Andy Brophy

Andy Brophyis a Lean & Innovation Improvement Advisor. He has been working in the Lean field for the last 15 years with a diverse range of organisations including manufacturing, government, services, software development, and hospitals.

Andy is a professional engineer and holds a 1st Class MSc in Lean Operations from Cardiff University and is Six Sigma Black Belt certified. In May 2010 he published the co-authored book Innovative Lean with John Bicheno of the Lean Enterprise Research Centerin the UK. This work is primarily based on the power of harvesting and implementing employee ideas and creating an innovative and empowered workforce.

Lean is a mindset guided by five principles of :

  1. Purpose: What are we trying to accomplish?
  2. System: Holistic view of the interacting components that deliver value
  3. Flow: Design the system to enable the delivery of value with minimum interruptions.
  4. Perfection: A recognition that there are always opportunities for continual daily improvement.
  5. People: The true engine of Lean, the core emphasis is to develop people’s creativity and potential.

Lean is founded upon integrity, trust and respect for people. It develops a culture that creates empowerment with engaged and motivated people that understand the importance of, and gain satisfaction from their contribution to the products and/or services offered by their organisation.

Lean is focused on constantly driving out waste and assuring that all processes are focused on maximizing safety and value for the customer, the employee, the investor and the community.

Why Adopt Lean to Transform your Organisation?

  • It defines value from the customers view point
  • Transforms waste into value (Lean demonstrates that pre-Lean processes are less than 5% value adding)
  • Reduces errors & mistakes
  • Decreases our stress
  • Empowers workers to solve problems that are getting in the way of them having as mooth shift
  • Uses “Work as Learning”
  • It is the Scientific method (Plan, Do, Study, Act) applied to all that we do
  • It merges Philosophy, People, Problem Solving, & Systems Thinking
  • Lean is not about working harder or faster, it is about finding waste and Transforming it into value our customers want.

We provide expertise and hands training and implementation in the following Lean practices across a wide range of industries including manufacturing, healthcare, and services:

  • Policy Deployment
  • Lean Leadership and Daily Management Process for Sustaining the Gains towards a Lean Culture
  • Lean Assessment
  • Management of Change
  • White, Yellow, Green, and Black Belt Lean Sigma Certification to ASQ Certification Level
  • Value Steam Mapping
  • Waste Watchers Walk
  • Kaizen Blitz Facilitation
  • PiT-Stop Accelerated Idea Workshop
  • Visual Management
  • Standard Work (SOP’s & Leader Standard Work)
  • 5S Workplace Organisation
  • Problem Solving
  • Quick Changeover
  • Total Productive Maintenance
  • Mistake Proofing
  • Everyday Lean Employee Idea Capture System
  • Kanban and Inventory Reduction
  • Continuous Flow and Theory of Constraints
  • Cellular Design
  • CreativityMethods
  • TRIZ
  • Lean Design and Development
  • Value Engineering
  • Lean Supply Chains
  • Lean Scheduling Concepts
  • Accounting for Lean





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