Better Productivity. Lower Costs.
Increasing costs, downtime, and inefficiencies reduce competitiveness. Gemba helps manufacturers across Kenya improve productivity, reduce waste, and increase profitability using proven Lean Manufacturing practices.
500+
Manufacturers Supported
12+
Years
40+
Industries
100%
Shop Floor Execution
Full-time on-site consultants
Shop floor execution, not just advisory
Results embedded into daily operations
Serving India, Middle East, and SE Asia
Your Factory Is Running. Productivity Still Isn't.
Most manufacturers lose 20-40% of their production capacity through hidden operational losses that become part of everyday work.
01
One bottleneck station limits the performance of the entire production line, often remaining hidden until detailed analysis is conducted.
We identify and eliminate the constraints limiting production flow through bottleneck analysis and throughput optimization.
Result: 53.9% throughput improvement achieved in cable manufacturing.
02
Some stations remain idle while work accumulates at others, creating uneven flow and reducing overall line productivity.
We use line balancing and Yamazumi analysis to distribute workloads effectively and improve production flow.
Result: 269% productivity improvement achieved in a manual assembly operation.
03
High WIP consumes valuable floor space, working capital, and operator attention while masking underlying flow issues.
We optimize production flow, remove constraints, and improve process synchronization to reduce unnecessary inventory buildup.
Result: Improved flow visibility and faster movement of materials across operations.
04
Poor facility layouts and inefficient material flow increase travel distances, handling effort, and production delays.
We redesign material flow and optimize shop-floor layouts to reduce non-value-added movement.
Result: 40% reduction in material movement waste achieved in FMCG manufacturing.
05
Without standardized work, the same task is performed differently across operators and shifts, creating variation in output.
We establish standardized work methods, cycle time controls, and operating standards to improve consistency.
Result: Improved process stability and predictable production performance.
06
Unplanned breakdowns, microstoppages, slow changeovers, and maintenance delays reduce available production time.
We implement TPM, OEE tracking, downtime analysis, and changeover improvement initiatives to recover lost capacity.
Result: 123% OEE improvement achieved across manufacturing operations.
Food Processing Industry
Packaging Manufacturing
Engineering Manufacturing
Consumer Goods Manufacturing
01
A 2-4 day on-site study. We walk your floor, observe your processes, and find where time, output, and cost are quietly being lost.
02
Scope defined from your data, not a template. Commercials built on a clear ROI case, so the decision to proceed is grounded in numbers.
03
Every process mapped in detail. A signed performance baseline established — the reference point against which every improvement is measured.
04
Solutions validated on the floor before full rollout. Implementation happens alongside your team. Training happens at the Gemba, in real conditions, under real pressure.
05
Review systems and audit structures built into your team before we step back. We do not exit on a deadline. We exit when the results hold.
We have supported manufacturers across:
Industrial Businesses Across 3 Continents
Every day your factory operates below its true potential, valuable production capacity and profitability are left behind. Improve OEE, eliminate bottlenecks, and increase manufacturing productivity with expert consulting.