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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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
0