Lean manufacturing · Operational excellence · Australia
Practical Lean manufacturing leadership for manufacturing, maintenance and service operations—aligning teams, stabilising workflows and building improvement systems that last.
Gieloff Consulting helps leaders turn complex operational problems into visible, manageable work.
Engagements combine analysis, hands-on implementation and leadership coaching. The result is a practical system your people can run, improve and sustain after the consulting work is complete.
Fewer delays, bottlenecks and hand-off failures.
Clear KPIs, actions, standards and ownership.
Leaders and teams equipped to keep improving.
Support can target one urgent constraint or build a connected transformation program across the operation.
See the whole system, focus effort where it matters and move from recurring firefighting to structured improvement.
Value Stream Mapping · Kaizen · 5S/6S · root cause analysis · standard work
Make work visible, find the constraints and redesign the flow around customer demand and operational reality.
Time and motion · VA/NVA · takt and cycle time · line balancing · layout and material flow
Create the routines and visual controls that turn performance into a daily team conversation—not a monthly surprise.
Performance boards · KPI and action tracking · Leader Standard Work · daily and weekly meetings
Bring production and maintenance together around equipment reliability, stable work and disciplined follow-through.
TPM · OEE · preventive maintenance · setup reduction · overhaul workflow optimisation
Connect business priorities to frontline action through a focused transformation plan and clear accountabilities.
Hoshin Kanri · X-Matrix · improvement roadmaps · project execution · budget and P&L insight
Improve material flow while equipping leaders and teams to solve the next problem without outside dependence.
Kanban · just-in-time · inventory and warehousing · workshop facilitation · Lean training · coaching
Results from Thomas Gieloff’s consulting and operational leadership experience. Every engagement starts with its own baseline, constraints and opportunity.
Delivered for consulting clients through flow, layout and waste elimination.
Achieved across multiple client transformation programs.
Helped deliver on a Queensland Rail contract.
Delivered alongside 30% fewer NCRs and 24% lower NCR costs.
50% setup-time reduction
15% OEE improvement
$20k monthly labour-efficiency saving
€3.06m operational savings delivered
No pre-packaged transformation theatre. The work is shaped around your operation, your people and the performance gap that matters now.
Observe the work, visualise the flow, test the data and create a shared fact base.
Translate the opportunity into a practical operating model, priorities and measures.
Run focused improvements, establish standards and coach leaders through the change.
Build daily management, visual control and problem-solving routines into normal work.
Founder & Lean advisor
More than 30 years of experience across German automotive manufacturing, Australian manufacturing, mining equipment refurbishment and consulting.
A mechanical engineer with hands-on leadership experience in production, maintenance, logistics, continuous improvement and leadership coaching, Thomas has led teams from frontline operations through national operational excellence roles.
His work is grounded in engaging managers and frontline teams, stabilising workflows, eliminating waste and embedding practical performance-management systems.
Start with the operation you have
Share the constraint, turnaround challenge or improvement opportunity you’re working through. The first conversation is about fit, priorities and the most useful next step.