Business Turnaround in Food Processing organizationApplication of key management tools and process

  • OEE Improvements
  • Key Performance Management at business and operation level
  • Application of Lean tools and techniques
  • Inventory Management both at RM, FG level
  • Daily Managment process
  • Communication Process Reengineering
  • Supply chain improvements

Problem before engagement

The Organization was struggling with  the following problems

  • Sales Turnover is stagnant for the last 3 years
  • Declining profitability
  • Manufacturing cost is ion increasing trend
  • No management reviews and  lack of data transparency among team
  • No proper coordination among Team on deliverables

Solution Approach

  • Educated  the team and implemented the OEE measurement system in the food processing plant and identified the waste in plant utilization, efficiency, and quality issues
  • Implemented Quick changeover techniques to reduce changeover losses between food products
  • Also identified constraints to improve OEE in the plant
  • Set the key performance metrics (KPI’s)for customer deliveries, cost, and quality and reviewed every month along with Business Head
  • Implemented sales and operational key performance reporting on a daily, weekly basis to avoid communication problems
  • Analyzed and implemented right inventory norms for both RM and FG  to improve stock availability and reduce inventory
  • Identified and implemented cost saving projects in plant and administration areas
  • Identified MANNING gap, recruited  people
  • Improved the communication process among operations, sales, and finance team to take decisions on time

Result Delivered

  • 30 % Improvement in plant capacity utilization;
  • Changeover reduction by 40 %
  • 5% overall manufacturing cost reduction
  • 40 % reduction in inventory value without affecting deliveries
  • Sales Turnover increased by 15 % only by increasing delivery performance 
  • Operating profitability increased

Ganesh’s dedication towards bringing the transformational change in the organization is very much appreciated by the team.I liked the very simple, practical, effective way of sharing concepts without much jargon.I never felt he was an external consultant to us, he was very much part of our organization.

On the technical front, he has vast experience to guide any manufacturing organization to next level performance as he is systematic in his approach and takes all people along with him.

I personally enjoyed interacting with him and all the best for his journey to contribute to organizations for next-level growth.

Rakesh Radhakrishna
Operations, Quality & Excellence, Maini Material Movements

Ganesh and I had both worked at TI Cycles, Chennai at different times, but came to know each other in his role as a Business Transformation coach.
He conducted an Emerging Leadership program for our organization spread over 12 months.
His dedication to the task and relentless effort and passion in drawing out the best from the participants resulted in us observing a transformed team that is now more open in communication and proactive in coming out with growth ideas.

Happy to have been associated with you Ganesh and wish you many more success.

Nadimuthu Srinivasan
Executive Director, SNAM Alloys Pvt Ltd

I know Ganesh babu for several years, and he is evolving himself continuously. I have witnessed his excellent facilitation skills in people development and conflict resolution skills in team management. He helped several young people to transform themselves on life excellence principles. Always he strives to do things in the RIGHT and BETTER way.

A H B Narayana Reddy
Senior Plant Director, Whirlpool of India Limited, Pune

Mr.Ganesh babu, with his rich knowledge, wisdom, team building ability, down to earth approach, winning the accepting mind from everyone, helped us to improve our score in frost & Sullivan Indian manufacturing excellence in 2015.I wish him all success in the continuation of his valuable services to industries in helping to achieve breakthrough results with his rare blend of abilities.

K Nagaraja Kumar
Head HR & Improvement Initiatives, L&T -Rubber Processing Machinery,Kanchipuram
Success Stories