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Lean Implementation

A Leading Auto Electrical Unit

Project was all about creation of model Single Part Flow Production Assembly Line. Time period: 6-months.

Objectives were: a) Improvement of Productivity by 30%, b) Reduction of PPM level by 50% (Quality), and c) Reduction in inventories.

Results acheived were: a) 40% increase in Productivity, b) 65% reduction in PPM level, c) 55% reduction in WIP inventories, d) 44% reduction in overall inventories, and e) 25% savings in space. Important to note that space was a critical constraint and hence, it came handy.

Key activities taken up were: a) Revamping of

cellular line, b) Implementation of 2 - Bin System, c) Cycle Time improvements through Video Studies, d) Hourly feeding of materials deploying Water Spider, e) Line balancing and employing Rabbit Chase concept, f) Avoiding wastes in material feeding by adopting direct feeding instead of multiple material handling, g) Reorganizing stores with better Visual Control & h) Improving overall 5S.

A Chassis Manufacturing Shop of a leading Automobile Company

Project was about enhancing value in Chassis Manufacturing process through eliminating wastes by application of Lean Principles. Duration: 9 - Months

Key objectives were: a) Improving Ergonomics (EEI), b) Improvement in Quality level from 191 DMP to 100 DMP, c) Improvement of 5S up-to 70% or more, d) Reduction of WIP’s, e) Organizing Warehouses in such a manner that FIFO is followed as system & inventories can be better managed, f) Improvement in Productivity by 20 - 30% and g) Safe work Environment eliminating Accidents & Incidents.

Basic theme considered was to declare a war against a) Too Messy, b) Too Much, c) Too Heavy and d) Poor Visual Control.

Typical results achieved were: a) 5S Level improved from 35% to 78% winning Second Position in 5S Excellence Award by AOTS - ABK, b) Quality level improved to below 100 DMP level, c) WIP reduced from 8 hours to 2 hours, d) Savings in space over 20%, e) Better utilization of operators due to streamlined material flow and deployment of Water Spiders, f) Avoidance of Excess / Non-Moving Stocks, g) Excellent Visual Control deploying better / smaller trolleys, bins etc.

A Lighting Unit

Project was deployment of Lean concept for increased cost competitiveness. Project Duration: 6 Months.

Results achieved were: a) Clean & Tidy Shop, b) Safer Work Environment, c) 16-22% reduction in direct manpower in 2 different shops, d) 20% reduction in inventories and e) 15% savings in space.

Typical activities taken up were: a) Re - laying out of Lines, b) Resolving critical issues concerning Quality and Production, c) Implementation of Standing work culture, d) Overhauling of Stores, e) Direct material feeding in between machines, f) Better utilization of manpower, g) Operators owning responsibility of cleaning own machines / work stations etc.

A Leading Switch & Socket Manufacturing Unit

Project was deployment of Lean concepts for increased productivity, quality and customer satisfaction. Project Duration: 6 Months

Results achieved were: a) Clean, tidy & a Visual Factory, b) Set-up time reduction in Moulding Shop by 60%, c) Increase of Productivity by 40-60% for different product assembly lines, d) Sharp reduction in Customer Complaints, e) Creation of a World-class Lab, f) Rearranging RM & FG Stores with FIFO and Quantity Control.

Typical activities taken up were: a) Cycle Time study & improvement, b) Adoption of Rabbit Chase concept in Assembly Lines, c) Rationalizing work contents of operators for better utilization, d) Creation of

Works and up-gradation of work Stations incorporating 2-Bin System, e) Material feeding frequently @ one hour by Water Spider, f) Improvement in packaging of outsourced items to facilitate direct material feeding, g) Employing concept of 3-Fixed in Stores including adoption of FIFO Tags & Quantity Control System, h) Streamlining Packaging & Dispatch process etc.

A corporate office of a leading Group of Industries

Project was establishing World-class 5S. Time Period: 3-Months

Result of the drive was: A clean, Tidy & Shining Office with basic concept of " A place for everything and everything at its place."

Areas covered were all offices, IT Room and canteen.

A Bus Body Building Shop of a leading Automobile Company

Project was to implement Lean Concept in Manufacturing Line and achieving World-class features including improvement in Warehousing system. Project Duration: 9 Months

Key objectives were to improve 5S Level beyond 70%, Quality Level by 30% or more, reduce inventories and create safe Work Environment avoiding any accidents.

Typical Results achieved were a) 5S Level improved from 47% to 72%, b) Quality Level improved from 900 DMP to 430 DMP, c) Inventories reduced from Rs. 25 Cr. to Rs. 13 Cr., d) Zero accidents from original level of 2 accidents per month on an average, e) Much space savings, f) Implementation of 268 nos. of

Kaizens, g) Organized Stores with built-in FIFO etc.

Basic activities taken up were: a) Controlled material supplies to Work Stations Bus-wise, b) Introduction of special material handling trolleys with innovative approach, c) Creation of special FIFO racks, Bins etc., d) Reorganization of Work Stations, e) Numerous safety measures concerning Welding & other critical processes, f) Better Tool Keeping, g) Efficient deployment of 3-Fixed in Stores all over, h) Process Improvements for better / reliable Quality, i) Visual Control all over etc.

An Electrical Wire & Cable Unit

Project was about implementing basic 5S Culture, reorganizing stores and reducing wastes in manufacturing shop for increased cost competitiveness by deploying Lean Principles. Project Duration: 6-months

Results achieved were: a) Clean, tidy and Visual Shop, b) 25% reduction in direct manpower, c) 40% increase in productivity, d) 25%-30% reduction in WIP inventories, and e) Ease of storage and material handling.

Activities taken up were: a) Removal of excess machines, materials, work tables etc., b) Relocating of some of the machines and work stations, c) Organizing storage of WIP’s defining norms, d)

Re - laying out of FG Stores with built-in FIFO system, e) Deployment of Water Spider System for material feeding, f) Adoption of proper 5S & Visual control for materials, tools etc.

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