Improve Productivity. Reduce Costs.
Manufacturing Consulting
We help manufacturers uncover these opportunities and turn them into measurable business results through practical, on-the-shop-floor execution.
500+
Clients Served
1M+
Consulting Hours
40+
Industries
12+
Years Experience
What We Solve
Your Factory's Hidden Opportunities
Most manufacturers lose 20-40% of their capacity through operational losses that have quietly become part of everyday work.
Most factories lose 20-40% of their capacity through operational inefficiencies that have become part of everyday work.
How Gemba Helps
We identify where time, output, and cost are being lost. We map your current state and establish a baseline to measure improvements. Result: Factories unlock 30-50% hidden capacity.
Avoidable costs hide in poor material flow, inventory buildup, energy waste, and unnecessary rework—silently impacting profitability.
How Gemba Helps
We reduce non-value-added activities, optimize inventory, and eliminate waste. Result: 15-25% reduction in operational costs.
Defects, inconsistent quality, and rework reduce output and customer satisfaction while increasing costs.
How Gemba Helps
We implement quality systems, standardized work, and process controls. Result: 30-50% reduction in defects.
Poor inventory management ties up working capital, consumes floor space, and creates material flow bottlenecks.
How Gemba Helps
We optimize inventory levels, improve storage efficiency, and streamline material flow. Result: 40-60% reduction in inventory carrying costs.
Unexpected breakdowns, maintenance delays, and slow changeovers reduce available production time and predictability.
How Gemba Helps
We implement TPM, OEE tracking, and downtime reduction systems. Result: 50% reduction in unplanned downtime.
Scaling production or adding new lines is risky without proven systems, standard processes, and trained operators.
How Gemba Helps
We build replicable operating models with documented processes, governance, and scalable systems. Result: Smooth scaling with consistent performance.
Proven Results
These are implemented outcomes from manufacturing plants, not projection models.
37%
Output Increase
53.7%
Final OEE
6 Mo
Timeline
OEE improved from 38.4% to 53.7% within 6 months.
53.9%
Throughput Gain
₹25 Cr
Revenue Impact
18.1%
Productivity Lift
Rolling mill output improved with strong revenue impact.
123%
OEE Improvement
47%
Changeover Reduction
36.6%
Wastage Reduction
Changeover and wastage reductions backed by live OEE visibility.
60%
Cost Reduction
43%
Storage Efficiency
69%
Turnaround Time
Inventory accuracy and storage efficiency improved significantly.
Our Method
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.
Scope defined from your data, not a template. Commercials built on a clear ROI case, so the decision to proceed is grounded in numbers.
Every process mapped in detail. A signed performance baseline established - the reference point against which every improvement is measured.
Solutions validated on the floor before full rollout. Implementation happens alongside your team. Training happens at the Gemba, in real conditions, under real pressure.
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.
Why Gemba
We work on the shop floor, where real improvements happen.
We turn recommendations into measurable results.
Trusted by 500+ manufacturing and supply chain businesses.
Proven expertise across 40+ industries.
From diagnosis to execution, we support you at every stage.
We build systems that deliver results long after the project ends.
Industries We Serve
We have supported manufacturers across:
“Our lines were running but output kept falling short. Gemba came in, worked directly on the floor, and fixed what we had stopped questioning. OEE improved, wastage dropped, and the results have held.”
Mr. Jainam Deliwala
Director
Rolliflex Cables Private Limited
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Trusted by
Industrial Businesses Across 3 Continents
Let's Talk
Let's identify where productivity, cost, and efficiency opportunities are hiding in your operations.
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