SABAT Consulting

11/06/2026

A plant was quietly losing half a million euros a year. Nobody was looking for it, because on paper, nothing was wrong. The machines ran. The reports were green. The OEE numbers were the envy of the sector.

I showed up on a Monday with a pen and one sheet of paper. No laptop. No dashboards. I picked a single part and followed it from the moment it arrived at the dock to the moment it shipped.

Four hours later I had the answer.

Actual time spent being worked on: 23 minutes. Everything else was days. Waiting for a forklift. Waiting for a quality sign-off. Sitting in a queue behind three other batches. Waiting for a manager to make a decision that should have taken thirty seconds.

I showed the director the sheet. He looked at it and said, "But our OEE is 85%."

He was right. His machines were efficient. His system was broken. Those aren't the same thing, and mixing them up is one of the costliest mistakes you can make in a factory. Equipment utilization tells you how busy your machines are. It says nothing about how long your customer waits.

And the customer never sees your OEE. They see lead time. You can run the busiest line in your industry and still lose the order to the shop that ships in 2 days, while you take 5. Your machines being busy isn't what the market feels. The wait is.

Here's the part that stayed with me. It wasn't the number. It was that the director had walked past this for years. Not because he was careless, the man was sharp, but because the waste was invisible from his office. It only turned real when he watched his own part sit still, day after day, on a single sheet of paper.

That is almost always how it works. People don't change because someone explained flow to them in a meeting. They change when they see the cost of standing still with their own eyes.

So here is the question worth sitting with: in your operation, where does a part, an order, or a decision spend more time waiting than being worked on? You probably already suspect where. The hard part is being willing to follow it and look.

If mapping that gap in your own plant sounds useful, this is exactly the kind of realization I help teams reach, fast, and in a way they don't forget. Connect with me, visit the site, or book a short call, and I'll show you how.

27/05/2026

Companies spend $50B/year on Lean training. Studies show 70% of it disappears within 6 weeks.
I used to think the problem was employee resistance. Or bad leadership buy-in. Or that Lean just doesn't work in certain industries.

I was wrong.

The real problem is simpler and more embarrassing: people can't apply what they have only heard about.

You can explain the 8 wastes in a beautiful slide deck. You can walk someone through value stream mapping on a whiteboard. You can quiz them, and they'll score 9/10.

Then they walk back to their job — and the conveyor belt runs the same way it always did.

Understanding the Lean concept is completely different from feeling what waste costs you.

When you're sitting in a simulation and your "factory" is hemorrhaging time, your team is frustrated, your customer satisfaction is tanking — that's when the concept becomes visceral.

That's when it sticks.

I've been thinking a lot about how we train people in skills that require judgment, not just knowledge. The answer seems to always point in the same direction: you must let people fail first, safely, before they get it right.

What's the biggest gap you've seen between what people learn in training and what they do at work?

25/10/2025

🚀 Master Lean Six Sigma — Learn from 25+ Years of Experience!

Ready to eliminate waste, improve quality, and drive real process results?
👉 The Lean Six Sigma Mastery Package from Sabat Consulting brings you the essence of Lean Six Sigma in 6 powerful courses.

💡 What makes it different:
✅ Built on 25+ years of real industry experience
✅ Includes practical examples, ready-to-use templates & forms
✅ Lifetime access — learn at your own pace, anytime, anywhere
✅ Perfect for training your team or developing your CI leaders

🎯 Ideal for: Process Engineers, CI/Kaizen Leaders, Production & Quality Managers — anyone serious about continuous improvement.

📈 Turn knowledge into measurable results.
👉 Start now: https://sabatconsulting.com/step/lean-six-sigma-mastery-checkout/

19/08/2025

“The biggest enemy of change? Not resistance. It’s the illusion of stability.”
🧠
Many leaders believe that the biggest problem with implementing change is… team resistance.
But the truth is different. The real enemy is the illusion that “if it works, we don’t need to change anything.”
The “everything works fine” syndrome is one of the most significant risks for companies that want to grow.
In lean management, we call it hidden waste – situations where a process delivers results, but at the cost of too much time, energy, frustration, or resources.
👉 When was the last time someone questioned the “standard” way of doing things?
👉 Do people feel safe to say: “This makes no sense”?
👉 Are we measuring efficiency only financially – or also in terms of human cost?
Lean teaches us that every process can be improved – constantly.
But to improve it, we first have to notice that something needs to change.
And that’s impossible from the “everything’s fine” perspective.
🔍 Signs that “stability” is becoming a threat?
• No new ideas
• “We’ve always done it this way” as a core argument
• People stop reporting problems
• Rising frustration despite “good results”
Sometimes, the most extraordinary courage a leader can show is to say:
“What worked yesterday might not be enough tomorrow.”
🚀 Lean doesn’t start with a revolution. It starts by questioning the “obvious.”
💬 What’s so “stable” in your company that it’s suspiciously unchangeable?

08/07/2025

🚀 Digital transformation without Lean is like a super-car… with the handbrake on.

Industry reports show 60 %+ of digital initiatives stall because companies digitise bloated, chaotic processes first.

