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Automotive Ancillary Plant, India

THE PROBLEM:

A press component manufacturer catering to the automotive industry had delivery performance as one of its biggest issues

THE BACKGROUND:

In this case, a walk through the shop floor helped us to quickly identify that the long hanging fruit was haphazard work in the dispatch area. The dispatch area was completely chaotic and poorly organized. It was apparent that inspection and packing was not carried out on priority. We also observed that parts shipped had quantity shortages.

THE SOLUTION:

A team was identified and mentored to work on the project. The team also got to build familiarity on the various tools that were used via the DMAIC approach. The tools used were zero level maps, process flow diagrams, value stream maps, trend charts for delivery performance, parts shortage, pareto-analysis, brain storming, fish bone diagrams, MSA and issue trees. The two key changes executed were layout modification and workplace organization. One of the concerns raised by the team was the lack of space to make any improvements. However, through brainstorming and leveraging on the creativity of team members, a large steel platform was fabricated and erected in the dispatch area. This platform helped in the better use of floor space, because prior to the change, the areas adjacent to the wall were not being used due to pipes running along the walls.

 THE RESULT:

 Work place organization not only remarkably improved the dispatch area appearance, but also helped in the better use of space. Functionally, the entire area got bigger. This was definitely the most required change for getting organized and improved delivery. This was the beginning of transformation in the factory; not just with processes but also with that of the morale of people involved. There was a 50% improvement in delivery as well as parts shortage. This project helped achieve an annualized saving of $20,000.

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Pradeep Kumar, Chief Executive

Pradeep Kumar has about three decades of professional experience against his name.  With multi-location and multi-cultural exposure paired with a Master Black Belt in Six Sigma & Lean, Pradeep’s core expertise comes from over a decade of specialization in a large multinational manufacturing company. He is a Certified MBB in Lean and Six Sigma by SBTI, Texas and trained by Mckinsey Consultants as a Lean Practitioner in Rock Hill-USA.

He currently works with large multinational companies, helping them drive Operational Excellence and implement lean strategies. Pradeep also guides senior leadership towards excellence in execution. He has trained candidates in Lean & Six Sigma in India, China, Japan, Thailand, Europe, Middle East, Sri Lanka and the USA; and mentored more than 500 Engineers and Managers in Lean & Six Sigma in India and overseas.  His expertise lies in understanding gaps in current systems, designing more effective processes and mentoring teams to swiftly achieve organizational goals

M.BALAJI, Principal Consultant, Management Systems

Balaji is a Mechanical Engineer with four decades of experience with the last thirteen years in Management consultancy.  His expertise is in Management Systems, with extensive experience in training, auditing and supporting imp mentation of Quality and Environmental Management systems.   He is also a qualified tool designer from NTTF and GTTC.

Balaji keeps abreast of the latest changes in international standards for implementing quality management systems and is a Lead Auditors for ISO 9001, ISO 14001,  ISO 9001, ISO 14001,  ISO 45001, ISO 22163 :2017.  Also auditor for  IATF 16949:2016.  He is a  Lead Assessor : EXIM Bank award for Business Excellence model .  With more than a decade of experience in management consulting, he has conducted 600 man-days of training and 250 man-days of audits; working with more than 35 clients.

ABRAHAM MATHEWS, SENIOR CONSULTANT

Abraham has more than two decades of experience in Quality Management and Operations, including designing quality, environmental and health & safety management systems, managing industrial engineering activities and heading a Plant.  He is an expert auditor of quality systems and in working with teams to implement robust processes that is sustainable.  Having worked in Aerospace and Automotive industry he understands the Industry requirements and is very meticulous in his approach in implementing the required standards.  He is also a trained Lean practitioner and support training and implementing Lean Manufacturing Systems. He also conducts Yellow belt Six Sigma training and supports Green belt training.