If your factory is struggling with long lead times, high inventory, quality rejections, machine breakdowns, or low productivity — Lean Manufacturing is the proven solution. And GreenDot Management Solutions is India’s most result-oriented Lean Manufacturing consulting firm.
With offices in Surat, Vadodara, and Valsad, we have implemented Lean systems across 1,200+ client engagements in Engineering, Pharmaceuticals, Chemicals, Plastics, Packaging, Textiles, Automotive, and IT industries across Gujarat and India.
We do not just train your team and disappear. We work on your shop floor, implement changes alongside your people, measure results weekly, and stay until targets are achieved and sustained.
greendot is considered as best lean manufacturing consultant india, and across the globe. We have sucess storoes to share.
Lean Manufacturing is a proven business methodology (developed from the Toyota Production System) that focuses on systematically eliminating waste (called “muda” in Japanese) from every step of your production process. Waste includes not just material waste, but time waste, movement waste, waiting time, overproduction, defects, excessive inventory, and unnecessary transportation.
In practical terms: Lean helps your factory do more with less – fewer people running around, less floor space wasted, less money tied up in inventory, faster delivery to customers – while delivering consistently better quality.
For Indian manufacturers specifically, Lean is critical right now because buyers (both domestic and export) are demanding shorter lead times, lower costs, and consistent quality. Factories that implement Lean gain a powerful competitive advantage over those that do not.
Most lean consultants deliver training presentations and leave. GreenDot works differently. Our 5-step on-site implementation process has been refined across 1,200+ engagements in Indian manufacturing conditions – and it consistently delivers results within the first 30 days.
We begin with a thorough Plant Diagnosis and Waste Mapping – conducting Value Stream Mapping (VSM) across your entire production floor to identify every bottleneck, every delay, every unnecessary movement, and quantify the cost in rupees per day. This gives you and your team a crystal-clear picture of exactly where your factory is losing money.
Within the first 30 days, we implement Quick Wins, high-impact, low-cost changes that show your team immediately that Lean works. These early wins build belief, momentum, and buy-in from your shop floor workers and supervisors — which is critical for long-term success.
We then implement a complete 5S Workplace Organisation system (Sort, Set in Order, Shine, Standardize, Sustain) creating the foundation for all further Lean work. A properly implemented 5S system alone typically reduces search time, accidents, and production delays by 20–35%.
Next we run focused Kaizen Improvement Events – structured workshops targeting specific production problems. Every Kaizen event has clear before-and-after measurements so results are undeniable and documented. We typically run 2–4 Kaizen events per month during an active engagement.
Finally, we build Sustaining Systems and Train Your Leadership Team – visual management boards, daily management routines, and supervisor training so your team owns the improvement process permanently. The #1 reason Lean fails in Indian factories is no sustaining system. We solve this before we leave.
GreenDot consultants are trained and experienced in the complete toolkit of Lean Manufacturing methodologies. We select the right tools for your specific situation — not a one-size-fits-all approach.
Our core Lean tools include 5S Workplace Organisation for foundational factory discipline and visual management; Kaizen for structured daily and event-based continuous improvement; TPM (Total Productive Maintenance) to maximize machine uptime and eliminate breakdowns; and SMED (Single Minute Exchange of Die) to reduce changeover times from hours to minutes.
We also implement Kanban pull systems to eliminate overproduction and reduce WIP inventory; OEE (Overall Equipment Effectiveness) measurement and improvement programs; VSM (Value Stream Mapping) to visualise and redesign your production flow; Quality Circles to build employee-driven problem-solving culture; and Poka-Yoke (mistake-proofing) systems to eliminate recurring quality defects at the source.
These are not theoretical projections or industry averages. These are actual measured outcomes from real GreenDot client engagements across Gujarat and India — documented with before-and-after data.
