200+ SUCCESSFUL CASE STUDIES
Discover how Tetrahedron Manufacturing Services has helped businesses optimize their operations, build trust, and drive sustainable outcomes.

Manpower Optimisation & Cycle Time Reduction
India’s Largest Automobile Manufacturing
Before Tetrahedron:
- Difficulty in identifying unutilized space & removing unnecessary items
- High inventory due to improper line balancing
- Manual operations increased cycle time
- Lack of ergonomic job & equipment design
Our Approach:
- Implemented 5S for workplace efficiency
- Line balancing using Time & Motion Study
- Automation solutions to reduce cycle time & manpower
- Ergonomic improvements for better working conditions
Results:
- ✔ 20% space saved
- ✔ 100+ unique posters suggested
- ✔ 30% manpower optimization
- ✔ 15% cycle time reduction

Productivity Improvement in Flock Manufacturing
India’s Leading Velvet Cloth Manufacturing
Before Tetrahedron:
- Low productivity, impacting VAPE
- High WIP & inventory due to poor planning
- Manual loading increased labor & time
Our Approach:
- Implemented SOPs for better production planning & WIP control
- Designed low-cost automation for efficient material handling
Results:
- ✔ 17% VAPE improvement
- ✔ 23% WIP reduction

Total Productive Maintenance (TPM) Implementation
Leading Gear Manufacturer (Faridabad, UP)
Before Tetrahedron:
- OEE at 45%
- Skill score below 30%
- Low productivity due to overtime & extra manpower
Our Approach:
- Designed an 18-month TPM roadmap
- Engaged employees through 5S & Kaizen
- Improved machine conditions & operator skills
- Enhanced breakdown, quality, safety & training
Results:
- ✔ Implemented planned maintenance to improve MTTR & MTBF
- ✔ Facilitated fault tree analysis with shop floor & management
- ✔ Identified recurring issues & implemented Kaizen solutions
- ✔ Created a work progress tracker for continuous monitoring

Inventory Cost optimization through focused improvement
Leading UPVC CPVC Pipes & Fittings Manufacturer (Dadri Plant, UP)
Before Tetrahedron:
- Low Productivity Leading to Lower VAPE
- High WIP and Inventory due to improper Planning
- Manual Loading leading to high labor and time
Our Approach:
- Tetrahedron implemented SOP to improve the Production planning reduce WIP reduction due to reduce order production mismatch, Designing of low-cost automation for material handling.
Results:
- ✔ VAPE improved by 17%
- ✔WIP reduction by 23%

A Success Story on Zero Incident & Zero Accident In Manufacturing Industry
Leading Steel Manufacturer (Gaziabad, Delhi-NCR)
Before Tetrahedron:
- No performance tracking of the safety management system
- Lack of urgency at the management level for safety improvements
Our Approach:
- Assessed OEE & safety gaps
- Developed an action plan & guided shop floor implementation
Results:
- ✔ Safety committee established
- ✔ Plant divided into designated areas with ownership
- ✔ Active involvement of top management
- ✔ Daily safety meetings with workmen

OEE Improvement
Leading Auto Components Manufacturer (Gurgaon, Haryana)
Before Tetrahedron:
- Poor delivery performance
- High product rejection due to quality issues
- Frequent machine downtime
- Low productivity
Our Approach:
- Assessed & tracked OEE parameters (Quality, Availability, Performance)
- Developed an action plan to improve OEE & reduce losses
- Guided shop floor implementation
Results:
- ✔ OEE tracking system implemented
- ✔ Loss codes developed for chronic issues
- ✔ Machine-level OEE data analysis conducted
- ✔ Loss contributions analyzed over 4 months
- ✔ OEE color band system introduced for performance monitoring

Quality Management System Audit
Leading Sole Manufacturer (Noida)
Before Tetrahedron:
- No QMS awareness among the employee
- No standard templates were followed
- No Proactive quality tool like PFMA was developed
Our Approach:
- Conducted the initial QMS gap audit
- Shared the findings with the management and staff team
- Trained the team on Process FMEA tool
Results:
- ✔ Training and hand-holding for PFMEA development
- ✔ 50+ Non-conformance points, 150+ observations, & 30 Opportunities points identified
- ✔ Trained employees on each clause of the QMS

Green Field Layout of Glazing Division
India’s Largest UPVC Manufacturer (Bhiwadi)
Before Tetrahedron:
- High costs due to manual manufacturing
- Low productivity from non-standardized products
- High WIP from inefficient material handling
- Manual packaging increasing labor costs
Our Approach:
- Identified 43 automation opportunities
- Implemented 17 high-impact projects
Results:
- ✔ 36% manpower reduction
- ✔ End-to-end material handling automation
- ✔ 70% reduction in handling breakages
- ✔ 40% increase in line productivity

