Paul Ducey
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Consulting · workshops · fractional · talks

Work with me

I take on a small amount of outside work. It runs the way I work at Solar: go see first, measure before and after with a source for every number, and leave the team able to run it without me. I'm also open to Director and VP of Operations roles in New England or remote.

01

Half a day · on site · your floor, your data

AI at the Gemba workshop

For a CI team or a plant leadership group that wants to use AI assistants without losing the floor. It's the talk, run on your own process.

  1. We walk one process together before anyone opens a laptop.
  2. The five principles: source tags on every number, poka-yoke for data, observe before solving, coach before drafting, respect for people.
  3. A live run on one of your own exports, an OEE or a value stream, with every formula shown and every unknown marked [NEEDS GEMBA].
  4. Everyone sets up the free toolkit and drafts one real deliverable before we finish.

You finish with: a working setup for the team, a data-safety rule for what goes into an AI tool, and a list of what to go look at on the floor.

02

90 days · one value stream · measured before and after

Flow sprint

For a line or a department where work waits more than it moves. One value stream, from walk to standard.

  1. Weeks 1 to 2: walk the stream, map the current state, and baseline lead time, throughput and the bottleneck, each with a source.
  2. Weeks 3 to 10: kaizen events on the biggest losses, run with your people, one A3 per problem.
  3. Weeks 11 to 13: standard work and a daily management rhythm to hold the gains, then measure again.

You finish with: a before-and-after you can defend, the standard work, and a team that knows how to run the next one.

03

Ongoing · a few days a month

Fractional operations leadership

For teams without a CI lead or a Director of Operations, or between hires.

  1. Tiered daily management that people actually look at.
  2. A3 coaching for the problems that keep coming back.
  3. Planning and capacity work, from demand back to the schedule.
  4. Hiring and developing the person who eventually replaces me.

You finish with: a management system your own people run.

04

Conferences · leadership teams · plant all-hands

Talks

"AI at the Gemba" is on at the GBMP 22nd Northeast Lean Conference on September 29 and 30, 2026. It adapts to a leadership offsite or a site all-hands.

  1. The deck and the handout are public, so you can see exactly what you would get.

You finish with: a talk your people can act on the next morning, with the free toolkit to go with it.

How I work

Four rules I don't bend

  • 1Go see first. No recommendation before time on the floor.
  • 2Numbers carry sources. Observed, from the system, or estimated, and it says which.
  • 3Build it so the team runs it. If it needs me to keep working, it isn't finished.
  • 4Respect for people. Freed capacity is a leadership decision, not a headcount plan.

What I've done

Packaging at Solar went from cost center to roughly three quarters of its capacity co-packing for other brands. A redesigned trim process moved bud-to-shake 57% → 76%. Before that: two generations of a connected medical device, and the Citi Bike NYC launch.

Work with me

Tell me what's on your floor.

A 20-minute call is enough to know whether I can help. If I can't, I'll say so and point you to someone who can.