Documentos de Académico
Documentos de Profesional
Documentos de Cultura
Background
Current Practices
Internal Quality Management System along with their global best practices standards to ensure systematic and well defined Processes Systematic handling of customer feedback through 8 discipline problem solving S t ti h dli f t f db k th h di i li bl l i Technique Tools like FMEA, Shainin DOE, SPC extensively used to solve problems Cost Reduction waves primary driver for improvements improvements.
Key Challenges
Increased Customer Expectations on reduced Lead Time Huge Growth and hence increased space need. Need to reduce cost due global slowdown Reduce Inventory carrying cost as transit time after dispatch was more than 30 days
The Journey.
Lean Training of Functional Managers & Line Leads g g
Provided basic understanding of Lean philosophy, fundamental and methodology to 20 senior managers and line leads Understanding & identifying Wastes & Variability in the system, elimination of which will benefit the business Going to the Gemba to understand the real problems and the need for primary data collection Use of simulation helps provide clarity and vision Key Decisions points
Identify CI manager to drive PEx Selected Personnel as Improvement Leaders Freeze Engagement Plan
Kanban Simulation
The Journey
Collect data C
Details
Address staff and operators about p p p purpose of Performance Excellence j journey. y Collect Primary Data. Identify opportunities of improvement. Transportation Index Calculate Potential Financial benefits. Design Lean dashboard. g
Diagnostic Chart
The Journey
Freeze layout
Details
Work out options for the future. future Create a future layout Cardboard Engineering Complete the Value Stream Map of the Future. Identify quick win projects and plan implementation Plan for involving people in the journey
Savings Pie
The Journey
Pilot Implementation
Vendor Managed Inventory Arrested all Leakage, Spillage and Wastages of oil/water/air Balancing the line to improve Flow & productivity p p y
Immediate Results
Immediate savings of about 8 lakhs every quarter. Productivity increase of more than 50% Rejections due to missing parts reduced by 90% Created the initial momentum to set out on this journey Team members learning Problem Solving Skills
The Journey
160 opportunities identified and segregated as Just Do its, Workouts and Events
e-suggestion system
.the journey
Visible and tangible benefits (Potential as on date) in excess of 3 Crores for two product lines. Space savings of about 40% on the shop-floor Governance system to manage this initiative is in design stage. Excess capacity generation by 12%-15% for equipments. yg y e-suggestion scheme leading to improvements from all levels .. it continues