Across our 1,200+ client engagements, GreenDot has consistently delivered lead time reductions of 30–85%, productivity improvements of 20–60%, cost reductions of 8–25%, on-time delivery improvements of 15–40%, and WIP inventory reductions of 25–50%. Specific examples include lead time reduced from 28 days to 6 days at an Engineering manufacturer in South Gujarat; WIP inventory cut by 38% in just 90 days at a Plastics manufacturer in Surat GIDC; machine downtime reduced from 22% to 6% through TPM at a Packaging company in Vapi; on-time delivery improved from 62% to 91% in 5 months at an Automotive ancillary in Vadodara; and Rs 48 lakh annual cost savings achieved through waste elimination at a Textile mill in Surat.
GreenDot’s lean consultants bring deep, hands-on experience across India’s core manufacturing industries. We understand that a pharmaceutical factory and a textile mill need fundamentally different lean approaches and we tailor our implementation accordingly.
We also offer Lean Manufacturing Training Programs for teams who want to build internal capability before or alongside a full consulting engagement.
Results begin within 30–60 days of starting. A complete lean culture transformation for an Indian SME typically takes 6–18 months depending on company size and commitment level. GreenDot's structured approach delivers measurable improvements — typically 20–60% productivity gains — within the first quarter of engagement.
Greendot's lean consulting engagements are priced based on factory size, scope, duration, and number of locations. Most SME engagements range from Rs 1.5 lakh to Rs 5 lakh for a structured 3–6 month program. We offer a FREE 30-minute plant assessment before any financial commitment, call us on +91 90237 28317 to start.
Yes, and often more effectively than in large factories. Small Indian manufacturers see faster results because decision-making is quicker, teams are easier to align, and changes can be implemented without complex change management. Greendot has successfully implemented lean in factories as small as 15 people.
No. Lean is implemented alongside regular production. Greendot works around your production schedule and plans all implementation activities to minimize disruption. In most cases, production actually improves within the first month of implementation.
Lean focuses primarily on eliminating waste and improving flow, making your process faster and more efficient. Six Sigma focuses on reducing variation and defects using statistical methods. They are complementary — many Indian manufacturers benefit from both. Read our full comparison: Kaizen vs Six Sigma — Which is Right for Indian Manufacturing?
For most Indian factories, we recommend starting with 5S, it creates the visual foundation and discipline needed for all other lean tools to work effectively. After 5S, Kaizen events and TPM typically deliver the highest ROI. GreenDot's plant assessment identifies the right starting point for your specific situation.
Learn Lean Manufacturing the way it actually works on Indian shop floors. In this practical online masterclass, Nirav Trivedi — NPC & QCI approved Lean consultant with 25+ years of hands-on experience — shares the methods Greendot uses with 1,200+ companies, so you can identify waste, improve machine performance and lead Lean implementation in your own plant.
There are many lean consultants in India. Here is what makes Greendot genuinely different and why 1,200+ manufacturers have trusted us with their operations.
We work on your shop floor, not from a conference room or via video calls. Our consultants physically work alongside your production team, operators, and supervisors. We get our hands dirty. This is the only way real lean implementation happens in Indian manufacturing conditions.
We set measurable targets upfront and track them weekly. Before we start any engagement, we agree with you on specific, quantified targets, lead time by X%, cost by Y%, OEE from A% to B%. Every weekly review measures progress against these targets. If we are behind, we adjust our approach. We do not wait until the end to measure.
We combine lean with your ISO systems. If you are already ISO certified or pursuing ISO Certification, our lean implementation strengthens your QMS simultaneously saving time and cost. Lean and ISO together is the most powerful combination for Indian manufacturers.
We build your team’s capability so you are not dependent on us forever. Through structured Corporate Training Programs running parallel to implementation, your supervisors and managers become lean champions who sustain and continue improvements after we leave.
Not sure where to start with lean manufacturing? Talk directly to a Greendot lean consultant — no cost, no obligation. We visit your factory, identify your top 3 improvement opportunities, and give you a clear lean implementation roadmap in 30 minutes.
Lean Manufacturing’s best practices emphasize principles like waste reduction. cycle time improvement, and quality enhancement. Through lectures, interactive workshops, group discussions, case studies, Gemba Walks, and practical exercises, participants will gain a comprehensive understanding of Lean Manufacturing concepts and the practical steps involved in its implementation.
