Why is it important?

Operational excellence in the automotive industry is constantly changing due to new technologies, digitalization and environmental considerations. These changes are intensifying and require ever stronger focus and effort to build and sustain waves of Transformation

Our experience

Lean Coaching has over 20 years experience in implementing Lean /Operational Excellence in major automotive companies globally. From strategic development, capability development, efficiency /quality improvement and manufacturing excellence in the main plants (Assembly, Power Train) and Supplier Interventions /Supplier Development

our results

Nothing makes us happier than when our clients see the results they’ve been wanting. We base our results on your KPIs. 

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Main workstreams

Based on a Diagnostic of the business challenges and Current State of operations, we develop a tailored Future State with detailed Implementation Plan, measurable objectives (KPIs), typically including some or all of the below Workstreams

Strategy and Production system design

Developing a vision, strategy and measurable plan (Hoshin Kanri) that can be deployed across the organization. Designing and tailoring industry/ company specific Production or Operating Systems, covering all direct and indirect functions.

Supplier management and development

Complete span of support of suppliers, from selection, through to strategic development to 'partnerships'. Also Supplier Interventions, if impacting (QCD) production or Cost Reduction, optimizing process and costings, leveraging continuous improvement and other lean tools.

Lean Organization

Building an effective organisational span of control, roles and responsibilities and processes, as a foundation for a culture of continuous improvement and problem solving that is maintained at all levels.

Performance/Shopfloor Management

Visual management and cascade of key performance indicators (KPIs) and SMART Targets. Shopfloor Management; effectively prioritizing issues, early intervention (containment), effective problem solving of recuring issues and process confirmation to prevent reaccurance.

Focused Improvement projects

Applying methods and tools in a step change improvement in performance in given area or process, to show impact and/or have initial quick-wins.

Lean Digitalization

Digital diagnostics of IT/OT, identify digital waste and potential digital value added Create Future and Ideal States with digital VSM, Systems architecture maps, Entity Relationship Diagrams to mesh/mock up simulations to tailored plan.

Leadership Development

Coaching and capability development based Standard work for leaders including process confirmation, go look see, planning and escalation, coaching and problem solving, creating high performing teams.

Change Agent Development

Set up training and development of a critical mass of Internal specialists, experts and coaches to replace external support and drive and sustain implementation of company Operating/lean System.

New Product Introduction (NPI)

Development of processes and capabilities to launch products or services on quality, cost and delivery targets and building in lessons learnt, built into next iteration (Keshikomi).

Case Studies

Check out case studies from our automotive clients!


Daimler Trucks Cleveland plant's KPI were all in critical condition. Lean Coaching was invited to help

Nelson Global Products

As the demand for tubed product increased TSCO found their ability to meet customer delivery expectations was challenging


Lean Coaching was engaged in order to provide a program that addressed biggest MAHLE’s issues and challenges