Business Turnaround in Precision Component manufacturing organizationApplication of key management tools and process

  • OEE Improvements
  • Key Performance Management at business and operation level
  • Application of Lean tools and techniques
  • Capacity enhancement through Line Balancing
  • Organizational Restructuring
  • Inventory Management both at RM stage
  • Daily Managment process
  • Communication Process Reengineering

Problem before engagement

The Organization was struggling with  the following problems

  • Not achieving breakeven point and making a loss every month
  • Dependant on a few customers and delivery commitments were not met consistently
  • Management reviews not effective
  • The business head was not able to identify the causes of negative profitability

Solution Approach

  • Brought clarity on organizational structures, roles, and responsibility among the business heads, functional head, and working level
  • Educated  the team and implemented the OEE measurement system in  and identified the waste in plant utilization, efficiency, and quality issues
  • Identified the causes for  poor delivery commitments and enhanced the capacity of the plant by mapping the product vs process and re-balanced the line with respect to  fluctuated customer’s demand
  • Initiated cycle time reduction in constraints process to enhance the capacity
  • Relayout the plant to improve the flow w.r.t product family
  • Set the key performance metrics (KPI’s)for customer deliveries, cost, and quality and reviewed every month along with Business Head
  • Identified cost optimization projects to reduce the overall manufacturing cost  and implemented the projects
  • Analyzed and implemented right inventory norms for RM to improve stock availability and reduce inventory
  • Reduced the process rejection through structured problem-solving methodologies
  • Improved the communication process among cross-functional team

Result Delivered

  • 30 %  growth in sales turnover
  • Operating profitability improved from negative to positive
  • Rejection reduction  by 64 %
  • Delivery improvement from 70 % to 86 % 

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.

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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.

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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.

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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.

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