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Transformation Project - USA

PROBLEM:

Productivity and profitability of the plant BACKGROUND: This case study was a part of a larger Lean project of transforming a plant in the USA. The value stream assigned to this team had several challenges and the same were addressed by following systematic diagnosis of the current state, design of the future state and evolving a deployment plan that was well executed.

SOLUTION:

 We carried out demand analysis to establish a finished good strategy for the value stream. Product segmentation was also carried out to group parts that had similar process steps. This helped us understand key product families within the value stream. Capacity analysis helped in identifying machines with critical OEE measurements. A complete review of standard work was carried out and new standards were established to meet Takt time with minimal resources. Several Lean improvements were also carried out in the value stream.

RESULTS:

  • Improved cell design. Reduced people-travel by 100 ft. per week. It also saved floor space by 1000 sq. ft.
  • Quick change over reduced time from 90 minutes to 30 minutes
  • OEE and TPM led to 80% increase in productivity
  • 6 shifts of packing inventory was reduced to 2 shifts
  • Material variance was reduced from 15% to 2%
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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.