Lean Layouting in Fettling Operation
Leading Global Automotive Part Manufacturer
Before Tetrahedron:
- Batch process fettling led to high WIP & frequent delivery failures
Our Approach:
- Conducted Time & Motion Study from shot-blasting to painting
- Designed a Lean Line with a 5-year capacity projection
Results:
- ✔ Operation time reduced from 24 hrs to 19 hrs
- ✔ Implemented Line Balancing (FIFO & sequential flow)
- ✔ Identified 20+ simple automation solutions
- ✔ WIP reduced by 50%

Energy Saving Projects Funnel Created
Leading Heavy Equipment Manufacturer(Odisha)
Before Tetrahedron:
- Monthly Energy Cost was too high
- The management team was serious about the reduction of the plant running costs
Our Approach:
- Delivered training on Energy Management System (EMS)
- Conducted a Level 3 energy audit across the plant
Results:
- Developed an internal energy auditing and management team
- 65 Energy Savings Project Funnel created

Energy Cost Reduction Project Implementation
Leading Gear Manufacturer (Faridabad)
Before Tetrahedron:
- High Energy Consumption
- No tracking of Heat loss
- No Energy-saving projects implemented
Our Approach:
- Conducted an on-site Industrial Energy Audit
- Developed energy isolation systems and implemented energy-efficient devices
Results:
- ✔ 25 Energy Saving Projects Identified
- ✔ 18% Energy Cost Reduced
- ✔ Energy-efficient devices installed across the plant

SCM & Logistic Expenses Optimization Through Heijunka Implementation
Leading Surgical Equipment Manufacture (Agra)
Before Tetrahedron:
- Unstandardized goods transportation
- Low volumetric efficiency
Our Approach:
- Tetrahedron optimized the supply chain by addressing inefficiencies in product planning and implementing Heijunka for smoother production.
Results:
- ✔Standardized logistics process
- ✔Achieved 96% volumetric efficiency
- ✔ Highly optimized supply chain

Logistic Cost Optimization & New Mode of Transportation Implementation
Leading Carbon Black Manufacturer (Faridabad)
Before Tetrahedron:
- Management was highly concerned for high logistic expenses.
Our Approach:
- Tetrahedron’s SCM experts visited the plant ,collected the initial logistic quantity, rate and route to destination map.
- Then analyzed the data and optimize the logistic expenses with multiple logistic partners also suggested client to cost friendly mode of transportation.
- TMS Team validated the quote both techno-commercially and supported the client for on-ground execution.
Results:
- ✔ Logistic expenses reduced by 30%.
- ✔ New Mode of transportation was selected and testing results of the implementation was highly successful.

DOJO Training Center Designing & Development
Leading Wire Harness Manufacturer (Gurgaon)
Before Tetrahedron:
- No DOJO Room or training flow
- No skill upgradation strategy
Our Approach:
- Tetrahedron set up a DOJO Training Center in 1100 sq. meters with 3D simulation, defined roles, and developed two innovative evaluation devices.
Results:
- ✔DOJO Center completed on time
- ✔ 18% Energy Cost Reduced
- ✔ 12 DOJO levels implemented

DOJO Training Strategy Integration with Existing HR Strategy
Leading Automotive Manufacturer (Rudrapur)
Before Tetrahedron:
- Limited DOJO (only Safety & Maintenance)
- No employee awareness of DOJO Training
Our Approach:
- Tetrahedron planned and set up a 2500 sq. meter DOJO Training Center, developed SOPs, a DOJO Strategy Manual, and linked training with skill levels.
Results:
- ✔ Department-wise DOJO training sequence
- ✔ Skill matrix integrated with DOJO
- ✔ OJT KPIs developed and tracked
- ✔Performance evaluation system implemented
- ✔ Video & poster-based learning introduced

Planned Maintenance Implementation
Leading UPVC CPVC Pipes & Fittings Manufacturer (Dadri Plant, UP)
Before Tetrahedron:
- High machine downtime
- Poor delivery performance, losing customers
- Low productivity & high manufacturing costs due to extra shifts
Our Approach:
- Tetrahedron tracked MTTR & MTBF, analyzed breakdowns, and implemented a maintenance strategy.
- The team was trained and guided from strategy to shop floor execution.
Results:
- ✔ Planned maintenance system improved MTTR & MTBF
- ✔ Chronic issues identified & loss codes developed
- ✔ Fault tree analysis conducted with shop floor & management
- Kaizen initiatives implemented to prevent recurring issues

