Lean Transformation & Operational Excellence

Better performance doesn't come from working harder.
It comes from improving the system.

Before we talk solutions, I'll show you exactly where your operation is losing capacity, and why. Then we fix it together. The scorecard is where we start.

Take the 5-min scorecard See my work
Charlotte Cordier
Charlotte Cordier
Senior Transformation Consultant · Sydney, AU
Lean Six Sigma Hoshin Kanri Kaizen TPM DMAIC AI & Digital Operations
17+
Years Experience
APAC & USA
Geographies
50+
Improvement Initiatives Delivered
Mean time between failures: 20 min → 10 hours $3M+ cost savings identified 900-person safety culture transformation 70% output increase in 4 weeks Mean time between failures: 20 min → 10 hours $3M+ cost savings identified 900-person safety culture transformation 70% output increase in 4 weeks

I don't just recommend improvements. I work alongside your team until the results are real and the capability sticks.

Lean Expert MIT Negotiation Master of Industrial Engineering CPSI Certified French · English · Spanish

About

Hands-on, data-led,
people-first

With 17+ years transforming operations across manufacturing, defence, energy, and pharmaceuticals, I've developed one strong conviction: the best improvement tools in the world deliver nothing without people who believe in them.

I was professionally shaped within one of the world's leading Lean practitioner networks, working alongside globally published authors and recognised experts. My work spans enterprise diagnostics, strategy deployment, Kaizen programs, daily management systems, capability coaching, and AI-enabled workflow design, always grounded in data and always focused on results that last.

I'm based in Sydney and work across Australia and globally.

Master of Industrial Engineering, ECAM France
Negotiation & Influence for Executives, MIT Sloan
Creative Problem-Solving Leadership, CPSI Buffalo NY
Lean Six Sigma Green Belt, SAI Global
NSW AME Committee Member

Selected clients & affiliations

Association for Manufacturing Excellence Honsha Thales AstraZeneca Essilor Landis+Gyr SBS Flexcon DSI Underground AGL Hanes Fenner Dunlop Service Stream Association for Manufacturing Excellence Honsha Thales AstraZeneca Essilor Landis+Gyr SBS Flexcon DSI Underground AGL Hanes Fenner Dunlop Service Stream

My Approach

A methodology built for
lasting results

Every engagement starts with deep diagnosis. No two organisations are the same, so I resist off-the-shelf solutions. What you get is a structured process tailored to your constraints, your people, and your ambition.

1

Diagnose

Performance data, process mapping, workflow analysis, cultural assessment, and stakeholder interviews. I get under the skin of your operation before prescribing anything.

→ Diagnostic report & prioritised improvement roadmap

2

Align

Collaborating with leadership to translate organisational strategy into aligned priorities, cascaded targets, and executable plans, using Hoshin Kanri and Strategy Deployment principles.

→ Strategy A3, aligned KPIs, and cadence design

3

Transform

Kaizen events, system redesigns, daily management implementation, rapid improvement workshops. We address variability, waste, and constraints, and measure every step.

→ Measurable improvements across output, quality, and lead time

4

Sustain

Structured coaching, Leader Standard Work, development workshops, and governance rhythms that transfer capability, so your team sustains and scales improvement independently.

→ Embedded capability, coaching plans, management systems

Case Studies

Results across
complex environments

From a pharmaceutical line lifted from 58% to 77% OEE, to a 900-person safety culture transformation — measurable results across manufacturing, defence, energy and mining.

View case studies

Free · 5 minutes

How much capacity is hiding in your operation?

Answer a few questions about flow, quality and capacity, and get an instant read on where performance is leaking — and what to fix first.

Take the scorecard →

Services

How I can help

Whether you need a focused diagnostic, a rapid improvement program, or someone to coach your team over the longer term, engagements are designed around your situation, not a standard package.

Operational Diagnostic

A rigorous read on where your operation is losing time, quality and capacity — delivered as a prioritised, costed roadmap.

Typically includes

  • On-site observation and data collection
  • Stakeholder interviews and value-stream mapping
  • Prioritised roadmap with ROI

Rapid Improvement Programs

Focused 6–12 week programs that attack one constraint — throughput, lead time or quality — with measurable results.

Typically includes

  • Kaizen events and structured problem-solving
  • Workflow redesign and pull systems
  • Daily management and standard work

Capability & Coaching Programs

I build improvement capability into your team, so the gains don't leave when I do.

Typically includes

  • Leader Standard Work coaching
  • Practitioner development workshops
  • Tiered Daily Management

Strategy Deployment

Hoshin Kanri facilitation that turns strategy into aligned priorities, targets and a cadence that sticks.

Typically includes

  • Executive strategy workshops
  • A3 and X-matrix development
  • Cascaded KPIs and review cadence

M&A Operational Due Diligence

Pre- and post-acquisition assessments that quantify productivity upside, surface risk and model investment scenarios.

Typically includes

  • Current-state operational assessment
  • Capacity and scalability modelling
  • Risk and constraint identification

AI and Digital Workflow Design

AI-enabled workflows and automations that cut manual overhead and free your team for higher-value work.

Typically includes

  • Digital workflow analysis and redesign
  • AI and low-code prototyping
  • Automation of reporting and tracking

Who I Work With

The right fit for
the right challenge

  • Manufacturers under capacity pressure

    You're leaving output on the table and you know it. The bottlenecks are real but unclear. You need someone who can find the constraint, fix it fast, and protect the gain.

  • Leaders who want to build capability, not dependency

    You're tired of improvement projects that fade the moment the consultant leaves. You want your own people to be able to diagnose problems, solve them, and hold the line.

  • Organisations navigating growth or M&A

    You're scaling up, integrating an acquisition, or entering a new market. You need operational clarity and rigour before you commit capital and headcount.

  • Complex, regulated environments

    You operate in defence, pharma, mining, or energy, where the stakes are high and the tolerance for error is low. I've worked in these environments for 17+ years. I understand the constraints.

Industries I've worked in

Mining Equipment Pharmaceuticals Defence Manufacturing Energy & Mining Consumer Goods Optics / FMCG Broadcasting Bedding & Retail Navy / Defence Smart Metering Fashion & E-Commerce

Get In Touch

Let's talk about
your operation

The best starting point is usually a conversation. Tell me what's frustrating you, what you're trying to achieve, and what you've already tried. We'll figure out together whether there's a good fit.

info@charlotte-cordier.com Connect on LinkedIn Sydney, NSW, available nationally and globally