Real Results From Real Operations
ClayLean delivers practical, measurable improvements that teams can feel and leaders can see. These case studies highlight how we’ve helped organizations reduce waste, improve quality, and build systems that actually work in daily operations.
Featured Case Studies
Case Study 1: Throughput Transformation in Pharmaceutical Manufacturing
Challenge
A high-volume pharmaceutical packaging site was struggling with low throughput, inconsistent staffing, and rising scrap. Lines were producing 550 units per hour, far below capability, causing missed targets and overtime.
What We Did
- Conducted a full waste and constraint analysis
- Implemented standardized work improvements
- Introduced visual flow and real-time performance tracking
- Aligned supervisors on shift cadence and intervention triggers
- Trained operators on problem-solving and flow awareness
The Result
- Throughput increased from 550 → 950 units per hour in just 3 months
- Significant reduction in overtime
- Improved quality consistency
- More predictable daily production and calmer work environment
Case Study 2: $7M Annual Savings Through Lean Deployment at Thermo Fisher Scientific
Challenge
The site needed a clear, sustainable improvement system to address waste, stabilize operations, and develop stronger daily accountability.
What We Did
- Designed and deployed Lean daily management across 8 departments & 6 buildings
- Implemented KPI boards, tiered meetings, and leader standard work
- Developed problem-solving capability through hands-on coaching
- Identified systemic waste in material flow, changeover, and quality loops
The Result
- Achieved $7 million in annual savings
- Increased workforce engagement and ownership
- Improved flow and reduced unplanned downtime
- Established a repeatable, self-sustaining improvement culture
Case Study 3: RPA Integration Eliminating 85% Process Waste in Field Service
Challenge
A field service and aftermarket team struggled with manual data entry, delayed updates, inaccurate work order statuses, and miscommunication between technicians, customer service, and parts teams.
What We Did
- Mapped the full workflow from request to closeout
- Identified bottlenecks and repetitive data steps
- Built and implemented an automated RPA solution
- Integrated notifications, routing, and data validation
- Designed visual dashboards to track technician and job status
The Result
- Eliminated 85% of administrative waste
- Increased technician utilization
- Improved customer communication and transparency
- Reduced errors and improved on-time completion
Consistent Outcomes Across Every Engagement
Whether it’s a full Lean transformation, a targeted Kaizen, or leadership coaching, ClayLean focuses on clarity, flow, and sustainable results. Clients consistently experience calmer operations, better coordination, and measurable performance gains.
- Waste reduction
- Improved flow & throughput
- Higher workforce engagement
- Stronger leadership alignment
- Visual clarity & KPI adoption
- More predictable day-to-day operations
Want Results Like These?
The next step is a short conversation to understand your goals and where you’re experiencing friction. ClayLean offers assessments, rapid improvement events, and fractional leadership support tailored to your operations.