Our Services
Helping You See Waste That Matters—And Do Something About It
At 2Gemba, we believe real improvement starts with Respect for People. That means empowering both leaders and frontline teams to see clearly, think critically, and own their improvement journey—because sustainable change only happens when the people doing the work are part of the solution.
We guide teams to apply Lean where it matters most—in strategy, new product and process development, manufacturing, and equipment reliability—always with an eye on Excellence in Process. We help teams recognize waste, reduce variation and overburden, and use the right tools at the right time to improve Safety, Quality, Delivery and Cost.
And we bring Innovation in Product and Service by showing how Lean thinking isn’t just for the factory floor—it can reshape how you design, develop, and deliver value across the entire organization, from Finance, to HR and even in Quality and Regulatory!
We’ll work shoulder-to-shoulder with your teams at the gemba, leading with clarity of purpose and empathy, and helping you build a culture that keeps getting better—without the jargon, and without the drama.
Lean Foundations
Introduction to Lean Thinking
Recognizing The Waste
Introduces the fundamentals of Lean Thinking, including variation, overburden, and waste, and helps teams differentiate between value-added and non-value-added activities.
Participants will learn to recognize and eliminate waste, with the option to apply their learning immediately in a hands-on Kaizen event for real-world impact
Foundational Lean
Build the Lean Muscle
Lasting Lean success starts with strong fundamentals. This training and Kaizen series introduces teams to core Lean behaviors that support daily problem-solving and continuous improvement.
We cover practical, real-world use of Value Stream Mapping, Transactional Process Mapping, 5S, Standard Work, Daily Management, and Root-Cause Analysis—not just as tools, but as habits teams can sustain.
Lean Management Systems
Make Leadership Visible. Make Problems Impossible to Ignore
This framework helps leaders show up where it counts—at the gemba. Through Tiered Daily Management, Leader Standard Work, Gemba Walks, and Layered Process Audits, we build daily routines that connect leaders to the frontline and focus attention on the processes that matter most.
At the heart of it all: powerful visual controls that make it obvious what’s working, what’s not, and what needs immediate course correction. Because real accountability isn’t about pressure—it’s about clarity
Creating Level Flow and Pull
Lean Cellular Flow
Create Flow That Works - One Step At a Time
We help teams design flow that’s visible, repeatable, and reliable. Through a series of layered Kaizen events, we guide the creation of Lean cells that move materials, WIP, and information smoothly between value-adding steps.
This includes 5S, standardized work, built-in quality, point-of-use materials, pull systems, and hourly performance scorecards—all focused on making problems easy to spot and fix in real time.
Pull with Kanban
Right Part. Right Place. Right Time
We help teams move from push to pull by designing material flow systems that respond to actual demand. Whether it’s Kanban or other custom pull signals, we create simple, visual systems that reduce inventory, improve flow, and make sure the right parts are always where they need to be—without overproduction or firefighting
Schedule Level Load
Smooth the work. Steady The Flow. Lower The Stress
Uneven schedules create chaos. We help teams apply Heijunka to level-load production, reduce variation, and eliminate the peaks and valleys that lead to firefighting and burnout. The result? Predictable, manageable workloads that support flow, reduce waste, and make life easier—for everyone
Advanced Lean Manufacturing
Take Lean Further - Where It Really Counts
When your teams are ready to go beyond the basics, this suite of advanced Lean methods helps you tackle the next layer of complexity with purpose. From faster changeovers to smarter quality control, we build the skills and systems that support high-mix, high-efficiency manufacturing environments
SMED or Quick Changeovers
Change Over Faster. Gain Back Time
We coach teams to approach changeovers with the precision and coordination of a Formula 1 pit crew—fast, focused, and mistake-free. Through structured SMED Kaizens, we reduce setup time, boost flexibility, and increase capacity without adding equipment. And it’s not just for machines—the SMED mindset applies anywhere waiting slows things down, from line changeovers to lab testing to admin workflows. We can cut times down by 50% or more each event.
