Do you find it difficult to trust your data?

We get it, as a maintenance engineer, collecting and processing accurate data to help make informed decisions isn’t easy. Especially when you’re already struggling to reduce downtime, retain staff knowledge due to high turnover and dealing with unreliable equipment. That’s why we created Gemba Lean.

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Gain real time insights
with Gemba Lean

Imagine a world where you can take your data issues and turn them into reliable insights for production line improvement. Gemba Lean is a scalable solution that does just that, collating and interpreting the most recent production efficiency data, so you don’t have to.

Gemba Lean provides visibility into production processes, supplies consistent insights for data- driven decisions to be made, fosters team collaboration, and maximises your equipment’s potential to boost productivity, saving you time and money.

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Where Gemba Lean can help maintenance engineers

  • OEE Dashboard – Overview of overall effectiveness
  • OEE Reporting – Includes Top 5 Losses and DIN 8743 indicators
  • Log book – Keep a record of key dates, actions and changes
  • Action tracker – Record issues and tasks to assign them to your team
  • Knowledge base – Log common issues and solutions to share with the rest of the team
  • Dynamic reporting – Configure your own data reports

Maximising client line productivity by up to 70%

“70% reduction in changeover time.”

Gemba workshop – CNC Machine Shop (Red Bull)

See our Gemba Lean manufacturing software as your strategic partner, there to drive continuous improvement

Insight. Gathering reliable data is no longer a chore. Gemba Lean helps to automatically provide consistent and reliable data, empowering decision makers to make insight-driven choices and improvements.

Improve. With the right resources and data to hand, Gemba Lean makes it easy for you to identify where improvements can be made, enhance productivity, optimise performance and streamline processes.

Repeat. Time to do it all again. Staying on top of your most recent updates, making improvements, and taking a step back to see how it’s going, encourages you to keep looking at what’s working and what’s not. Creating an ongoing journey towards continuous improvement.

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Prefer to speak to someone directly? Call +44 (0) 1827 338512

Why Gemba Lean?

Without Lean

  • Unreliable production, data insights and documentation
  • Unable to take immediate production line action
  • Productivity is minimised
  • Manually collating and interpreting data
  • Lack of training resources / knowledgeable staff

With Lean

  • Data-driven decision making
  • Maximise output
  • Identify bottlenecks and inefficiencies
  • Automated data collection
  • Suite of training guides for staff

Your maintenance engineer questions answered

  • Q: How does Gemba Lean help me trust my data?

    A: Dynamic reporting tools enable users to dive deep into production data to identify losses, inefficiencies, or areas where improvements can be made. This can involve examining various data points, timeframes, or specific metrics to understand the root causes of losses.

    From personal reports, to global reports, you will have access to a range of insights with customisable filters, to help you get the most out of your analysis and make data-driven decisions confidently.

  • Q: How does Gemba Lean help manage knowledge retention due to high staff turnover?

    A: Within Gemba Lean there is a self-service library that may include information about processes, procedures and ‘how to’ guides to get the most out of the software and your manufacturing machines.

    This library will help new starters, and even seasoned staff, find solutions to problems, therefore improving their knowledge and solving issues quicker.

    The log book can also be used as a means of communication among different departments and shifts within a manufacturing facility. Your workers can review the log book to understand what happened during previous shifts and what tasks need to be completed, such as fixes or maintenance.

  • Q: How does Gemba Lean help me make informed data-driven decisions?

    A: The OEE Dashboard offers a clear and comprehensive view of production processes. It provides data on equipment performance, production rates, and quality metrics. This visibility allows maintenance engineers and operators to monitor operations effectively, and make decisions from there.

    The Gemba Lean dashboard presents key performance indicators (KPIs) related to OEE, including availability, performance, and quality metrics. These KPIs empower you, as the decision-maker, to make data-driven choices to improve production efficiency and quality.

  • Q: How does Gemba Lean ensure product quality is always high?

    A: The Gemba Lean Dashboard highlights bottlenecks and inefficiencies in the production line. This could include machines that are underperforming. Identifying these issues promptly is essential for minimising downtime and maximising output.

  • Q: How does Gemba Lean minimise downtime and unplanned stoppages?

    A: Armed with data, you as the production manager will have visibility of the recurring issues that are impacting performance and be able to prioritise maintenance activities focused on minimising downtime and improving productivity.

  • Q: How does Gemba Lean combat miscommunication across departments?

    A: Firstly, Gemba Lean conveniently accommodates multiple teams, with access to the same consistent data to reduce miscommunication and confusion.

    Alongside this, the Action Tracker is designed to monitor and track individual actions, tasks, or activities. It helps to ensure that each task associated with a product or production line issue is accounted for and managed effectively, eliminating the need for paperwork.