Business Operations and Improvement
Kentin
Operational efficiency up 60%, downtime down 55%, errors down 40%, schedule adherence at 98% — from 5S, Kanban and a management team that now runs its own improvement cycle.
Results at a glance
Operational efficiency
60%
Reduction in errors
40%
Reduction in downtime
55%
Schedule adherence
98%
The challenge
Where they were
Waste had settled into Kentin's operations and was quietly eroding operational efficiency, in the way it usually does — not as one obvious problem, but as a dozen small ones that had become normal. Downtime. Movement that added no value. The same data entered twice. Rework. Non-conformances. An unsafe workplace in places it did not need to be.
Underneath all of it, capable people were being underutilised: staff spent a meaningful share of the day working around the process rather than in it. None of this appears as a line item, which is exactly why the efficiency loss had persisted.
What we did
- Worked closely with both management and floor staff — the improvement plan was developed with the people who would have to live inside it
- Developed and implemented an operational efficiency plan built on 5S, targeting the areas carrying the most waste
- Introduced Kanban signalling systems so that communication between stages of the process stopped depending on someone remembering to pass it on
- Delivered training to embed Lean systems, rather than leaving behind a set of practices nobody owned
- Established regular toolbox meetings to build a continuous improvement culture that keeps running after the engagement ends
The outcome
What changed
Operational efficiency improved by 60%. Errors fell by 40% and downtime by 55%. Schedule adherence now runs at 98% — which, for an engineering business, is the number customers feel. The efficiency gain was not a one-off clean-up: toolbox meetings and Lean training left Kentin with the habit of finding and removing waste itself.
Measured results
- 60% improvement in operational efficiency
- 40% reduction in errors
- 55% reduction in downtime
- 98% schedule adherence
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