Bharat Kumar

Lean Manufacturing Consultant

I help manufacturing organizations improve performance, lead change, and build the operational discipline that outlasts any single project.

A Lean manufacturing consultant working at the intersection of Lean methodology, cross-functional leadership, and advanced manufacturing — across automotive, FMCG, and pulp & paper operations.

Committed to advancing British Columbia's manufacturing sector — from plant floor to provincial strategy.

IndustriesAutomotive·FMCG·Pulp & Paper·CurrentlyCascades Inc.·Vancouver, BC
6+
Years industry experience
22%
OEE improvement, reliability programme
$100Ks
Saved across Lean projects
E2E
Projects across ops, maintenance & logistics

Industries served

Automotive assembly line
Automotive
Precision & high-mix assembly
Assembly and hydraulic systems, SOP development, precision inspection, and line balancing in complex, high-mix production.
Automated food packaging line
FMCG
High-volume packaging & flow
Line rebalancing, changeover reduction, standard work, and SAP S/4HANA adoption across high-volume packaging operations.
Paper roll on a pulp and paper mill machine
Pulp & Paper
Heavy process & reliability
TPM deployment, plant relocation, frontline CI capability, and cross-site continuous-improvement strategy.

The story

"I didn't start with a methodology. I started with machines."

Started on the assembly floor. Moved into continuous improvement. Now operate at senior advisory level across Western Canada — with a next chapter aimed at British Columbia's advanced manufacturing future.

Read the full story

My career began on the assembly floor — hydraulic systems, structural components, work instructions, and the kind of operational knowledge you can only build with your hands. I learned early that performance problems never have one cause. They live at the intersection of equipment reliability, process design, team alignment, and leadership discipline. That lesson has shaped everything since.

From there, I moved into continuous improvement and quickly grew into leading professional and production teams across multi-site manufacturing environments — FMCG, packaging, and industrial operations. The work spanned the full value chain: maintenance strategy and asset reliability, production flow and bottleneck elimination, logistics and receiving process redesign, inventory control, and end-to-end ERP adoption. In each domain, the goal was consistent: turn operational complexity into structured, measurable improvement that teams could own and sustain.

The financial impact across those Lean projects runs into the hundreds of thousands of dollars — cost reductions, labour efficiency gains, inventory variance eliminated, and throughput improvements that compounded across sites. But the metric I am most proud of is the capability left behind: supervisors who can now run their own A3s, operators who surface problems before they become crises, and daily management systems that keep performance visible without needing a CI person in the room.

Today at Cascades, I operate at a senior advisory level — coordinating cross-site CI priorities, leading plant transformation work, and building the next generation of frontline improvement capability across Western Canada. My next chapter is contributing directly to British Columbia's advanced manufacturing future — whether through operational leadership, advisory work, or partnership on projects where operational discipline is what separates a strategy that ships from one that stalls.

Vision for BC manufacturing

British Columbia has a narrow window to build a manufacturing sector that is competitive, resilient, and rooted here.

LNG, critical minerals, EV supply chain, mass timber, shipbuilding, clean energy — facilities are being announced faster than the operational systems needed to realise them. Reliability engineering, Lean discipline, and the practical Industry 4.0 stack are the difference between industrial investment that delivers jobs and investment that stalls at commissioning.

01
Operational grounding for policy
Strategy informed by what happens on a shift, in a stores room, at a Monday production huddle — not extrapolated from a slide.
02
Reliability-first Industry 4.0
Data systems built around real failure modes and operator workflow. TPM before dashboards. FMEA before AI.
03
Workforce capability that compounds
Improvement capacity built into the organisation itself — not rented from consultants, not lost at the next cycle.
04
Bridge between floor and strategy
Fluent in the vocabulary of Cabinet and the language of a maintenance planner. Translation is where projects hold their timeline.

What I do

Continuous improvement
Continuous improvement
Kaizen, DMAIC, VSM — deployed end-to-end across operations, not isolated projects.
Asset reliability
Asset reliability
TPM, FMEA-driven PM redesign, OEE optimisation — connecting equipment uptime to throughput.
Supply chain and logistics
Supply chain & logistics
Inventory control, receiving redesign, and end-to-end flow improvement across warehousing.
Capability building
Capability building
Coaching teams to solve their own problems — A3s, Kaizens, daily management that outlasts the project.
Plant transformation
Plant transformation
Relocations, ERP rollouts, workflow redesigns — high-stakes operational change with continuity.
Industry 4.0 integration
Industry 4.0 integration
Bridging Lean discipline with digital systems — technology that serves the floor, not just the strategy deck.

