Maturity and current-state assessment
We review management systems, shop-floor discipline and performance data together. You end up with a scored maturity map that shows exactly where you stand.
Solutions · 01
Operational Excellence Consulting
Operational excellence links strategy to daily work on the shop floor, measures losses in money and turns improvement from a series of one-off projects into a management system. We build that system around your organisation and work alongside your teams until the first results are in.
- 196
- cost-loss analyses
- 946
- days of field work
- 6+ yrs
- average client relationship
What is operational excellence?
In many companies improvement comes in waves: one year it is Kaizen, the next it is 5S, then priorities shift and the gains quietly fade. Operational excellence exists to break that cycle. Instead of running Lean, Six Sigma, TPM and Hoshin Kanri as separate initiatives, it brings them under one management system tied to the same goals.
Our starting point is always data. We first put a money value on the losses in the plant, then choose together which project will close which loss. The improvement budget goes to the problem that costs the most, not the one that makes the most noise.
Scope
What the work covers
Cost-loss analysis (Cost-Loss Deployment)
We identify losses one by one and rank them by their financial impact. Once it is clear which loss drives which cost, choosing projects stops being a debate.
Operational excellence roadmap
We turn the findings of the assessment and loss analysis into a plan that moves in waves, with priorities, resources and timing.
Policy deployment with Hoshin Kanri
We cascade company goals into department and team objectives. The X-matrix makes it visible who does what, and for which goal.
Daily management and KPI system
With start-of-shift meetings (Asakai), visual management boards and escalation rules, deviations are caught the same day rather than in the monthly report.
Standardisation and sustainability
We lock in the gains with standard work, control plans and regular system audits, and bring the system to a level your own teams can run.
How we work
How an operational excellence programme unfolds
- 1
Introductory meeting and site visit
We listen to your goals and see the plant in person. This meeting is free and carries no obligation.
- 2
Assessment
Using data, shop-floor observation and interviews, we establish the maturity level and the structure of losses.
- 3
Roadmap and leadership sign-off
We agree prioritised projects, target KPIs and owners with senior management.
- 4
Pilot area
We run the first projects on a selected line or department and test the approach under your real conditions.
- 5
Roll-out
What works in the pilot moves to other areas, and we develop internal trainers and belt holders.
- 6
A self-running system
Once the audit and review rhythm is in place, consulting support tapers off and your own teams run the system.
What changes?
- Losses are known in money terms, and the improvement budget is allocated accordingly.
- Managers at every level know how their objectives connect to company goals.
- Deviations are discussed in the same shift, not in the monthly meeting.
- Improvement continues after the consultant has left.
Who is it for?
- Manufacturers that have launched several improvement initiatives but could not make the results stick
- Companies commissioning a new plant or line that want to build the system right from the start
- Group management looking for a common excellence model across sites
- Suppliers preparing for global customer audits and supplier assessments
Frequently asked questions
Common questions.
What is operational excellence?
Operational excellence is an approach that links strategy to daily work on the shop floor, prioritises improvement by measuring losses and makes continuous improvement part of the company's management system. It brings methods such as Lean, Six Sigma, TPM and Hoshin Kanri together under one system.
How does operational excellence differ from lean manufacturing?
Lean manufacturing is a way of thinking and a set of tools built around flow and waste. Operational excellence is a wider framework that includes Lean: it combines policy deployment, performance management, problem solving and leadership behaviours in the same system.
What is cost-loss analysis?
Cost-loss analysis (Cost-Loss Deployment) identifies the losses in production, such as downtime, scrap, rework and yield losses, and calculates the financial impact of each one. The result is a prioritised list showing which improvement projects will deliver the highest return.
When do results show?
The first projects in the pilot area usually deliver measurable gains within a few months. Embedding the system across the company takes longer and depends on the size of the organisation and its starting maturity. We agree the timeline together after the assessment.
Which industries do you work with?
Our experience is mainly in manufacturing: beverages, tobacco, consumer durables, electronics. Programmes have been delivered at organisations including Coca-Cola, Japan Tobacco International, Johnson Controls and Imperial Tobacco.
Do you work with international companies' plants in Türkiye?
Yes. Programmes have been delivered at the plants of international groups such as Coca-Cola, Japan Tobacco International, Johnson Controls and Imperial Tobacco. Consulting and training can be run in Turkish or English, so local teams and headquarters abroad work from the same language.
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