Kaizen and Suggestion Systems for Manufacturers, Without the Paperwork

Most plants already know how to run improvement schemes. What stalls them is the paperwork, the response time, and the shift workers who never get a login. This page is about what a suggestion system has to do for a 50 to 150 person plant, and how Harmoni handles it.

What most plants already have

Walk around a typical 100-person plant and you will find some version of the same setup: a kaizen board in the canteen, a suggestion box near the clock-in point, a monthly CI meeting, 5S walks, and a spreadsheet that somebody updates when they remember. None of that is wrong. It is how improvement has worked for decades.

Then the familiar failure points show up:

  • Ideas go into a folder and the person who wrote them hears nothing back.
  • Shift workers without a desk, a work email address or a company laptop never take part.
  • Safety and process suggestions that need to be anonymous never get submitted.
  • Supervisors cannot see one queue. Ideas arrive by paper, WhatsApp, email and a shout across the shop floor.
  • Nobody can say how many ideas came in last month, how fast they were answered, or what any of it saved.

What a digital suggestion system has to do

  • Work on a phone in under two minutes. Browser, no app install, no company email needed for the submitter.
  • Take anonymous suggestions. That is where the honest ideas about process and safety come from.
  • Keep categories simple. Safety, quality, cost, maintenance, process, environment. If a supervisor cannot pick a category in a second, you have too many.
  • Give each supervisor one queue with approve, revise or shelve decisions, and a status the submitter can see.
  • Hold a first-response time. 48 hours for an acknowledgement is achievable and it is the single thing that keeps people submitting.
  • Run a campaign against a real problem, for example changeover time on one line or waste in one cell, with a deadline.
  • Recognise across shifts. A leaderboard that only ever names day shift will kill participation on nights.
  • Report by area: ideas submitted, answered and implemented, by department or site, not just a total.

How Harmoni maps to that list

  • Runs in any browser on desktop, tablet or phone, so it reaches the shop floor without new hardware.
  • Employees join through an invitation link and use it in the browser. No Microsoft licence required.
  • Configurable submission form. Keep it to description, area and expected benefit for shop floor ideas, and switch on budget, timeline and risk fields for larger proposals.
  • Anonymous idea submissions at every band.
  • A manager review queue: approve, ask for a revision, or shelve with a reason, with feedback going back to the submitter.
  • Innovation challenges for a specific line, cell or site, with a deadline and a company portal for announcements.
  • Points, badges and leaderboards, so night shift gets the same recognition as day shift.
  • AI assistance that turns a rough note into a structured proposal, and AI scoring to help managers triage the queue.
  • Analytics, reporting and export of submissions.

The product detail is on the features page.

Why flat pricing matters on a shop floor

Per-seat pricing forces a choice nobody wants to make: which shifts get to take part. Every plant has more people than licences under a per-user model, and the people who lose out are usually the ones closest to the work. Harmoni is priced by the size of the organisation, so the whole workforce can be in the system, including nights, maintenance and the agency staff you expect to keep.

Harmoni planOrganisation sizePriceSeats
StarterUp to 50 employees£99 / monthAll employees included
Team51-150 employees£249 / monthAll employees included
Growth151-400 employees£399 / monthAll employees included
401-1,000 employeesWhole organisation, one flat price£699 / monthAll employees included
1,001-2,000 employeesWhole organisation, one flat price£1,199 / monthAll employees included

Harmoni prices as listed on this site in September 2026. Flat bands by employee count, all employees included, no per-seat charges.

A 30-day start plan for one plant

  1. Week 1: pick one area and one real problem. Agree the categories, decide who reviews what, and brief the shift supervisors before anyone else.
  2. Week 2: launch a challenge to that area only. Put a short link or QR code by the clock-in point and on the noticeboard, and hold supervisors to a 48-hour first response.
  3. Week 3: run the first reward cycle and post the results on the noticeboard and in the company portal. Add a second area.
  4. Week 4: review response times and participation by shift. Fix the slowest step, then open it up to the rest of the plant.

Honest limits

  • It is not a full lean or CI suite. No gemba tooling, no OEE dashboards, no document control, no ISO audit pack.
  • Anonymous suggestions are not a replacement for a formal accident and near-miss reporting process. Keep the two separate and say so in your policy.
  • If your whole plant runs on Microsoft 365 and you specifically want the tool inside Teams, a Teams-native app may suit you better. We explain the trade-offs on the Microsoft Teams page.

If you are starting from paper, the UK suggestion scheme guide covers the policy, the reward rules and the response cadence that make any of this work.

Common Questions

It is the same continuous improvement loop most plants already run, moved off paper: employees submit improvement ideas from a phone or terminal, ideas go into one review queue per supervisor, every submitter gets a status and a response, and the results are visible across shifts and sites.

Employees join through an invitation link sent to an email address, work or personal, and then use Harmoni in any phone browser. There is no app to install and no Microsoft licence needed, which matters if only office staff have M365 seats.

Yes. Anonymous submissions are part of the product at every band, which is what gets the awkward but useful ideas about process, tooling and supervision into the system.

No. Harmoni is idea capture, triage, review and follow-through. It does not do gemba walk tooling, OEE dashboards, document control or ISO audit packs. If you need an integrated lean platform, buy one, and we will say so rather than pretend.

£249 a month for 51-150 employees, with every employee included. There are no per-seat charges, so you can invite all three shifts without watching a seat count. Monthly billing in GBP, no annual lock-in, 14-day free trial with no card.

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