Better Productivity. Lower Costs.
OEE & Throughput Improvement
Every minute of downtime reduces production potential. We target bottlenecks, changeover losses, and flow instability so output grows without immediate capex.
500+
Clients Served
1M+
Consulting Hours
40+
Sectors
5
Countries
What We Solve
Hidden Bottlenecks Are Stealing Your Throughput
Most plants lose 20-40% of their capacity through operational losses that have quietly become part of everyday work.
One bottleneck station limits the performance of the entire production line, often remaining hidden until detailed analysis is conducted.
How Gemba helps
We identify and eliminate the constraints limiting production flow through bottleneck analysis and throughput optimization.
Result: 53.9% throughput improvement achieved in cable manufacturing.
Some stations remain idle while work accumulates at others, creating uneven flow and reducing overall line productivity.
How Gemba helps
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.
High WIP consumes valuable floor space, working capital, and operator attention while masking underlying flow issues.
How Gemba helps
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.
Poor facility layouts and inefficient material flow increase travel distances, handling effort, and production delays.
How Gemba helps
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.
Without standardized work, the same task is performed differently across operators and shifts, creating variation in output.
How Gemba helps
We establish standardized work methods, cycle time controls, and operating standards to improve consistency.
Result: Improved process stability and predictable production performance.
Unplanned breakdowns, microstoppages, slow changeovers, and maintenance delays reduce available production time.
How Gemba helps
We implement TPM, OEE tracking, downtime analysis, and changeover improvement initiatives to recover lost capacity.
Result: 123% OEE improvement achieved across manufacturing operations.
Proven Results
These are implemented outcomes from manufacturing plants, not projection models.
37%
Output Increase
53.7%
Final OEE
6 Mo
Delivery Horizon
OEE improved from 38.4% to 53.7% within 6 months.
53.9%
Throughput Gain
18.1%
Productivity Lift
INR 25 Cr
Revenue Impact
Rolling mill and conductor output improved with a strong revenue impact.
123%
OEE Improvement
47%
Changeover Reduction
36.6%
Wastage Reduction
Changeover and wastage reductions were backed by live OEE visibility.
58%
Output Improvement
25%
OEE Improvement
37%
Setup Time Reduction
Maintenance and tracking systems stabilized line performance.
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.
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
Book a free consultation. We will review your current constraints and outline where the fastest throughput gains are likely to come from.
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