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Lean Manufacturing & Supply Chain Consulting

PhD-Level Expertise for Operational Excellence

We partner with manufacturers to eliminate waste, optimize supply chains, and build world-class operations — backed by 45+ combined years of Fortune 500 experience.

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What We Do

Six Domains of Expertise

From lean transformation to AI-enabled operations, we bring deep technical knowledge to every engagement.

Lean Manufacturing & Six Sigma

Value stream mapping, waste elimination, DMAIC methodology, and 3-tier lean transformation systems.

Supply Chain & Distribution

Strategic sourcing, inventory optimization, distribution network design, and 3PL management.

Design for Excellence (DfX)

Design for manufacturability, assembly, testing, serviceability, and supply chain integration.

AI-Enabled Operations

Demand forecasting, predictive maintenance, Industry 4.0 integration, and AI + Lean synergies.

New Product Development

Prototype-to-scale transfer, life cycle cost management, and production readiness systems.

Acquisition Integration

Post-M&A operational integration, manufacturing consolidation for PE-backed companies.

Why Lean Ops Gurus

Built on Real-World Results

We don't just consult — we've led operations at Fortune 500 companies, built lean cultures from the ground up, and published peer-reviewed research on manufacturing excellence.

2
Doctoral Degrees (MIT, Lamar)
45+
Combined Years of Experience
6+
Fortune 500 Companies Served
4
Countries of Operations
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Ready to Transform Your Operations?

Let's discuss how PhD-level lean and supply chain expertise can drive measurable results at your organization.

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Our Services

Six Domains of Manufacturing & Operations Expertise

Each engagement is led by senior practitioners with doctoral credentials and decades of hands-on experience in complex manufacturing environments.

Areas of Focus

What We Work On

We are a senior, execution-focused boutique lean consulting firm. Every engagement is led hands-on by our partners — no junior staff.

  • Value Stream Mapping Kaizen (current & future state)
  • Transaction Process Improvement Kaizen
  • Factory Layout Improvement & Cell Design Kaizen
  • Gemba Walks (shop floor observation)
  • Tier 1, 2 & 3 Boards for Visual Management & Problem Solving
  • KPI Baseline & Cost-of-Waste Quantification
  • Prioritized Improvement Roadmap
  • 5S
  • Line Balancing / Load Balancing
  • Setup Reduction (SMED)
  • Kanban / Pull Systems
  • Bottleneck Elimination
  • Make-Buy Supply Chain Strategies
  • Delayed Differentiation Model
  • DfX (Design for Manufacturing, Reliability, Supply Chain, Cost)
Engagement Packages

Four Ways to Work With Us

Fixed-fee engagements. No surprises. All travel expenses within the continental US are included.

Package A

Executive Diagnostic Sprint

2 Days On-Site
$10,000

All travel included (continental US)

Best for: CEOs / COOs wanting a quick expert point of view, pre-deal due diligence, post-acquisition triage, factories with unclear bottlenecks, supply chains with cost and delivery constraints.

What We Deliver

Day 1

  • Gemba walk (shop floor + warehouse) or Supply Chain Value Stream Mapping
  • Leadership interviews
  • KPI scan — leading and lagging indicators, SMART KPIs

Day 2

  • Issue Prioritization Workshop
  • Core problem framing (constraints, flow issues)
  • Executive readout
Deliverables
  • 8–12 slide executive summary
  • Top 5–7 prioritized opportunities
  • Rough-order-of-magnitude savings estimate
  • Recommended next steps (roadmap lite)
Package B — Most Popular

Deep Dive + Kaizen Launch

1 Week On-Site
$24,000

All travel included  ·  Optional: Add 4 remote follow-up sessions for $3K

Best for: Clients ready for action, not just diagnosis. Plants with leadership buy-in. Clarifying operational inefficiencies and launching real improvement.

What We Deliver

Days 1–2

  • Full diagnostic (expanded)
  • Value Stream Mapping (current state)

Days 3–5

  • Run 1 Kaizen event (e.g., Manufacturing Layout, Future State VSM)
  • Quick wins: 5S zone, line balancing, bottleneck fix
  • Train client team live
Deliverables
  • Future-state value stream map
  • Implemented improvements (visible on floor)
  • KPI baseline + improvement targets
  • 30–60 day execution plan
Package C

Transformation Sprint

2 Weeks On-Site
$35,000

All travel included (continental US)

Best for: Factories needing real operational turnaround. PE-backed companies under pressure. Operations with measurable cost and capacity issues.

