S.no |
Industry |
Issues / Struggles |
Tool / Technique Application |
Results Achieved |
1. |
Vehicle Mfg |
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) |
2. |
Casting Mfg |
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 |
3. |
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 % |
4. |
Forging Mfg |
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 |
5. |
Gear Mfg |
Delivery back log and Team morale issues |
OEE Improvements, Flow manufacturing, KPI focus, Daily management |
39 % sales turn over increased. |
6. |
Signage Mfg |
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 |
7. |
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 % |
8. |
Casting Mfg |
Delivery backlog / Growth stagnation |
Performance management, Lean Iniativies, Daily work management |
Business turnover increase by 34 % |
9. |
Auto Component Mfg |
Delivery backlog / brim capacity utilization |
Value Stream Mapping , OEE Improvement, People Engagement Initiatives |
Production Capacity Enhancement by 15% without investment |
10. |
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 |
11. |
Plastic Extrusion comp Mfg |
Poor layout / low productivity |
Greenfield project with lean layout design and implementation |
Space Productivity by 25 % |
12. |
Construction Extrusion comp Mfg |
Delivery backlog / Low manpower productivity |
Line Balancing, methods Improvement |
Manpower productivity by 32 % and Plant Capacity Enhancement |
13. |
Food Processing |
Delivery backlog / Low productivity |
OEE Improvement Inventory Management |
Productivity Improvement by 30 % |