3P Kaizens - product, Process, Preparation
7 x 7 Ways to Design Better From The Start
In these rapid, hands-on events, teams iterate through low-cost prototyping, brainstorming, and scenario planning to create new manufacturing layouts, workflows, or products that are easier to build, scale, and improve
Lean Quality Inspection and Control Plans
Quality Built In, Not Bolted On
We help teams redesign inspection and manufacturing control plans to reduce over-inspection, eliminate redundant checks, and focus on real control points that drive defect-free outcomes
FMEA's - Failure Mode Effects & Analysis
Think Through The Risks, Before They Happen
We coach teams through practical FMEA sessions to identify potential process or product failure modes, assess risks, and put meaningful prevention and detection controls in place—without the bureaucratic bloat.
Equipment Reliability with Total Productive Maintenance
Keep Your Machines Running—and Your Teams in Control
Equipment shouldn’t be the reason you miss delivery, quality, or cost goals. Starting with an assessment and executed via a TPM Action Plan and Kaizen funnel, this set of services helps teams build a reliable, data-driven maintenance culture that improves uptime, reduces firefighting, and puts ownership where it belongs—on the floor
OEE Tracking and Loss Visualization
You Cant Fix What You Can't See
We install practical systems for tracking OEE, along with daily loss analysis to make downtime visible and actionable.
Teams also get introduced to key reliability metrics like TEEP, MTBF, and MTBR—without the overwhelm.
Focused improvement for OEE losses
Get To The Root. Fix What Matters
Using structured problem-solving techniques, teams learn to tackle breakdowns, short stops, speed losses, and defects with precision. This is the brains of TPM—where teams shift from reacting to systematically improving
Preventive Maintenance Optimization
Do The Right Maintenance, Not More Of It
We strengthen PM systems by refining scope, frequency, and standardization of tasks. We also improve spare part management, maintenance workflows, and response times—so your PM program actually prevents problems.
Operator-led Maintenance
Teach Operators To See The Early Signs
Operators are trained to take ownership of basic equipment care through CILTR routines—Clean, Inspect, Lubricate, Tighten, Replace—keeping small issues from becoming big problems, and engaging them as true partners in reliability
TPM KPI's for Leadership
What Get's Reviewed, Gets Prioritized
We help integrate maintenance and reliability KPIs—like OEE, MTBF, and downtime trends—into your Management Operating Systems and Review Cadence. This ensures leadership isn’t just aware, but actively engaged, supporting action plans and resourcing teams where the impact is greatest. Because reliability isn’t just a maintenance issue—it’s a leadership priority
Early Equipment Design
Design It Right. Maintain It Less
We partner early in the equipment design process to apply Design for Maintenance and Lean Conversion principles, ensuring machines are easier to maintain, operate, and improve—right from day one. By addressing potential failure points before they show up on the floor, we help you avoid costly breakdowns and design smarter systems that support long-term reliability and flow
Lean Product Development
Design Smarter. Launch Faster. Waste Less
Great products shouldn’t come at the cost of bloated timelines, firefighting, or endless rework. This set of services helps organizations apply Lean thinking upstream—where product ideas become real work. We guide engineering, design, and cross-functional teams to eliminate waste, reduce lead time, and build products that flow smoothly into production
Introduction to Lean Product Development (LPD)
Bringing Flow to Product Development
We introduce your teams to the principles of Lean Product Development—flow of knowledge, Set-Based Thinking, and front-loading decisions—so innovation becomes more structured and less reactive.
Value Stream Mapping for LPD
See The Gaps In Your Design Process
We guide teams in mapping the full product development value stream, uncovering bottlenecks, long queues, unclear handoffs, and missed learning opportunities—so you can improve where it counts most
Accelerating Time to Market
Get There Faster - Without Cutting Corners
We help teams reduce cycle time through smarter workflows, clearer decision-making, and visual controls that prevent costly delays. The focus: speed with quality, not speed at any cost.
Visual Product Development Management
Stop Managing Projects in Silos
We install simple, visual systems to track work, surface risks, and support decision-making in product development. This brings transparency, focus, and flow to even the most complex product portfolios.
Product Development War-Rooms (Obeya)
One room. One Mission. Total Alignment
We help teams set up and run effective Obeya Rooms—visual project spaces that connect strategy to execution, keep everyone aligned, and make progress and problems visible in real time