Business Transformation Through Order Delivery Improvement

Problem State
 
Solution State
 
Result
Manufacturing company specialized in casting and machining business struggled to fulfill customer's order consistently in every month .The average service level for all customers was below 60 % and management was under threat from customers to pullout the business.
 
  • For each customer , established key delivery metrics
  • Created management forum to track the target performance on daily basis
  • Identified resource constraints and resolved through management intervention
  • Identified equipment constraints and Improved critical machine overall effective utilization
 
  • Overall average customer service level increased to > 85 %
  • 100 % delivery achieved consistently for key customer and business threat was eliminated
  • Business Turnover Improved by 45 %
 

Application of key management tools and process:

Performance Metrics Management, Daily Management Process, Industrial Engineering.

Productivity Improvement and Order Service Level Improvement

Problem State
 
Solution State
 
Result
Manufacturing company specialized in extrusion & assembly process struggled to meet the customer delivery commitments and not able to manage the backlog .Also management was concerned about the increasing conversion cost due to lower manpower productivity than industry standard.
 
  • Conducted production study to understand the losses in extrusion and assembly process
  • Identified the imbalance factor in assembly process.
  • Re Line Balanced with customer's demand
  • Recommended different manpower configuration for fluctuating customer's demand
 
  • Customer demand was met consistently
  • Manpower productivity increased by 32 % for given customer's demand
 

Application of key management tools and process:

Industrial Engineering -Methods Improvement, Line Balancing, Manpower Planning

Greenfield Lean Plant Layout Design and Implementation

Problem State
 
Solution State
 
Result
Manufacturing company specialized in extruded cup manufacturing business had invested on equipments without assessing the capacity utilization and laid out the layout in adhoc manner which resulted into unnecessary movements , complicated planning process and low manpower productivity. The company was looking for new location to put up a plant with existing layout.
 
  • Studied machine utilization pattern and assessed capacity
  • With proper Factory Master Plan , identified right equipment investment
  • Designed Lean Plant Layout with right sized equipments and simple FLOW
  • Recommended the new production planning process to improve delivery and productivity
 
  • Two excess machines pulled out from the line and used for future growth
  • Two excess machines pulled out from the line and used for future growth
  • supervisory manpower productivity by 50 %
 

Application of key management tools and process:

Plant Layout, Industrial Engineering Methods Improvement, Factory Master Plan

Production Capacity Enhancement Through Constraint Elimination

Problem State
 
Solution State
 
Result
Manufacturing company specialized in auto chain manufacturing process could not able to increase the production beyond certain capacity even though there was huge demand. Management was contemplating for capex investment to increase plant capacity within short term.
 
  • Conducted value stream mapping of the entire supply chain along with Team
  • Identified critical equipment process cycle time was constraint for next level improvement
  • Team was encouraged to improve the bottleneck process and came out with innovative solution of changing the coil feeding mechanism, which removed the constraint.
 
  • Production output improved by 10 % without any major investment
  • Team had learnt the process of constraint elimination and engaged for next level capacity enhancements.
 

Application of key management tools and process:

Lean Manufacturing, Value stream Mapping, Industrial Engineering Time study