What We Deliver

Week 1

  • Full diagnostic + value stream mapping
  • Kaizen Event #1 (flow / bottleneck focus)

Week 2

  • Kaizen Event #2 (setup reduction, pull system, or layout)
  • Daily management system setup
  • Leadership coaching
Deliverables
  • 2 implemented improvements (hard results)
  • Measurable KPI movement (early indicators)
  • Visual management system installed
  • 90-day transformation roadmap
  • ROI model (credible, not theoretical)
Package D

Monthly Advisory & Sustained Improvement

Long-term transformation support. Same-day response on key issues. Up to 40 hours of remote work and support per month. Minimum 3-month commitment.

$10,000/month

3-month minimum

Day Rate Reference

Managing Partner (on-site)$2,500/day
Lean Transformation Advisor (on-site)$2,500/day
Blended rate (both partners, on-site)$4,500/day
Video / Remote Consulting$300/hour
Travel time (actual hours)$300/hour

No travel cost for same-city engagements. Flight, hotel, rental car, and meals billed at cost for custom engagements outside fixed-fee packages.

Let's Talk

Which Challenge Can We Help You Solve?

Every engagement begins with a no-obligation assessment of your current operations and a clear roadmap for improvement.

Request a Free Assessment
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About Us

Where Academic Rigor Meets Manufacturing Reality

Lean Ops Gurus was founded on a simple premise: the best consulting comes from practitioners who've done the work themselves.

Our Story

Founded by Operators, for Operators

Lean Ops Gurus, LLC brings together two senior manufacturing leaders with doctoral-level training and decades of hands-on operational experience at companies like GE, Danaher, Fortive, CVS Health, Schlumberger, and Baker Hughes.

We've led lean transformations that won company-wide recognition, managed FDA-regulated medical device manufacturing, turned around underperforming plants, and deployed lean systems across six locations in four countries.

Our consulting practice is built on the belief that lasting operational improvement requires deep technical knowledge, cultural understanding, and executive-level strategic thinking. We don't send junior consultants to do senior work — every engagement is led by a PhD-level practitioner with real P&L accountability.

Based in the Austin, Texas area, we serve manufacturers across the United States and internationally.

Leadership Team

Meet the Partners

Omar A. Hasan, PhD
Omar A. Hasan, PhD
Founder & Managing Partner

Dr. Hasan holds a PhD in Mechanical Engineering from MIT (4.9/5.0 GPA, full financial aid) and is a GE Certified Master Black Belt. He holds 2 US Patents and brings 20+ years of progressive leadership in lean manufacturing and operations.

Most recently, he served as Executive Director at CVS Health, where he led a distribution site to win the Lean Culture Transformation award across all 17 distribution centers. Previously, he held the role of Director of Manufacturing at Fortive, overseeing FDA-regulated, ISO 13485 medical device production.

His career spans senior roles at GE, Danaher, and SLB, with deep expertise in lean, Six Sigma, DfX, supply chain, distribution, and new product development across medical devices, electronics, distribution, and oil & gas industries.

  • PhD, MIT Mechanical Engineering
  • GE Certified Master Black Belt
  • 2 US Patents
  • Medical Devices
  • Electronics
  • Distribution
  • Oil & Gas
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Dr. Pugalenthi Pandian
Dr. Pugalenthi Pandian
Lean Transformation Advisor

Dr. Pandian holds a Doctor of Engineering in Industrial Engineering from Lamar University, with a dissertation focused on Quick Response Manufacturing. He is a certified Lean Six Sigma Master Black Belt with 25+ years of lean manufacturing expertise.

Currently serving as VP of Operations and General Manager at Ultra Clean Technology in Austin, TX, Dr. Pandian brings executive-level operational leadership to every engagement. Previously, he was Senior Plant Manager at Baker Hughes and spent 22 years at Schlumberger across Singapore, Houston, Shanghai, and Belfast.

He is an internationally recognized expert in High Mix Low Volume (HMLV) lean manufacturing, with 3 published academic papers and speaking engagements at the Asian Lean Six Sigma Summit. His experience spans operations across 6 locations in 4 countries.

  • Doctor of Engineering, Lamar University
  • Lean Six Sigma Master Black Belt
  • 25+ Years Lean Experience
  • 3 Published Papers
  • Semiconductor Equipment
  • Oil & Gas
  • Automotive
View LinkedIn Profile
Work With Us

Put Our Experience to Work for You

We bring the same rigor, discipline, and results-orientation to your operations that we've delivered at the world's best companies.

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Get in Touch

Let's Discuss Your Operations Challenge

Whether you need a full lean transformation or a focused assessment, we'd love to hear from you.

Contact Information

Reach out directly or fill out the form. We typically respond within one business day.

Email

hasan@leanopsgurus.com

Location

Los Angeles, CA Metropolitan Area

Service Area

United States & International

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