"Nirav has communication skills to get connected with hard working dedicated employees. He supports to bring each employee to visualize broad spectrum role. "
Atul Limited
"A person with who can create a roadmap to build strong value and take you to the next level "
MAAK & Associates
"Had a very good experience working with Greendot Consultancy, we have been resulted into skill improvement and develop personal view to grow our company and how to balance industry in many aspects. "
Alltech Industries
"Practical and Innovative way to resolve problems. Highly positive attitude. Implementation of suggested modification and changes is easier. "
Chiripal Polyfilms"Have been associated with Nirav's team, Green Dot for 2 years. These two years were quite focused on our objective and the goal set by the organization. Despite Covid lockdown we could achieve a successful milestone. Support extended by Nirav and team was just fantastic. Thanks Nirav, "
Atul Limited
"Nirav is an excellent Management Consultant. His company was appointed by our customer for Vendor Management Program, which included 5S and Lean Management practices. The program was quite effective. Later we engaged him for Strategic Management Program. This program is excellent and very effective. I recommend this program to companies who wants to take benefit from this.. "
Prima Automation (India) Pvt.Ltd
"I am working with greendot since last 12 + year. We are consistently improving our business process and Improved our productivity in paper mill and corrugation industries. In last couple of month we have increased our productivity by around 20% by implementing lean practice. Amazing productive experience with team greendot. They are the only consultant who can retain a client for this much duration and helping our industries to grow. "
RBR Papers LLP
"Nirav Trivedi is an excellent management consultant & coach. He and his team at Greendot has been helping multiple industries in improving productivity and reducing cost by training manpower to optimize processes and increase capacity of machines. I highly recommend his knowledge and expertise in this area. "
Accenture"Mr. Nirav Trivedi is an excellent coach both on personal and professional front. He has exceptionally curated his TQM course to identify gaps and increase productivity in sort span of time. I wish him and his team best of luck for all endeavors. "
Atul Limited"Mr. Nirav Trivedi is a excellent business consultant we have work with so far. His advice as a consultant has allowed our organisation to expand our business tremendously. He has helped us to implement changes in our policies and strategies that have made our organization more efficient and profitable. He is costliest among all the consultants, but WORTH IT ! "
Alltech Industries"We have worked with Mr Nirav Trivedi and Green Dot team for 5S implementation and journey is so good so far. 5S is not only house keeping improvement but it will help us in many other areas viz. productivity, inventory, money generation by identifying unwanted items, motivation and many more. "
Atul Limited
"Best in class Consultant for Business System development "
Shah Traders (Vapi)
"I personally Know Mr Nirav Since a Decade Now. Based on My professional experience & feedback from our a few common client of Cps Technologies & Green Dot, i can say Mr Nirav is having rich experience for management consulting in various Industry Verticles incl a working with out of India's clients, Practical approach in Problem Solving & creating A niche segment for his consulting by coaching , consulting & make client practice six sigma , lean management & etc. Techniques successfully. "
CPS Technologies
"Green Dot and NIrav Trivedi is very understanding on problems that organisation is facing and suggest remedies which suits to culture and receptiveness of employees to start off. On process improvement and setting best practices He delivers worth for company, particularly. We worked with him and satisfied with services he delivered. All the best and keep nurturing on. "
Rajhans Group of Industries
"I am enjoying with his consultation.if u want your business in automode i strongly recommend Mr Nirav Trivedi.i am in Automode r u? jaha apni soch bandh ho jati hai waha se unki soch suru hoti hai. Thank you Nirav Sir. "
Jalaram Khichdi
"Industry specific bull's eye approach with their expertise is an effective combination in Greendot's management, for industries to upgrade their operational standards... "
Sahajanand Valves
"Nirav, has worked with our Cluster for Lean Mfg implementation. He is constantly striving for excellence in his chosen domain and working hard towards his goal to taking Green Dot to the next level. Immense clarity of thought, good methodology for implementation across wide spectrum of Industries, keeping himself abreast with latest theories. He is a good orator and a good influencer. I highly recommend Nirav to those who are seeking business solutions for the better. "
RBD Engineers Pvt Ltd
"I know Nirav for many years, he is very committed to his work and his problem solving ability is his biggest asset. He always sets very high standards for him and his team which is difficult for others to match. Wish him all the best in future! "
Firmenich
"I know Nirav ji from last 5 years and I had learned a lot from him specially how to make consistent growth in career, excellent personality with in depth knowledge Truly it was Great experience to be connected with you....Thanks for being my connection "
Pacific Group of Companies
Very happy with Greendot's services and their support in continuous development of our organization. Over an year we have not only managed to keep our inventory under control, but also improved productivity. Our profit has increased , cost has minimized and we are currently able to utilize our capacity in very efficient manner. In addition to this, we have also managed to integrate all departments through one system. Greendot team members are very professional, always supportive, polite and have helped our employees adapt to change over a short period of time. Under the guidance of Mr. Trivedi's leadership and vision Greendot success is guaranteed.
