Example Lean & TPM Case Studies
Case Study 1: Implementing 5S and TPM in a Manufacturing Plant
A medium-sized manufacturer was struggling with unplanned equipment breakdowns and disorganised workspaces. I delivered on-site 5S training, created visual standards with the team, and ran a TPM pilot programme with operators and maintenance staff. Result: a 30% reduction in downtime and a safer, more efficient work environment.
Case Study 2: Value Stream Mapping for a Logistics Operation
A regional logistics company wanted to improve delivery times and reduce waste. I facilitated a Value Stream Mapping workshop with key stakeholders, identified bottlenecks, and developed a future-state map with clear actions. The company reduced process lead time by 25% within six months.
Case Study 3: Lean Leadership Development for a Large Retailer
I worked with a major retail business wanting to embed continuous improvement principles across its daily operations. This involved training over 200 managers nationwide and extending the Lean Management Programme to key suppliers. As part of this, I was asked to design and deliver a Lean training programme based on the Lean Practitioner curriculum from the Lean Enterprise Research Centre. This resulted in a series of “learn by doing” projects that delivered significant cost savings, improved customer satisfaction, and boosted employee engagement.
Case Study 4: TPM Implementation and Lean Training for a Multinational Paper Products Manufacturer
I supported a large multinational paper products manufacturer with a Total Productive Maintenance (TPM) project to successfully bed in and commission a multi-million dollar plant upgrade. Alongside this, I delivered Lean training programmes to enhance team capability and embed continuous improvement practices. The project resulted in improved equipment reliability, smoother plant startup, and a stronger culture of proactive maintenance.
Case Study 5: Operational Excellence Implementation for a Multinational Food Manufacturer
Over an 18-month engagement, I supported a multinational food manufacturer rolling out its Operational Excellence program across sites in Australia, Malaysia, and Thailand. My role focused on transferring Lean and continuous improvement capabilities to internal teams through tailored training, hands-on coaching, and ongoing mentoring. This approach empowered local teams to sustain improvements independently and embed a culture of continuous operational excellence across the region.
Testimonials
Japan Lean Experience Tour 2018
HEALTH ALLIANCE FPSC NZ
Over the last 7 years I have had the pleasure of getting coached by Richard; for both business and personal development. This has enabled me to flourish and grow in many different ways and supported me to deliver upon my potential in the commercial world and at home. He has helped me to identity opportunities, to dare to push my boundaries further and then work towards these identified goals in a positive way. He has also helped me to realize the potential in others and support them on their journey. I could not recommend Richard enough; he is a wonderful coach who has helped me in many different ways.
Jon McEvoy
UNISON NETWORKS LIMITED
I have been working with Richard since Sept 2016. The relationship has flourished because of the trust and professionalism built up through Richards coaching skills. This has enabled me to reflect, question and develop new thought processes. Not only has my potential at work developed and improved. Richard has also helped me by coaching me on subjects outside of the immediate work arena. I now feel that I am able to flourish and objectively help others using the coaching skills that Richard has given me. I would highly recommend Richard, he has so much experience of working with different people and organisations he can always find a way of drawing on some experiences to help you think about your issues in different ways.
Andy Knipe
Operations Excellence, Lean Training and Consulting 