Material Handling & Process Automation
India’s Largest Precious Metal Exporters
Before Tetrahedron:
- Extremely labor-intensive operations resulting in high costs
- High pilferage of precious raw materials
- Quarterly INR 40 Lacs of raw material unaccountable or pilfered
Our Approach:
- Tetrahedron helped the company to turn around the operations of the company in an industry which resistant to change.
- Following results have been achieved.
Results:
- ✔ 15% reduction in Manpower; 20% reduction still ongoing
- ✔Truck Loading Time Reduced by 28%
- ✔Contract Worker Cost Reduction by 42% (18 to 10)

Energy Audit
Leading Door & Windows Manufacturer (Rudrapur)
Before Tetrahedron:
- High Energy Cost
- 40% machine breakdown due to air pressure down
Our Approach:
- Tetrahedron conducted a Level 3 energy audit on the plant set up.
- Tetrahedron energy expert identify the inefficient devices which are consuming more energy and suggested the energy efficient devices.
Results:
- ✔ 30% Energy consumption cost reduced
- ✔ 12 new energy efficient pump implemented
- ✔Training done on Energy Management System

Single Minute Exchange of Die (SMED) Implementation
Leading Medical Equipment Manufacturer (Agra Plant)
Before Tetrahedron:
- DOJO room had only Safety & Maintenance training
- Employees unaware of DOJO training
Our Approach:
- Tetrahedron set up a 2500 sq. meter DOJO Training Center, developed SOPs, a DOJO Strategy Manual, and linked training with skill levels.
Results:
- ✔ Department-wise DOJO training sequence
- ✔ Skill matrix integrated with DOJO
- ✔ OJT KPIs developed & tracked
- ✔ Video & poster-based learning introduced

5S Culture Implementation
India's Leading Shoe Sole Manufacturer (Hosiery Complex, Noida Phase II Extn, Noida Plant)
Before Tetrahedron:
- Poor 5S practices in shop floor & office
- Machines in poor condition
- No defined aisles for movement
- No employee engagement in 5S
Our Approach:
- Tetrahedron conducted a 5S audit, identified contamination sources, and implemented daily audits & weekly reviews.
- This improved 5S scores and workplace culture.
Results:
- ✔ Workplace divided into 17 zones with assigned leaders
- ✔5S Champion appointed at the organizational level
- ✔Core team & zone leaders trained in 5S
- ✔Initial audit findings shared via reports & graphs
- ✔Employees engaged in daily 5S practices
- ✔Joint efforts led to shop floor improvements & higher motivation

KAIZEN Strategy Implementation
Leading two wheeler component Manufacturer (Binola, Haryana)
Before Tetrahedron:
- No process improvement initiatives
- High employee resistance to change
- No awareness of KAIZEN strategy
Our Approach:
- Tetrahedron assessed employee mindset and guided management on motivating KAIZEN reporting and implementation.
Results:
- ✔ Team trained in KAIZEN identification & implementation
- ✔ KAIZENs reported based on key themes
- ✔ KAIZEN Jury Team formed to shortlist impactful ideas

TPM-JH Pillar Implementation
Leading Garments Manufacturer (Sector 36, Gurugram, Haryana)
Before Tetrahedron:
- No TPM awareness at the organizational level
- Poor machine condition & auxiliary parts
- Short machine lifespan
Our Approach:
- Tetrahedron developed a TPM Master Plan, trained the team, and standardized abnormality identification.
- Maintenance initiatives improved machine life.
Results:
- ✔ TPM-JH pillar implemented
- ✔Organization-wide TPM awareness training
- ✔Standardized abnormality check sheets
- ✔Identified & corrected contamination sources
- ✔HTTA & SOC improvements through brainstorming
- ✔Abnormality tracking system implemented

TPM-Skill Building & Training Pillar Implementation
Leading Medical Equipment Manufacturer (Taj Expressway Link Rd, Nunhai road, Industrial Estate, Agra Plant)
Before Tetrahedron:
- Employees not assigned as per skill set
- No structured training calendar
- Root cause analysis challenges
- No preventive maintenance schedule
Our Approach:
- Tetrahedron tracked OEE, developed an improvement plan, and guided implementation on the shop floor.
Results:
- ✔ Staff skill score improved by 65%
- ✔ Team trained on TPM – Training & Education Pillar
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