Kingsley Ecotech Pvt Ltd
Very Professional on Management !
Hebei Yitaike Bearing Co.,Ltd - ETK Bearings
"He has immense and thorough knowledge of lean management, quality management system and backed by excellent academic. projects taken care by Nirajji is always hv a new experience and on time completion. "
JSW MI
"Good experience of having interacted with Mr. Nirav Trivedi. He delivered a motivational speech for undergraduate Chemical Engineering students at SCET during my tenure as Head of Chemical Engineering "
Sarvajanik College of Engineering & Technology
"Nirav is a good human being to work with and a highly professional management consultant. He has been instrumental in helping many organisations for course correction. wishing him all good things ahead. "
SEC GLOBAL CONSULTING AND INITIATIVES LLP"Most Reliable consultant, Bring our company to the next level now able to drive the company towards desire mission "
Jalaram KhichdiVery Professional on Management !
Hebei Yitaike Bearing Co.,Ltd - ETK Bearings
"Nirav has innovative thoughts and I like his management tips. "
Shreemad Rajchandra
"I would like to recommend Mr.Nirav Trivedi as a management consultant and productivity coach, Himal. "
HMC Sales
"Nirav is one of the most dynamic, versatile person i have ever came across in my professional career. He is one of the best management consultant we have in the whole Gujarat State. He has done some amazing assignments which resulted in huge cost savings , increased productivity for his clients and in some cases he along with his team managed to turn around the companies with their in depth knowledge of the subject matter. He & his team spends great amount of time to understand the root cause of the client & then they come up with the customised solution for them. I wish nirav & his team all the very best & i am sure nirav along with his team of green dot will create many more wonders in the corporate world with their expert knowledge. All the best nirav!! Keep doing the good stuff & keep helping the corporates to evolve & grow!! "
White Turtle Consulting and K&K Associate
"I was looking for an HR consulting firm and came across Nirav and his organization. Having worked with various consultants, I expected the same stuff but was pleasantly surprised to find his methods refreshingly different. Here was also a consultant who guaranteed a positive change... what could be more interesting? We are currently working with his firm and moving forward creating agents of change... Would definitely recommend him to anyone "
Vertellus Speciality Materials (India) Pvt.Ltd
"Nirav Trivedi is amazing person with great knowledge on team management and also with all the great ideas for growing own business with different tools to have faster and success. All completely solution for business for small and big business.. Amazing person with very down to earth and also ready to help everyone.. "
Imperial Overseas Education Consultants( Imperial Platforms Inc)
"I Know Nirav more the 20 years , he is Master of Management !! Keep it up "
Indobuilt Storage System Pvt.Ltd
"Superb insight in Small Business operations. Good at decoding SME bottlenecks. Polite service of the entire Organisation. Very well Read. Recommended for Management Consulting "
Usha Die Casting INDS
"Nirav & his Tem@ GreenDot Effectively Practices Trade as a Consultant to Various Small to Enterprise Organizations with ease , be it Improving Profitability, Brand Image, HR , Productivity, Efficiency & as team an asset to get associated with ! "
Matrix Network and Solutions
"Good 5s consultant "
Agarkar HR Services Pvt Ltd
"I highly recommend Mr.Nirav for his his professionalism and result oriented approach. "
Yashaswi Consultants
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