01 · GEMBA
A day in the life
Observing the process with the operator, conversation, data and identifying real losses.
→
Operational excellence · manufacturing
Less waste. More throughput. Stable production.
Andrzej Smoleński — production and operations transformation manager. I combine shop-floor experience, Lean Six Sigma, TPM and digitalization so change ends in a business result, not a slide deck.
For boards, business owners, recruiters and manufacturing organizations.
20+ years of operations experience
PLN 1.5Mannual Kaizen program impact
6.5 h → 45 minaverage changeover time
150injection molding machines covered
30 millionunits/month with no scrap
80% OEEafter new plant start-up
6 FTEof organizational capacity freed up
Profile
Transformation starts at the process
First a gemba diagnosis, conversations with people and data. Then priorities, standards, accountability and automation. Technology strengthens a good process — it doesn't replace it.
Production and operations transformation manager with more than 20 years of experience in management, team development and process efficiency improvement.
I combine practical operational experience with Lean Manufacturing, Six Sigma, TPM and process digitalization. I focus on productivity growth, quality improvement, cost reduction and production stability.
Method
From observation to a lasting result
No implementation theater. Every stage has a clear goal, owner, metric and link to the organization's result.
02 · PRIORITY
Pareto of problems
Choosing the barriers with the strongest impact on throughput, quality and the team's work.
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03 · SYSTEM
PDCA and standard
Solving the problem, standardization, competence development and daily process control.
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04 · SCALE
Data and automation
Once habits are stable: digitalizing measurement, automating reporting and scaling.
✓
Areas of activity
Support for organizations that need results
Scope tailored to the business problem — from diagnosis and an improvement project to taking ownership of the transformation.
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Operations transformation
Strategy, management system, KPIs, accountability and implementing cross-functional change.
Scope of work →⚙
Production and flow
OEE, line balancing, layout, quality, on-time delivery, throughput and plan stability.
Scope of work →Σ
Lean Six Sigma, TPM and SMED
Tools used as a means to reduce losses and build organizational capability.
Scope of work →01
Process digitalization
Reporting automation, production data, ERP/MES and fact-based decisions.
Scope of work →Proof of work
Anonymous case studies
I don't publish organization names without their consent. I show the problem, the approach and the result — specifically enough to assess the scale of the experience.
medical device manufacturing
6.5 h → 45 min
Changeovers on 150 injection molding machines
A program based on SMED, work standards and team competence development.
150 machinesSMEDcapacity without CAPEX
Read the case study →serial manufacturing
PLN 1.2M
Annual operational savings
Production reorganization, better resource utilization and loss-reduction projects.
productivityqualitycost
Read the case study →technical materials
−30%
Unplanned downtime
A TPM program combined with quality improvement and reduced tool failure rates.
TPM+15% qualityapprox. PLN 800K
Read the case study →Knowledge Hub
Practice instead of a tool catalog
Content for managers, leaders and teams who want to solve problems, not just implement trendy labels.
OEE Without a Million-Dollar Budget
Excel, a standard cycle time and correlating settings with quality get you there — but OEE never replaces gemba.
Read the article →An Operator Leaving vs. a Manager Leaving
We call a manager's growth ambition, a good operator's departure sometimes a lack of loyalty. The same need, two different labels.
Read →The Define Phase
"Let's get OEE to 85%" is an expectation, not a problem. A well-run Define phase turns it into a defined problem, scope and goal.
Read →Next step
Do you have a process that isn't delivering results?
30 minutes is enough to determine whether the problem needs a quick diagnosis, an improvement project or a broader transformation.