CURRENT STATE · T0
A floor with no signal.
- No hard KPIs – decisions made on „I think so".
- Daily firefighting instead of planned work.
- Churn eats know-how faster than HR can hire.
- Best operators know how to fix it – nobody asks.
01 / DIAGNOSIS
Your factory is losing 18% of its capacity. Every day. And no report will ever show it to you.
I combine the classic Japanese Lean school (Kaizen, TPS, Six Sigma) with proprietary AI tools running 100% offline. Your data never leaves your premises.
- MSc Eng. + 7 years of experience in international corporations
- Started on the shop floor
- Offline AI · Kaizen · Six Sigma
AI · 100% OFFLINE
KPI · 01
Capacity lost / day
18% ↘
PnWtŚrCzPt · · ·
Average hidden loss across manufacturers before Lean implementation.
Source: industry data and Lean literature on manufacturing SMEs.*
02 / SYSTEM DIAGNOSIS
Recognize this pain? It costs you real money. Every single day.
The 8 wastes (Japanese „muda") defined in the Toyota Production System. They don't show up on your P&L – because nobody ever puts them there. But they show up on your bank account.
- MUDA · 01
Overproduction
Capital frozen in goods nobody ordered.
You produce „just in case". Stock sits in the warehouse, loses value, ties up cash you'd rather spend on raw material.
Frozen cash flow - MUDA · 02
Inventory
A warehouse full of money you can't spend.
Every pallet of raw material and WIP is cash that isn't working. You pay to store it, insure it and count it.
5–15% of value / year - MUDA · 03
Transportation
Forklifts haul your profit between halls.
Every meter of internal transport adds zero value to the product. Customers don't pay for it. You pay for fuel, operator and time.
Operator hours, zero ROI - MUDA · 04
Motion
Your people walk for their wages. 8 km each, every day.
A poorly designed workstation means hundreds of unnecessary steps, bends and turns per day. Over a year: hundreds of hours and chronic back injuries.
Throughput + sick leave + churn - MUDA · 05
Waiting
A €500k machine idle because of a €0.50 screw.
An operator waits for material. The line is down. The shift lead chases a manager for a signature. Every minute idle is capacity you will never recover.
Lost production capacity - MUDA · 06
Over-processing
You deliver more than the customer ordered. They won't pay for it.
An inspection step required only by an outdated SOP. Polishing a surface the customer never sees. Three signatures instead of one. You waste time and material on a feature nobody buys.
Margin eaten silently - MUDA · 07
Defects
Complaints the customer no longer forgives.
Every defective product costs you twice: once at production, again at rework or return. A third time when the customer leaves for a competitor and tells their network.
Margin + reputation - MUDA · 08
Unused human potential
Your best operator knows how to fix it. Nobody asks.
The person at the machine sees what's broken every single day. They have a solution. But „it's not their job". Six months later they leave for a competitor – taking all your process knowledge with them.
Churn + lost know-how
03 / WASTE CALCULATOR
Calculate what you lose every day. No deck. No email. Right here, right now.
Four numbers from your company. Results update live. The numbers stay in your browser – they never leave.
Operators, shift leads, QC – anyone „on the floor".
€ / month
Gross + employer social charges. Not take-home.
Conservative estimate. Real audits often surface higher losses. Formula adds 15% fixed-cost overhead per additional shift (energy, depreciation, lease).
04 / TRANSFORMATION
From chaos to production rhythm. 90 days. Measurable. Without replacing the team.
On the left: your shop floor today – without a measurable process, you only have opinions. On the right: the same floor after a full Audit → Plan → Implement → Supervise cycle.
AFTER 90 DAYS · T+90
A floor that tells you what works.
- 5S boards, work standards, visual bottlenecks.
- Real-time daily KPIs (OEE, FPY, Lead Time).
- Operators raise Kaizen – and see the effect in 2 weeks.
- Shift leads run the process, not the exceptions.
Hard metrics – typical results of Lean transformations*
- M01 +22 pp
OEE
Overall Equipment Effectiveness
62% 84% - M02 −64%
Lead Time
Order to shipment
14 d 5 d - M03 −38%
WIP Inventory
Capital frozen in process
100% 62% - M04 −75%
Ergonomics
Operator walking / shift
8 km 2 km
* Reference values based on industry data, subject literature, and the author's own research conducted during university studies and a master's thesis. Improvement ranges depend on the initial state of the process and do not constitute a guarantee of results.
05 / SOLUTION
Three pillars. One goal: your profit. Classic school + custom software + offline AI.
Every transformation in the previous section runs on one of three pillars – or a combination of them. All three deploy on your premises. Not on us. Not in the cloud.
