Lean & Six Sigma for South African manufacturers
Practical Lean and Six Sigma implementation, led by a Black Belt who has run production floors, not just advised them. Less firefighting, shorter lead times, and standards that hold.
Example from the free calculator
One line, 80 scheduled hours a week
55% 70% OEE
12 hrs
recovered every week
6 shifts
extra capacity a month
No new machines, no new hires. Try it with your own numbers.
6–8 wks → 3–4 wks
Lead time, wood manufacturing
~R2 million
Cash freed by cutting stock from 6 to 2 months, packaging
6% → 1.5%
Rework, built-in quality project
Why most Lean efforts fail
Most companies try Lean tools without building the structure behind them. The KPI boards and 5S posters appear, but the waste stays hidden, the firefighting continues and the standards slide back within weeks.
Lean is daily behaviour, not posters. We work on your floor with your people to build the routines, standards and leadership habits that make improvement stick, and we measure it.
Services
Improve flow, remove waste and stabilise production on the shop floor.
5S implementation and audits · Waste elimination · Flow and layout · Takt and cycle time · Visual management · Standard work
Learn more →Build the daily leadership discipline that keeps performance improving.
SQDCP boards · Leader standard work · Gemba walks · KPI reviews · Structured problem solving
Learn more →Build your team’s own capability for data-driven problem solving.
White, Yellow and Green Belt · Lean Basics · DMAIC project coaching · On-site or virtual
View courses and pricing →How we work
1
We talk through your biggest operational headache and whether we can help.
2
Remote or on site: a scored assessment of your floor and your top 5 losses.
3
Quick wins first, then visual control, then the routines that sustain it.
4
We work alongside your team, coach your champion and measure the result.
New · anywhere in South Africa
Your team captures photos, video and data with our step-by-step pack. We walk your floor with you on a live video call, then deliver a scored report, your top 5 losses and a 90-day roadmap within 10 working days.
Fixed price
R7 500
excl. VAT
100% credited to implementation if you go ahead within 30 days
Tools & Templates
Free
Two minutes, eight numbers: see what your lost line time is worth per year.
Download free →Free course
Eight short modules with a knowledge check and certificate. Run it as weekly toolbox talks with your team.
Download free →Best value · R1 290
OEE calculator and guide, 5S training deck, A3 template, takt and line balancing calculator, and more.
See what’s inside →Case studies
Wood manufacturing
Mapped the workflow, removed motion and waiting, reorganised workstations for flow and standardised daily routines.
6–8 wks → 3–4 wks
Packaging
Introduced pull systems and Kanban controls, cut over-ordering and made stock visible.
Stock 6 → 2 months
Manufacturing
Added in-process checks and standards at each station, with immediate feedback and smaller batches.
Rework 6% → 1.5%
About
Lean Six Consulting is owned and run by a Six Sigma Black Belt and Lean specialist with more than 15 years of hands-on manufacturing management, running factories and leading Lean transformations across assembly, packing, engineering and warehouse operations in high-mix manufacturing.
We understand production pressure, engineering pushback and quality risk, because we’ve managed them. Our approach is practical and non-punitive: we score the system, not the people.
Lean Six Sigma Black BeltFactory managementLean training design
Book a free 30-minute call. We’ll look at where you are and the one improvement that would make the biggest difference first.
Contact
Gauteng, South Africa · working with manufacturers nationwide