Productivity Improvement and Order Service Level Improvement


Application of key management tools and process

Industrial Engineering -Methods Improvement, Line Balancing, Manpower Planning

Problem State

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.

Solution State

  • 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 deman


  • Customer demand was met consistently
  • Manpower productivity increased by 32 % for given customer’s demand
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“Winning Minds” has helped us in building a culture of management by numbers from top down bottom. This has given us insight in to the operations, enabling us to clearly define goals at every level. Setting of the goals and the targeted actions has enhanced the operational efficiency and business growth over 30 %.

J S R K Prasad
CEO, Better Castings, Vijayawada
Success Stories