GembaFlow
Lean · Six Sigma · Food Manufacturing

See the Real Place.
Solve the Real Problem.

GembaFlow combines 25+ years of operational experience, advanced data analytics, and hands-on visual implementation to eliminate waste and create better flow across your food manufacturing site.

Book a Free Site Walkthrough Our 4-Stage Approach
⚠ Before: Chaos
Disconnected spreadsheets
No visibility · Recurring waste
✓ After: Clarity
98.2%
OEE
↑ 4.1%
1.3%
Waste
↓ 2.8%
99.7%
Hygiene
↑ 1.2%
Live
Dashboards
Real-time
The Challenge

Sound Familiar?

Medium-sized food manufacturers face the same recurring pressures. Tight margins, expensive labour, and small inefficiencies compound into major, measurable losses.

📊

Disconnected Data

Production, waste, and hygiene figures live in separate spreadsheets nobody trusts. Decisions are made on gut feeling rather than real-time evidence.

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Recurring Problems

The same issues appear in meeting after meeting. Root causes are never fully addressed because the systems to support lasting change don't exist.

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Unaligned Departments

Production, quality, and hygiene teams pull in different directions. Without shared visibility, cooperation is reactive rather than proactive.

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Visible Waste

Overproduction, product loss, downtime, and poor line changeovers are accepted as normal. But each represents a direct hit to your margin.

Our Difference

Three Disciplines.
One Joined-Up Service.

Very few are able to combine operational understanding, data intelligence, and real visual implementation into one cohesive service. GembaFlow brings all three together under one roof.

01
⚙️

Operations

Alex · 25+ Years Experience

Deep, practical understanding of food manufacturing reality — production efficiency, hygiene compliance, departmental cooperation, and waste management grounded in decades of shopfloor experience.

02
📈

Data Intelligence

Andy · Analytics & Systems

Converting messy, disconnected spreadsheets into clear, real-time dashboards, interactive reporting tools, and data collection systems that surface the truth in your numbers.

03
🎨

Visual Implementation

Jakub · Design & Fabrication

Translating problems into physical and digital shopfloor solutions — signs, shadow boards, control panel stencils, hygiene visuals, shift report templates, hygiene scheduling systems, CIC makers, cleaning instruction videos, and instruction presentations that make the right way the obvious way.

The People

Meet the GembaFlow Team

Three specialists. Complementary skills. One shared mission: to make your factory run better, every single day.

A
Alex
Operations Director

With over 25 years of hands-on food manufacturing management, Alex brings unmatched practical credibility. Having led production, hygiene, and multi-department operations at scale, Alex understands exactly where time, margin, and morale are being lost — and how to fix it sustainably.

Alex leads every client engagement, performing the initial gemba walk, stakeholder alignment sessions, and the structured review programme that underpins lasting improvement.

Production Management Hygiene Standards Waste Reduction Dept. Cooperation OEE Improvement Change Management
A
Andy
Data & Systems Lead

Andy has the rare ability to find meaningful trends in any data source — from raw production logs to complex multi-site ERP exports. He transforms what most businesses treat as noise into clear, actionable insight that management teams can act on daily.

Andy builds interactive dashboards, automated reporting pipelines, and simple data collection tools that fit your environment — without expensive software licences or IT consultants.

Data Analytics Dashboard Design KPI Systems Process Automation Trend Analysis Reporting Tools
J
Jakub
Creative & Fabrication Lead

Jakub combines graphic design, photography, videography, and a fully equipped fabrication studio to turn operational problems into physical and digital solutions. With direct experience in food hygiene environments, he understands the constraints of the shopfloor — and designs around them.

From branded shadow boards and safety signage to control panel stencils and visual SOPs, Jakub also creates hygiene improvement systems including shift report templates, hygiene scheduling systems, CIC (Cleaning Instruction Card) makers, cleaning instruction videos, and instruction presentations — giving teams everything they need to work to the right standard, every time.

