problem-solving is at the core of continuous improvement and lean thinking. Many manufacturing organisations struggle to build the right skills, habits and leadership behaviours needed to address recurring issues. That’s where the 8D Assessment comes in, it provides a structured evaluation of your current problem-solving capability, behaviours and leadership engagement. Why an 8D Assessment Matters When problems keep recurring, cost rises, waste accumulates and doub

Many manufacturing organisations know what  needs to improve. What they struggle with is how  to do it quickly, effectively and with measurable impact. Lean interventions are designed exactly for that: focused, high-impact initiatives that target specific problems and deliver results while building internal capability. Why Lean Interventions Matter Improvement programmes that drag on or dilute effort often run out of steam. Lean interventions inject pace, clarity and purpose

Strong improvement plans only deliver results when they are executed with discipline, focus and alignment. In many manufacturing organisations, the challenge isn’t a lack of ideas, it’s ensuring the right actions are delivered consistently, at the right pace, with the right level of accountability. Lean Deployment Support is designed to solve exactly that. It brings structure, rhythm and hands-on guidance to turn improvement plans into measurable productivity gains. Why Lean