That’s why 2025 belongs to Lean 5.0 – the fusion of classic Lean, AI and ESG goals.

🔍 What is Lean 5.0?
1️⃣ Lean: eliminate muda, shorten flow, tidy the Gemba.
2️⃣ AI: IoT sensors + predictive algorithms spot deviations in real time, while cloud Kanban boards close PDCA loops in hours, not weeks.
3️⃣ ESG: optimised processes = smaller carbon footprint 🌍 and lower material costs 💸.

📈 Mini case study: A packaging manufacturer I worked with combined AI-Vision and Lean Kaizen, cutting film scrap by 18 % and CO₂ emissions by 12 % in just six months. No mega-budget capex – they simply streamed line data to a cloud Andon board and ran daily GEMBA walks with new green KPIs.

💬 Question for you: Where do you see the biggest waste of data or energy in your process today? ⤵️

31/03/2025

Hey everyone,

I'm excited to share a project I've been passionately working on—my new course, Mastering Team Building & Leadership for High Performance. This course is a culmination of years of experience building dynamic, high-achieving teams, and I'm thrilled to finally share it with you.

It's designed to equip you with fresh strategies and actionable insights that can truly transform the way you lead. The first 100 people to enroll will get free access as a special bonus!

Your feedback would mean the world to me—every review helps refine my approach and deliver even more valuable content in the future.

Check it out here:
https://www.udemy.com/course/mastering-team-building/?couponCode=1A3DBFF8B22FB27F1184

I appreciate your support, and let's build great teams together!

Team Building: Master Collaboration Skills to Create High-Performing Teams and Achieve Success Together

16/02/2025

🌱 Want to streamline processes in your company and implement effective solutions? 🌱
Join my Lean Management training, based on 25 years of experience in implementing Lean principles across various organizations. Gain practical knowledge and tools that will help you:
✅ Eliminate waste and improve process quality,
✅ Increase team efficiency,
✅ Implement changes that bring real benefits.
Based on my experiences and real-life case studies, this training combines theory with practice.
📅 Sign up now and learn how Lean Management can support your company's growth! 📲 Register here: https://sabatconsulting.com/product/courses/lean-management/

04/09/2024

Discover the key to unlocking your company's full potential with the "GET LEAN" simulation game – your ultimate guide to Lean Management. This innovative and interactive training tool is designed to make Lean principles more accessible and practical, helping employees develop a deeper understanding of improving efficiency and driving business growth 🚀.

**Experience learning by doing**:
"GET LEAN" isn't just a game; it's a comprehensive journey through the intricacies of production processes 🔄. With 13 to 16 participants actively taking on different roles, from Kaizen leader to warehouse manager, each team member gains valuable, hands-on experience 🛠️. The simulation highlights the differences between traditional work methods and those founded on Lean principles, demonstrating the clear advantages of the latter 💡. It's an opportunity for your team to see first-hand how Lean Management can transform work processes for the better 📈.

**How can it benefit your business?**
By participating in "GET LEAN," your company can achieve significant improvements in efficiency ⚙️, customer satisfaction 😊, and time management ⏳. The game focuses on reducing waste, optimizing workflows, and shortening lead times, giving your business a competitive edge 🏆. Simulation games like this provide an engaging learning environment where employees learn the theory and experience the impact of their actions, ensuring the knowledge gained is immediately applicable in real-world scenarios 🌍.

**Why choose a simulation game?**
Simulation games are a proven method for combining theory with practice 🧠💼. They break away from traditional learning approaches by offering an interactive and dynamic experience that promotes team collaboration 🤝 and problem-solving 🧩. Participants learn the principles of Lean and practice applying them, working together to find the most effective solutions for your company's specific challenges 💪.

Ready to explore how "GET LEAN" can drive real change in your organization? Learn more at www.getlean.pl 🌐 and see how this simulation game can be the key to your company's success 🔑!

03/09/2024

🚀 Want to boost your company's efficiency? 💼✨ Check out two essential courses that can transform your approach to management and problem-solving! 🎯💡
1️⃣ Lean Management in Practice 📈 – A 9,5-hour course 🎓 based on my 25 years of experience 🌍 implementing Lean Management principles in companies 🏢 across Poland 🇵🇱 and Europe 🇪🇺. You'll learn how to introduce Lean principles 🔧, which tools to use effectively 🛠️, and how to step-by-step increase your company's operational efficiency 🚀.
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2️⃣ Effective Problem-Solving Process 🔍 – A 2.5-hour course ⏰ that teaches you how to identify and solve problems 🤔 in your organization effectively. This approach helps you understand the importance of in-depth problem analysis 🔎, data gathering 📊, root cause identification 🧠, and implementing acceptable solutions ✅.
📍 The course is available at: https://www.udemy.com/course/mastering-problem-solving-critical-thinking-skills/?couponCode=41E548BDC7C70259543E
📚 Both courses are available on Udemy for just $12.99 each! 💸🎉
🕒 Special offer valid only until the end of September! Don't miss this opportunity to enhance your management and problem-solving skills 💪. Invest in your knowledge 📖 and the growth of your team 👥! 🌟

Experts in the fields of production and logistic process optimization