TPM and OEE improvement
On high-volume lines we break OEE down into availability, performance and quality losses, and build autonomous and planned maintenance steps with the line teams.
International
Lean Six Sigma and Operational Excellence Consulting in Poland
We provide Lean Six Sigma, lean manufacturing and operational excellence consulting for plants in Poland. In Poland we worked on an international Lean programme for Japan Tobacco International (JTI). Consulting and belt training are delivered in English, on site, with online coaching between visits.
- JTI
- international Lean programme
- 1,000+
- improvement projects
- EN / TR
- working languages
Manufacturing in Poland and where improvement matters
Poland is one of the largest manufacturing bases in Central Europe. Automotive and automotive parts, household appliances, furniture, food and beverages, tobacco and electronics assembly are among its main industries. Because of its proximity to Western Europe, many multinational groups run their Polish plants as nearshore production sites supplying Germany and neighbouring markets.
Many of these plants run high-volume, highly automated lines. Competitiveness depends less on labour cost and more on line efficiency; as wages rise and experienced staff become harder to find, OEE losses, changeover times and scrap become more visible. Multi-site groups face a further question: how to run the Polish plant with the same method and the same KPIs as the other sites in the group.
Most relevant work for plants in Poland
Changeover reduction with SMED
On lines running many product variants we analyse changeovers with video and observation, separate internal from external work and cut changeover time.
A common operational excellence system for multi-site groups
We set up daily management, Hoshin Kanri and a KPI structure in the Polish plant that matches the rest of the group, so sites can be compared on the same basis.
Green Belt training in English
We deliver Green Belt training in English at your plant for engineers and shift managers. Each participant runs a DMAIC project from their own line during the programme.
What we have done in Poland and how we work there
In Poland we worked on an international Lean programme for Japan Tobacco International (JTI); a JTI Lean programme was also delivered in Jordan. Our working language in Poland is English. Diagnosis, Kaizen events and belt training take place on site; project follow-up and coaching run online between visits.
How an international programme runs.
- 1
Introductory call
We discuss the plant, the targets and the team structure in an online call. The working language (English or Turkish) and the scope of the first site visit are agreed at this stage.
- 2
Diagnosis on site
On the first visit we walk the lines, review the data and identify the largest losses together with the management team. Programme priorities are based on what we see on the shop floor.
- 3
Programme plan
We put into writing which projects run with which teams and in what order, so that headquarters and plant management work from the same plan.
- 4
Site visits and remote coaching
Projects move forward through regular site visits. Between visits we hold online coaching sessions with project leaders and review analyses and milestones together.
- 5
Training and sustainability
Belt training is delivered face to face, ideally at the plant itself. The goal is to build internal experts who keep the programme running without a consultant.
Frequently asked questions
Common questions.
Have you delivered Lean projects in Poland?
Yes, in Poland we worked on an international Lean programme for Japan Tobacco International (JTI). A JTI Lean programme was also delivered in Jordan.
Do you offer Lean Six Sigma training in Poland?
Yes, we deliver White/Yellow, Green and Black Belt training in English, in-house at your plant in Poland. Training is face to face and participants work on a real project during the programme. We do not train in Polish.
Can you help a multinational align its Polish plant with group standards?
Yes, aligning a site with group standards is a core part of our operational excellence work. We set up daily management meetings, KPIs and a project selection method that match the rest of the group, working with local teams in English.
How often are you on site in Poland?
Visit frequency is agreed with you according to the scope of the programme; there is no fixed schedule. Diagnosis, Kaizen events and training are on site, while project follow-up and coaching between visits are online.
Led by
Abbas Erdenal
Lean Six Sigma Master Black Belt · Founder of Fega Partner
More than 25 years on the shop floor, over 1,000 improvement projects and programmes delivered in seven countries. Abbas Erdenal personally leads every consulting engagement and training.
About Abbas Erdenal