Graphic Design Shadow Boards Sign Fabrication Photography & Video Visual SOPs Stencils & Labels Hygiene Scheduling CIC Maker Shift Reports Instruction Presentations
How We Work

Our 4-Stage Model

A structured, repeatable process that goes from your current reality to sustained improvement — with no assumptions and no generic templates.

1

Diagnose

We visit your site, walk the gemba, review your data, and identify exactly where waste and inefficiency are occurring. No assumptions — only evidence from the real place.

2

Design

We create tailored KPI dashboards, meeting formats, visual communication tools, and reporting structures designed specifically for your teams and your environment.

3

Implement

We physically deploy the systems — installing shadow boards, printing signage, launching dashboards, and training teams so everything integrates seamlessly into daily operations.

4

Sustain

Ongoing review, retained support, and performance monitoring ensures improvements stick. We track the numbers alongside you and adapt as your operation evolves.

Service Packages

Choose Your Starting Point

Every GembaFlow engagement is tailored to your site. Our packages provide a clear starting point — all pricing is bespoke. Contact us for a custom quote based on your operation's size and scope.

Foundation
Performance
Diagnostic
Ideal for sites that need clarity on where losses are occurring before committing to a full programme.
What's included
  • Full site gemba walk with Alex
  • Data review and waste pattern analysis
  • KPI gap assessment against industry benchmarks
  • Departmental alignment interview sessions
  • Written diagnostic report with prioritised recommendations
  • 1-hour presentation of findings to leadership
Request a Quote
Most Popular
Full Flow
Transformation
A complete end-to-end improvement programme covering data, operations, and physical visual management.
Everything in Diagnostic, plus
  • Custom KPI dashboard design and build (Andy)
  • Live waste and OEE tracking system
  • Tiered daily meeting structure and formats
  • Shadow boards and 5S visual tools (Jakub)
  • Hygiene visual SOPs and zone signage
  • Control panel stencils and shopfloor labels
  • Team training sessions (each discipline)
  • 30-day post-implementation review
Request a Quote
Ongoing
Retained
Partner
Ongoing access to the full GembaFlow team. For sites committed to sustained, long-term improvement culture.
Everything in Full Transformation, plus
  • Monthly site visits and performance reviews
  • Continuous dashboard refinement and updates
  • Priority access to fabrication studio (Jakub)
  • Ad-hoc data analysis and reporting requests
  • Ongoing manager coaching and support
  • Quarterly strategic review with leadership
  • New hire onboarding materials and visual SOPs
  • Annual performance benchmarking report
Request a Quote

All packages are custom-quoted based on your site size, complexity, and scope. Contact us to arrange a free 30-minute discovery call.

What We Deliver

Tangible Deliverables

Everything GembaFlow produces is designed to be used on the shopfloor — not filed in a drawer. Every output is purpose-built for your environment.

📊

KPI Dashboards

Real-time, interactive performance dashboards giving management and team leaders instant visibility of what matters most on any shift.

🗑️

Waste Tracking Systems

Simple, accurate tools for logging and analysing waste at line level — from overproduction to product loss — linked directly to root cause workflows.

🔧

Shadow Boards & 5S Tools

Custom-fabricated shadow boards, equipment control panels, and 5S visual tools that make workplace organisation self-sustaining and audit-ready.

🚿

Hygiene Visual Standards

Photographic hygiene SOPs, cleaning schedules, and zone maps designed to meet BRCGS requirements and communicate standards clearly to all teams.

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Meeting Structures

Tiered meeting formats from shift handovers to weekly management reviews, ensuring the right information reaches the right people at the right time.

🎯

Performance Systems

Structured frameworks for setting targets, tracking progress, and holding accountability — aligned to your existing culture and adjusted as you grow.

📱

Custom Apps & Digital Tools

Lightweight web-based tools and mobile-friendly forms replacing paper-based processes — data collection, checklists, and audit tools built for factory use.

🎬

Photography & Video SOPs

Professional shopfloor photography and instructional video SOPs capturing best practice for consistent onboarding and training at scale.

📌

Signage & Stencils

Fabricated, durable signage and machine control panel stencils built in our workshop — ready to install in food-safe, washdown environments.