Core competencies

Lean / Six SigmaKaizen facilitationOEE · MTBF · MTTRValue stream mappingEnd-to-end project deliveryDMAIC / A3 / 5 WhyTPM deploymentLogistics process redesignChange managementDaily management systemsPower BI · ExcelSAP S/4HANAServant leadershipIndustry 4.0 adoptionCapacity optimisationKPI development

Selected impact

01
Maintenance · Operations
+22% OEE — Asset reliability programme
Availability was running at 72% with unplanned downtime as the hidden constraint. CMMS loss baselining, Pareto root-cause sessions, PM redesign, and operator inspection routines lifted availability to 88% — OEE reached 82% within 90 days.
02
Operations · FMCG
$120K/year saved, +6.7% throughput — Packaging line
A chronic bottleneck was being managed as a staffing problem. VSM and time-study exposed the real flow imbalance. Kaizen rebalancing cut labour cost 14% and lifted throughput 6.7% — sustained through standard work.
03
Logistics · Supply chain
$70K → under $20K per period — Inventory variance
Variance at ~$70K/period was a process discipline problem, not a system problem. Receiving workflow redesign and embedded standard work brought it under $20K — and held.
04
Digital transformation
SAP RISE S/4HANA — ERP to plant-floor translation
Led change management and training across multiple facilities for a full S/4HANA rollout — translating ERP logic into plant-floor language so teams owned the process, not just the screens.
05
Plant transformation
Full facility relocation — Continuity through high-stakes change
End-to-end CI and operational readiness across floor mapping, equipment layout, FMEA updates, and startup planning. Throughput targets held through the move.
06
Forward-looking
De-risking new BC manufacturing sectors from day one
Operational discipline belongs at project charter — not retrofitted at commissioning. For green-field BC facilities, OEE targets set at FEED, TPM designed into commissioning readiness, workforce capability mapped before foundations are poured.

Where I've worked

Cascades Inc.Pulp & Paper
Senior Continuous Improvement Advisor — Western Canada
Vancouver, BC · Sept 2024 – Present

Owning continuous-improvement strategy and execution across Cascades' Western Canada plants — from the shop floor to cross-site transformation.

Cross-site CI strategy TPM deployment Kaizen & Six Sigma Plant relocation (Surrey → Burnaby) FMEA & startup readiness KPI dashboards Frontline CI training JHSC · safety-first
Wonderbrands Inc.FMCG
Regional Continuous Improvement Engineer
Winnipeg, MB · June 2022 – Sept 2024

Led a regional CI team delivering Lean and DMAIC projects across high-volume FMCG packaging operations — every project tied to a measurable business KPI.

Led a team of four CI professionals Line rebalancing Changeover & bottleneck reduction DMAIC & root cause SAP S/4HANA rollout Inventory control Standard work & visual management
Tigercat Industries + Rajasons ToolsAutomotive · Heavy equipment
Mechanical Technician · Manufacturing Technologist Intern
Kitchener + Windsor, ON · 2021 – 2022

Where it started — hands on the machines. The operational instinct that underpins everything since.

Assembly & hydraulic systems SOP development Line balancing 5S & waste elimination SPC & quality

Leadership philosophy

"My job is not to solve problems. It's to build organisations that solve their own."

Servant leadership in manufacturing is the most practical approach available when you need results from people you do not directly control. Listening before leading, removing barriers before issuing directives, and building capability that outlasts your involvement. That is how improvements stick.

"The gap between a good improvement and a sustained result is almost always organisational."

Tools are the easy part. Getting a production team to trust the data, getting a supervisor to own the new standard, getting a site leader to protect the improvement when output pressure spikes — that is the actual work. I treat change management not as a phase in the process, but as the process itself.

"Technology creates value only when it works for the people closest to the process."

I am not the person who builds digital systems. I am the person who ensures they solve real operational problems — connecting the predictive model to the PM schedule, the dashboard to the daily huddle, the Industry 4.0 strategy to the floor reality. That translation layer is where most transformations fail. It is where I add value.

Education

2021
MEng, Mechanical Engineering (Automotive)
University of Windsor, ON · Canada
2019
BTech, Mechanical Engineering
Guru Nanak Dev University · India

Certifications

Lean Six Sigma Green Belt
Certified
Certified Kaizen Facilitator
Certified
Project Management Professional (PMP)
In progress — PMI
P.Eng. (EGBC)
In progress — BC licensure pathway

Insights & writing

Field notes on Lean, reliability, and advanced manufacturing in the Canadian context — where operational discipline meets provincial strategy.

How I engage

The 90-Day Plant Diagnostic
A frontline CI capability programme — deployed, tested, sustained.
01BaselineLoss study, OEE, VSM
02DesignStandard work, daily management, KPI board
03Build capabilityFrontline coaching, A3s, Kaizen
04SustainHandover to line leadership
Adaptable to a 90-day plant diagnostic, a reliability sprint, or a full transformation.

Contact

If your plant needs a step‑change, let's talk.

Based in Vancouver, BC — open to remote & on-site across Canada

I work with manufacturing operations across BC and Canada — Lean transformation, TPM deployment, and Industry 4.0 integration. Best fit: multi-site CI programmes, plant turnarounds, and advisory roles where operational discipline drives financial results.

Bharat Kumar · Manufacturing Transformation & Operational Excellence