Engagements — Digital Kaizen

Track 01

Diagnostic.

2 weeks · Fixed fee

A two-week on-site assessment. Manual OEE baseline, loss ranking, value-creation bridge, capability audit. Ends with a signed 100-day plan.

Manual OEE on critical assets
Top-20 losses ranked by EBITDA
Reference-architecture review
Capability & governance audit
Signed 100-day plan

From R 480,000

Track 02 · Most common

100-day foundations.

100 days · Sensei-led

The full foundational programme. Daily management live, first Kaizen events complete, instrumentation plan signed off. You run the rest.

Diagnostic (Track 01) included
Tiered daily management live
3 Kaizen events on top losses
Reference architecture deployed
Year-one Kaizen calendar locked

From R 2.4m

Track 03

Full programme.

18 – 36 months · Retained

End-to-end deployment through all seven interventions. Monthly steering. Embedded senseis. Handover milestones at month 18 and 36.

All seven interventions deployed
Embedded senseis on site
Monthly executive steering
Capability transfer milestones
Scheduled sensei disengagement

Retained · scoped per site

The 100-day plan

Same plan. Every engagement.

A single template applied to every client. Variance lies in the findings, not the process.

Days 0 – 14

Baseline.

Manual OEE captured on every major asset. Finance and operations reconciled to one number. Top 20 losses ranked by EBITDA impact.

Days 15 – 45

Stabilise.

Tiered daily management live from line to executive. Three Kaizen events completed on highest-ranked losses. Standard work documented for the top-three products.

Days 46 – 75

Instrument.

Sensor rollout complete on critical assets. Reference architecture live. First real-time dashboards retired their manual equivalents.

Days 76 – 100

Commit.

Value-creation plan signed by management and board. Three-year EBITDA bridge agreed. Capability transfer plan published. Year-one Kaizen calendar locked.

Outputs by day 100

A board-ready operating plan.

→ Signed 3-year EBITDA bridge
→ Instrumented baseline on critical assets
→ Tiered daily management running
→ Year-one Kaizen event calendar
→ Reference-architecture deployment plan
→ Capability-transfer plan & sensei engagement
→ Incentive & tax-credit application pipeline

Reviewed quarterly. Bridged annually.

Outcomes

A typical EBITDA bridge.

Across 40+ prior engagements, value resolves into six components. Shape is consistent; mix varies.

Illustrative · indexed, start = 100 18 – 36 month horizon

100

+42

+24

+12

+18

+14

210

Start Operations Supply chain Energy Commercial Incentives End

Fit check

Who we take on.

We are selective. An engagement only works when management is committed and the business has the scale to compound.

Mid-market manufacturers, R 200m – R 1.5bn revenue.

Our methodology assumes a physical-product operation with at least one plant, a management team of meaningful depth, and enough cash flow to fund the programme. Below this scale, the fixed cost of the programme overwhelms the return; above it, engagements are structured differently.

A committed executive sponsor.

The CEO or COO must personally sponsor the programme. Not delegate it. Not "support" it. Own it. Engagements where the sponsor is unclear do not survive the 100-day plan, regardless of the consulting hours applied.

Willingness to start with manual measurement.

Every engagement begins with manual OEE measurement. If the first instinct is to install software, we are not the right fit. Digital comes after stability, not before it.

A multi-year horizon.

Kaizen compounds. Twelve months is short. The full programme plays out over 18–36 months, sometimes longer. Clients looking for a quarter-end story should look elsewhere.

Willing to leave capability behind.

Every engagement includes an explicit capability-transfer plan with sensei disengagement milestones. Clients who want permanent consulting dependency are a poor fit for our method and our pricing.

Three ways to engage.