Why GembaFlow

Real Experience.
Real Results.

We are not consultants who parachute in with generic frameworks. Every recommendation we make is grounded in lived shopfloor reality — and delivered with the tools to make it stick.

⚙️

Shopfloor-First Thinking

Every solution starts at the gemba — the real place where value is created and waste occurs. We diagnose before we recommend.

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End-to-End Delivery

From data analysis through to fabricated physical tools — one team, one scope, no handoffs to third parties who don't understand your operation.

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Built to Last

We don't leave after the project ends. Our retained support model ensures the improvements you invest in continue to deliver value long-term.

🏭

Food Manufacturing Specialists

BRCGS, hygiene zoning, production efficiency, and allergen management — we speak the language and understand the regulatory environment you operate in.

25+
Years of food manufacturing management experience
3
Specialist disciplines united in one service
4
Stage delivery model — diagnosis to sustained improvement
0
Generic templates — every engagement is bespoke
Methodology

Grounded in Lean &
Six Sigma

01
Define ValueIdentify what your customer actually pays for — and ruthlessly remove everything else.
02
Map the FlowVisualise the entire value stream to expose delays, bottlenecks, and hidden waste.
03
Create FlowRemove obstacles so value flows continuously from raw material to finished product.
04
Establish PullProduce only what is needed, when it is needed — reducing overproduction and inventory waste.
05
Pursue PerfectionEmbed a culture of continuous improvement where every team member contributes to better performance.
"Go to the gemba. See the real place. Understand the real problem. Only then can you create real flow."
GembaFlow takes its name from this principle. The gemba is where value is created — and it's where we always begin. We combine Lean's waste elimination framework with Six Sigma's data-driven problem solving to deliver improvements that are both practical and measurable.
Lean Manufacturing Six Sigma 5S Methodology DMAIC Visual Management Kaizen OEE Tracking BRCGS Aligned
Example Projects

The Work in Practice

Below are representative examples of the type of work GembaFlow delivers — the tools, outputs, and results our clients can expect across data, operations, and visual implementation.

Data & Systems
Example Project
97.4%
OEE
1.8%
Waste
99.1%
Uptime
Chilled Ready Meals · 280 Employees

Live Production Dashboard & Waste Tracker

Replaced 6 disconnected weekly spreadsheets with a single live dashboard tracking OEE, waste by line, and hygiene compliance — updated automatically every shift. Management time spent on reporting reduced by over 60%.

↓62%
Reporting time
↓2.1%
Product waste
6→1
Spreadsheets
Visual Implementation
Example Project
🔧
✂️
📏
○
🔩
🪛
○
📋
Line 3 · Tool Control Board
Bakery Products · 140 Employees

5S Shadow Boards & Hygiene Zone Signage

Designed, fabricated, and installed a complete set of shadow boards, cleaning station displays, and hygiene zone maps across 4 production lines. Resulted in a clean BRCGS unannounced audit and 40% reduction in tool search time.

AA
BRCGS grade
↓40%
Tool downtime
4
Lines upgraded
Operations
Example Project
S
Sort
S
Set
S
Shine
S
Stand.
S
Sustain
Meat Processing · 420 Employees

Full Flow Transformation Programme

End-to-end 12-week engagement covering diagnostic, KPI redesign, meeting structure overhaul, and shopfloor visual management. Departments aligned around shared daily metrics for the first time in the site's history.

↑18%
Throughput
↓34%
Downtime
12wk
Delivery

Your Site Could Be Next

These are representative examples. Every GembaFlow engagement starts with a free site walkthrough — no templates, no assumptions, just an honest look at your operation.

Book Your Free Site Walkthrough
Get In Touch

Book Your Free
Site Walkthrough

The best place to start is where the work happens. Get in touch to arrange a free, no-obligation site visit. We'll walk your operation together, identify the highest-impact opportunities, and show you exactly what GembaFlow would look like in your environment.

🌐
Website GembaFlow.co.uk
📍
Serving UK Food Manufacturing Sites
📧
Email [email protected]

Request a Diagnostic Review