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Success case study
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Issues / Struggles
Tool / Technique Application
Delivery delay / low Capacity Utilization
OEE improvement in Fabrication and Assembly lines, People engagement, Inventory Management
Manufacturing lead time reduction by 50 %(21 days to 10 days)
Eroding profitability / Low manpower Produtivity
OEE Improvements, Setting time reduction, Low cost automation, KPI focus, Maintenance Management, People Engagement
Production Capacity Enhancement per day increased by 22 %; Setting time reduction from 4.5 hrs to 2 hrs; Profitability in crease by 3 times
Precision Comp Mfg
Delivery issue / Low plant utilization
OEE improvement , Flow Improvement, Cycle time reduction, Build in Quality initiatives, Inventory management
Plant manpower productivity increase by 27 % ; Production Schedule actualisation improved from 76 % to 96 % ; Overall manufacturing cost reduction by 7 % ; Inventory reduction by 60 %
Delivery issue /Negative operational profit
OEE improvement, Setting time reduction; Structured problem solving, KPI focus, daily management
100 % delivery improved; setting time reduction from 4.5 hrs to 1 hr; 25 % manpower productivity improvement ; 8 % improvement in material yield
Delivery back log and Team morale issues
OEE Improvements, Flow manufacturing, KPI focus, Daily management
39 % sales turn over increased.
Delivery backlog / low productivity / lack of daily management
OEE focus, Line balancing, Relay out from process to product, Setting time reduction, Cycle time reduction, KPI focus, daily management
28 % reduction in mfg cost; Mfg lead time reduction from 10 days to 4 days
Al Casting Mfg
Delivery backlog / Losing of customers / Negativeprofit
Performance management, Industrial Engineering, Daily work management
Business turnover increase by 45 % , Loss making to profitability; Customer service improvement-from 60 % to > 85 %
Delivery backlog / Growth stagnation
Performance management, Lean Iniativies, Daily work management
Business turnover increase by 34 %
Auto Component Mfg
Delivery backlog / brim capacity utilization
Value Stream Mapping , OEE Improvement, People Engagement Initiatives
Production Capacity Enhancement by 15% without investment
Tube Products Mfg
Delivery backlog / Low eqpt utilization
Value Stream Mapping, SMED
Delivery lead time reduction by 50 %, Setting time reduction from 5 hrs to 2 hrs
Plastic Extrusion comp Mfg
Poor layout / low productivity
Greenfield project with lean layout design and implementation
Space Productivity by 25 %
Construction Extrusion comp Mfg
Delivery backlog / Low manpower productivity
Line Balancing, methods Improvement
Manpower productivity by 32 % and Plant Capacity Enhancement
Delivery backlog / Low productivity
OEE Improvement Inventory Management
Productivity Improvement by 30 %
How to maximize profitability in SME organization?
why do some organizations engage transformation initiative and others not?
Typical misconceptions about Lean system thinking
Three important rituals a SME Business head must do in the first week of every month?
How to develop problem solving competency inside the organization?
Are you effectively managing your Business?
What every SME Business head must know about his Business?