Every Manufacturing Facility carries some level of Waste, Variation, and Inconsistency — whether it shows up as Uneven Quality, Longer Cycle Times, Rework, or Improvement Initiatives That Don’t Stick. At SmartRun Technologies, our Lean Assessment gives you a factual, current-state read on your Lean and Six Sigma Maturity across the manufacturing process, so any investment in Continuous Improvement is targeted at what will actually move the needle.
A solution is only as good as the problem it’s solving. These are the signals that tell us where to look.
Inconsistent Quality
Defect rates and rework vary from shift to shift with no clear root cause on record.
Hidden Waste
Non-value-added steps, excess motion, and waiting time are baked into “how it’s always been done.”
Unpredictable Cycle Times
Output varies run to run, making schedules and delivery commitments hard to trust.
Reactive Problem-Solving
Issues get fixed after the fact instead of being caught by standard work or control limits.
Low Process Visibility
Leaders rely on end-of-shift reports instead of real-time signals from the floor.
Improvement Fatigue
Past Lean or Six Sigma initiatives started strong but faded without a clear baseline to build on.
A structured engagement that turns floor-level observation into a clear, prioritized roadmap for improvement.
Current State Discovery
On-site walkthrough of the process, stakeholder interviews, and review of existing quality and production data.
Value Stream & Data Analysis
Mapping material and information flow end-to-end, analyzing data for variation, downtime, and defect patterns.
Maturity Scoring
Each domain is scored against a defined Lean and Six Sigma maturity model to establish a factual baseline.
Roadmap & Readout
Findings and a prioritized, sequenced improvement roadmap are presented to your team, ranked by impact and effort.
From the shop floor to strategic decision-making, we cover every domain of Lean and Six Sigma maturity.
Standard Work & 5s
Consistency of work instructions, workplace organization, and visual discipline at each station.
Quality & Defect Control
Defect rates, root-cause practices, and the statistical rigor behind quality decisions.
Changeover & Downtime
Setup times, unplanned downtime, and how disciplined the process is at recovering from stoppages.
Inventory & WIP
Work-in-process levels, buffer sizing, and whether inventory is masking upstream problems.
Data & Visual Management
Whether the floor has real-time visibility into performance or relies on end-of-shift reporting.
Root Cause Discipline
How systematically problems are investigated, resolved, and prevented from recurring.
Most engagements run 2–4 weeks, from on-site discovery through the final roadmap readout, depending on the size and number of production lines assessed.
The assessment covers your full manufacturing process — from value stream flow and standard work to quality control, changeovers, inventory, and how well data is used to manage the floor. Each area is scored against a defined Lean and Six Sigma maturity model.
Yes. Every domain we assess is scored against a structured Lean and Six Sigma maturity model, so results are objective and comparable — both across your own facilities and over time as you improve.
You receive a maturity scorecard, a gap analysis showing where the process falls short, and a prioritized improvement roadmap ranked by impact and effort — so your team knows exactly what to act on first.
Book a free 30 – minute consultation with our Smart Manufacturing experts. No pitch. Just practical solutions.
We are committed to providing personalized industrial solutions.
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