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PPG Architectural has selected Gemba Solutions to help improve the efficiency of its manufacturing plants in Birstall and Morley, UK.

PPG’s Birstall site houses a large manufacturing facility for decorative coatings, producing a range of brands such as Leyland and Johnstones.

Gemba Solutions was chosen to install its Gain4 Efficiency software at PPG’s sites.

‘The Gain4 software’s open architecture means that we can easily interface to existing systems on our sites, which helps future proof our operations,’ said Lee Riley, PPG manufacturing improvement manager.

‘Gemba’s team was able tailor the software to our needs with a common sense approach,’ he added.

During the initial pilot installation, the software gathered and reported on data from one area of the Birstall site.

Lee and his team were quick to make use of the data and within two weeks of full operation, output had doubled on the pilot line.

Speedy implementation of the system by Gemba has allowed PPG to immediately utilise the features of the software, which is now being rolled out across the rest of the plant.

Gemba Solutions sell software and services that maximize production efficiency.We are specialists in delivering tangible results quickly.


We can help you to:


*Slash production costs
*Increase capacity
*Eliminate waste
*Save energy
*Optimise labour


Here’s what some of our customers say:


“We saw a 10% increase in output from a key production cell by closer monitoring of the bottleneck machines.”


“Gemba Solutions’ software is allowing us to make significant savings throughout our manufacturing facilitiy each year. Through these savings, the system paid for itself in 6 weeks.”


“Over the first three months of the software’s use, we identified productivity savings of approximately £30,000 from just 2 machines.”

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