CASE STUDIES

Energy Audit

(Leading Door & Windows Manufacturer (Rudrapur))

Challenges: (Before Tetrahedron )

• High Energy Cost
• 40% machine breakdown due to air pressure down

Approaches:

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    

Quality Management System Audit

( Leading Sole Manufacturer (Noida))

Challenges: (Before Tetrahedron )

• No QMS awareness among the employee
• No standard templates were followed
• No Proactive quality tool like PFMA was developed

Approaches:

Tetrahedron conducted the initial QMS gap audit .Shared the findings with the management and staff team. TMS QMS  Consultant trained the team on Process FMEA tool and developed jointly with the team , and helped the team to identify the potential failure mode of the sole.

Results:

• Training and hand holding for PFMEA development.
• 50+ Non-conformance points, 150+ observation & 30 Opportunities points identified
• Trained employee on each clauses of the QMS.      

Lean Layouting in Fettling Operation

(Leading Global Automotive Part Manufacturer)

Challenges : (Before Tetrahedron )

Operating as a batch process fettling operation leading to huge  WIPs and frequent delivery failures due to unavailability of finished goods.

Approaches 

Tetrahedron conducted a Time & Motion Study for Shot-blasting to painting operation of the fettling line with a target to develop a Lean Line with 5 years capacity projection. The result achieved in 6 months.

Results

• 3 Shifts (24 Hrs) operation reduced to 19 Hrs
• Line Balancing Implemented – Sequential Flow of Goods, FIFO
• Line formation with exact manpower requirement with projections
• Identified 20+ Simple Automation
• Multiple Operation by single workman by formation improvement
• WIP reduced by 50%

Green Field Layout of Glazing Division

(India’s Largest UPVC  Manufacturer (Bhiwadi))

Challenges: (Before Tetrahedron )

• High Cost due to High Manual Manufacturing
• Low Productivity  due to non standardized product
• High WIP because of Material Handling
• High Manual Packaging leading to high labor Costs

Approaches 

Tetrahedron studied the entire production line and helped to identify at least 43 opportunities to implement automation. With this in mind, 17 high-impact projects were taken on.

Results 

• 36% Manpower Reduction
• Ideation and Implementation of end to end Material Handling
• Material Handling breakages reduced by 70%
• 40% Line Productivity Enhancement

Energy Cost Reduction Project Implementation

(Leading Gear Manufacturer (Faridabad))

Challenges : (Before Tetrahedron )

• High Energy Consumption
• No tracking of Heat loss
• No Energy saving project implemented

Approaches :

Tetrahedron Energy Management Consultants team conducted an on-site Industrial Energy Audit and inspected the individual energy-consuming devices and track their performance and loss %. Some devices were found old, defective, and energy inefficient. In the end, energy isolation systems were developed and energy-efficient devices implemented. Energy KPI was established to track energy consumption.

Results :

• 25 Energy Saving Project Identified
• 18% Energy Cost Reduced
• Energy-efficient devices were installed across the plant.

Energy Saving Projects Funnel Created

(Leading Heavy Equipment Manufacturer(Odisha))

Challenges: (Before Tetrahedron )

• Monthly Energy Cost was too high
• The management team was serious about the reduction of the plant running costs.

Approaches :

Tetrahedron Energy auditor team delivered training on Energy Management System (EMS) to the plant staff and operator level. In addition, 4 Energy Auditors conducted a Level 3 energy audit across the plant and presented the Energy Management Opportunities (EMO)s to the plant management team and identified energy savings projects for the energy team.

Results :

• Developed an internal energy auditing and management team including 3 Management persons, 5 technical Staff & 10 technicians.
• 65 Energy Savings Project Funnel created

Logistic Cost Optimization & New Mode of Transportation Implementation

(Leading Carbon Black Manufacturer)(Faridabad)

Challenges : (Before Tetrahedron )

Management was highly concerned for high logistic expenses.)

Approaches :

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.

SCM & Logistic Expenses Optimization Through Heijunka Implementation

(Leading Surgical Equipment  Manufacturer)(Agra)

Challenges : (Before Tetrahedron )

• No fixed mode of goods transportation
• Low Volumetric Efficiency

Approaches :

Tetrahedron team worked on this project with a dedicated on-site resources. Captured the client’s pain area and logical reasons behinds the non-standardized practices. TMS team did thorough analysis of the end-to end process and optimized the SCM. Product planning part was the major concern observed during the analysis. TMS team helped the client to Implement Heijunka practices for smooth production planning

Following results were achieved:-

Results :

• Logistic process standardized
• Volumetric efficiency achieved 96%
• SCM of the company highly optimized

DOJO Training Center Designing & Development

(Leading Wire Harness Manufacturer (Gurgaon))

Challenges : (Before Tetrahedron)

• No DOJO Room across the plant
• No Skill Up-gradation Strategy
• No flow established for proper training

Approaches : 

Tetrahedron DOJO Expert team charted a One Month project plan for DOJO Training Set-Up in 1100 Sq. Meter area. Developed a 3D Simulation and process flow design validated with the management team. Roles & Responsibilities of the team developed and TMS onsite resource tracked the daily work progress. Two innovative products were developed by the TMS team which are “Sensor-Based Walking Speed Measurement “ devices and “ Standing Posture Evaluation Devices”

Results :

• DOJO Center set up within time frame
• 12 Levels of DOJO implemented

DOJO Training Strategy Integration with Existing HR Strategy

(Leading Automotive Manufacturer (Rudrapur))

Challenges : (Before Tetrahedron)

• Only Safety and Maintenance DOJO was present in DOJO room
• No awareness of DOJO Training among the Employee

Approaches : 

Tetrahedron DOJO Expert team charted a One –Month project plan for DOJO Training Set-Up in 2500 Sq. Meter area. Developed SOPs and documentation of the DOJO training strategy. Implemented  “DOJO Strategy Manual” including DOJO Score Card, Training effectiveness Measurement System. and linked the  DOJO strategy with the Skill level of the workmen

Results :

• Department wise DOJO training sequence developed
• Skill  matrix integrated with DOJO training
• DOJO On Job Training (OJT) KPIs are developed and tracked
• On Paper Performance Evaluation System Implementation
• Video-based & Poster based learning system developed