FOUNDATION
Lean & Six Sigma
The proven Japanese school.
VSM, SMED, 5S, Kaizen, TPM, DMAIC. Stabilize the process before you automate anything. Automating chaos just gives you faster chaos.
- VSM audit – full value-stream map
- SMED – changeovers cut by 40–60%
- 5S + work standards – visual bottlenecks
- Kaizen – operator-driven improvement loop
TECH
Custom Software
Semi-automatic spreadsheets that do what your ERP can't.
Files that replace the work of three people. Generators producing technical drawings and 3D models straight from your database. Quoting calculators, production dashboards and integration scripts – tailored to your process, not to a market average.
- Semi-automatic Excels – what ERP won't do
- Drawing & 3D model generator from your database
- Quoting and cost-estimation calculators
- Integration scripts across systems (ERP/MES/CAD)
AI · OFFLINE
Agentic AI (Offline)
AI that doesn't leak.
Local LLMs and computer-vision models running on your own servers. The Muda analyzer reads waste straight from CCTV footage. The voice-to-SOP generator turns 30 minutes of recording into ready documentation – instead of 3 days of an engineer's writing. Anomaly detection on MES streams.
- Muda analyzer from video – CV waste detection on the floor
- Voice-to-SOP generator – 30 min audio → ready procedure
- Anomaly detection on MES data streams
- Operator assistant – RAG over technical docs
- LOCAL MODEL
- 100% PRIVATE DATA
- NO CLOUD
06 / PROCESS
From audit to sovereignty. 5 steps. Hands-on. Zero PowerPoint theory.
Every project runs the same disciplined sequence. I don't take two clients in parallel – when I walk onto your floor, you are my only customer for the quarter. Here is exactly what you receive at each step.
DEPLOYMENT PATH · 8–12 WEEKS
-
Audit & VSM
A Gemba Walk on your floor. Notebook, stopwatch, safety boots.
I physically walk the line with operators and shift leads. I measure takt, identify bottlenecks, document the cash leaks no executive sees from the office. Output: a value-stream map of the current state, with hard numbers – not opinions.
DELIVERABLE - Current-state VSM report (PDF, ~30 pages)
- Cash-leak inventory with estimated annual cost
- Bottleneck map with photographs and measurements
-
Outcome Architecture
We don't fix everything. We fix what earns the fastest.
From the loss inventory we pick 3–5 areas with the highest ROI and shortest implementation time. The rest goes into a backlog for cycle two. Every action gets a time budget, success KPI and an owner on your side. No „culture transformation" hand-waving.
DELIVERABLE - Project roadmap with ROI prioritization (Gantt + table)
- Time and cost budget per action item
- RACI responsibility matrix
-
Frontline Work
I'm on the floor, not in the boardroom.
Kaizen workshops with operators, workstation layout changes, 5S implementation, deployment of proprietary tools (Excel, offline AI, MES dashboards). I stand next to the person at the machine and explain why the change matters to THEM – not the CEO. That's why there is no resistance.
DELIVERABLE - New workstation layout (technical drawings + photos)
- 5S boards and visual work standards deployed
- Proprietary AI/Excel tools running locally
-
Stabilization & KPI
Hard numbers every week. No excuses, no „I think so".
Every Monday – a KPI report for the previous week: OEE, FPY, Lead Time, Muda reduction. If a metric isn't moving as planned, I correct the approach within 48 hours. This is where I differ from competitors: I don't vanish after deployment – I stay until the process is stable.
DELIVERABLE - Real-time KPI dashboard (local, offline)
- Weekly reports with deviations from plan
- 48-hour correction plan for every red metric
-
Sovereignty Transfer
Your company must run sharply once my contract ends.
Training internal leaders (shift leads, process engineers) into full owners of the Lean system. Handover of SOPs, Excel calculators, AI tool documentation. Goal: 90 days after I leave, the company generates Kaizens on its own, monitors KPIs on its own, optimizes on its own. No dependence on me.
DELIVERABLE - Full visual SOP set (PDF + shop-floor posters)
- Quoting and costing calculators (Excel with macros)
- Trained internal leaders with Lean competency certification
I didn't learn about manufacturing from textbooks or in air-conditioned conference rooms. I built my experience directly on the shop floor, solving real problems and analyzing processes shoulder to shoulder with operators and maintenance.
The people on the floor can sense my experience and my approach within the first 5 minutes. That's why they stop resisting change. They talk to a theorist in a suit very differently than to an engineer who has spent thousands of hours on the floor. On the floor, I don't build authority through job title. The people at the production lines talk to me openly, because they know I understand their real problems – not just numbers in a spreadsheet. I'm not afraid to dig deep into the process, get my hands dirty, and look for solutions where the waste actually happens.
07 / ABOUT
An engineer's approach. Frontline experience.
No metaphors. Only numbers, tools and outcomes. Three worlds – shop floor, academia, corporate – woven into a single, repeatable optimization method.
- ⊕ VBA Advanced Excel
- ⊕ PYTHON AI · automation
- ⊕ KAIZEN TPS / Six Sigma
- ⊕ LOCAL LLM Offline RAG
-
[FIELD SERVICE] Service Engineer MRI scanner field service, work with cryogenic liquids. Oversight of logistics and helium-tanker orders (USA, Qatar). Critical maintenance discipline.
-
[R&D DESIGN] Design Engineer Design and prototyping of HVAC systems. Project delivery for global automotive and industrial OEMs. Documentation standardization, CAD/SAP training.
-
[PRODUCTION LAUNCH] Design Engineer Development of new industrial valve designs. Engineering oversight of a new production line launch in China. Cost optimization and production support.
-
[PROCESS CONSULTING] Project Engineer / Consultant Design, optimization and relayouts of large-scale warehouses and intralogistics (projects for leading logistics and pharmaceutical brands).
Mateusz Mrugała. MSc Eng. – Mechanical Engineering (Wrocław University of Science and Technology) + Strategic Management (WSB Merito).
My approach rests on a simple truth: to optimize a production process with code, you first have to understand the physics of the machines and the psychology of the people on the floor. As a mechanical-engineering graduate, I don't look at a factory as a pile of abstract data in the cloud, but as a living, cooperating organism where every second of takt time counts.
Experience gathered designing systems, supervising international supply chains and running relayouts of large logistics facilities taught me a rigorous approach to quality standards. I translate that knowledge into proprietary systems: instead of theory I deliver tools that automate the work of process engineers, cut employee onboarding times and safeguard the company's key know-how.
MOD-01 / SHOP FLOOR
Practice
Shoulder to shoulder with operators. Takt-time measurements, Muda elimination directly at the cells. Not from a conference room.
MOD-02 / ACADEMIA
Precision
Engineering foundations (MSc Eng. PWr + WSB). Mathematical precision, design of algorithms and offline analytical systems.
MOD-03 / CORPORATE
Scale
Rigorous automotive standards (IATF, PPAP, APQP). The reality of large-scale rollouts. ROI language for the board.
-
Python
Process automation, local analytical scripts, specification generators.
-
VBA + advanced Excel
Semi-automatic engineering macros and bespoke ROI calculators tailored to each process.
-
Lean / Six Sigma
VSM, SMED, 5S, layout optimization (CAD), bottleneck management.
-
CAD Systems
Catia V5, Inventor, HiCAD, SolidEdge, AutoCAD, SAP ECTR.
Now you know who will stand by your machine. See how I run the project.
08 / SECURITY
Your AI safer than the cloud. Not marketing. Architecture.
Every SaaS claims to be „secure". Most send your data across 3 continents before they generate an answer. I built this differently. Below is the exact data flow – ready for an audit by your IT team.
CLOSED-LOOP TOPOLOGY
DRAWING N° SEC-001 · REV.A 4 pillars of deployment security
Edge Computing
Inference on your own hardware.
AI computation runs exclusively on your workstation CPU or local server. Zero external API calls. Zero data transfer outside your infrastructure.
- CPU x86_64 / GPU NVIDIA optional
- Inference latency: <2s typical
- Zero per-token cost
No network access
Scripts run without the internet.
My Python tools and Llama-3/Mistral models don't require an internet connection to operate. We can deploy in a fully isolated network (air-gap) – the standard in defence and pharma sectors.
- Air-gap deployment supported
- Offline package + SHA-256 checksums
- No „auto-update" – control stays with you
Data sovereignty
The model and data stay with you.
After deployment: the model, vector database, documentation and logs remain on your hardware. I have no remote access. I don't remain admin. There is no „kill-switch" on my side.
- Zero backdoor / zero kill-switch
- Keys and passwords under your control
- Full source code handover at the end
Excel as the safe layer
A format your IT has known for 25 years.
Where AI isn't needed, I use semi-automatic Excel files with VBA macros. A tool your IT department already has audit procedures for – no new vendors, no new DPAs, no new risks.
- Microsoft Excel + VBA (no add-ins)
- No new DPA / SCC contracts needed
- Compatible with your existing IT backup
09 / CONTACT
Let's stop the cash leak in your company. 30 minutes. No slides. No sales jargon.
Fill in a short diagnostic brief. I'll reply within 24 business hours with a proposed slot for a technical call – just numbers and concrete options for your process.
DIAGNOSTIC LEAD FORM
Data stays with us – it never enters any CRM.