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Consulting Team 30+

  Complete Projects 250+

  Plant Layout Setup 50+

 Google Reviews 70+ 

Tetrahedron Manufacturing Consulting Services

Industries We Serve

Our dedication is unwavering, ensuring that each industry receives tailored solutions and expertise. Our commitment is to propel every sector forward, enhancing productivity and fostering innovation. Your success is our mission.

MANAGEMENT CONSULTING

Manufacturing Consultant

We are Professional Manufacturing Consulting Firms in India, helping manufacturing organizations by improving up-to 10%-20% profitability, advising on how to improve their performance and solve complex problems as well as identifying opportunities of growth, increase energy efficiency, Manufacturing and energy cost reduction, and improve the overall organizational operations. Under the Manufacturing Consulting we are offering Plant Layout Design, Safety Management System, Dojo Training Center.

SKILL TRAINING

Manufacturing is a complex industry that requires a variety of skills and expertise. We have done 350+ Training & Skill Development Modules (On-Line, On-Site, Hand-Hold, Mentoring) that focus on enabling clients’ employees to acquire relevant knowledge + practical + implementable skill for Senior, Middle, Line Managers as well as Supervisor, Workers and Operators to excel in their roles. Some of our focus key areas for manufacturing training and skill development are Process, Strategic, Behavioral, & Technical Training, DOJO Centers.

AUTOMATION: INDUSTRY 4.0

Industry

Industry 4.0 involves the integration of advanced technologies such as automation, artificial intelligence, and the Internet of Things (IoT) into manufacturing processes to revolutionize the manufacturing industry by reducing waste, increasing flexibility. Under the automation in Industry 4.0, we serve AR VR services. In-house developed AMR (Autonomous Mobile Robot) for material handing. Development & Design of Electric Vehicle, Qualification Packs & NOSs for EV Modules. Also we are leading in AGV manufacturers in India as well.

Trusted by Brands

Why Choose Us

Discover How Our Services Lead to Your Success

Letter of Appreciation from Valued Clients

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With Tetrahedron

Manufacturing ExcellenceProcess Improvement
Focuses on Gain and SunstainFocuses on Gain only
Strengthening of organizationStrengthening of process
Include the whole organizationInclude a person/ Small team
Top-Down ApproachBottom-Up Approach
Scope extends to customers & suppliersScope mostly limited to a dep/ section
Aligned with organization vision missionAligned with processes’ cost,saftey,quality
Unique and can’t be copied for other organizationWorks like medicine to relieve pain quickly
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Lean Plant Layout development detailed approach

When developing a Lean Plant Layout design, meticulous planning and careful analysis are required to increase efficiency. Before starting, we have to collect all the requirements and thoroughly understand the production process. So we have a proven approach consisting 8 steps that will help to make the plant layout design conceptual with optimized output, reduce expenses, and foster a secure work environment.

Plant Layout 8 Steps Detailed Approach

Process Specific DOJO

Fire Safety Board

Safety Shoe Simulator

Head Safety Simulator ( Helmet) Included in safety shoe)

Walking Speed measuring

Heat Sensing

Eye Similar Diameter

Eye Different Diameter

Eye Different Shapes

Cycle Time Game (Rope Rolling)

5S Game

PLC Panel Board

Demo kit for Instrumental Tubing and fitting

Cut section of valves

Fire Alarm System

Training Kit for Load Cell & RTD Function

Instrumentation Cables

Motor Operated Values actuators

Three Phase Induction Motor Trainer

Electrical Safety Trainer

Coil Placement on Conveyor

Brazing_2 (With Input Control)

Coupler / Nipple / Nozzle Fitting & Removal

HLD Checking

Hair Pin Insertion

Screw Handling Ambidexterity

Screw Handling Ambidexterity with Tightening

Emergency Siren Pattern

Fire Extinguisher

Fire Hydrant

Fire Safety Board (Fire Triangle)

Electrical Safety Board

Gas Cylinder Safe Handling_SoftContent

Gas Cylinder Safe Handling

TPM Pillar (3’X2′)

LOTO Board (6’X4′)

SOP (3’X2′)

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Growth

For business

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How can an Industry get Deming Certification?

We have a team of consultants with in-depth implementation experience of Deming’s certifications. We help companies to guide through the deming certification journey and support companies to adopt industry-leading practices, enhance their operational efficiency, excellence in quality management and ultimately achieve deming certification.

Deming’ 12 principle in Total Quality Maintenance

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how can we help you?

Contact us at the Consulting WP office nearest to you or submit a business inquiry online.

safety consultant

Process Specific DOJO

Without TQM, what issues do manufacturing industries face?

Lack of Standardization: No standardized signage and inconsistent 5S practices across the factory.

High Work-in-Progress (WIP): Excessive WIP in various zones due to inefficient processes.

Frequent Equipment Failures: Regular equipment breakdowns leading to high downtime and maintenance costs.

Inadequate Maintenance Practices: No formal maintenance schedules or systematic approaches to equipment upkeep.

What approaches will Tetrahedron take to address failures?

5S Implementation and Individual Improvement:

We conducted basic 5S awareness training, defined 5S zones and leaders, and established a red tag area to identify and remove unnecessary items. We also implemented visual management systems with over 3,000 signage opportunities and conducted regular 5S audits, linking 5S scores to staff KPIs.

Autonomous Maintenance:

We developed and displayed machine ownership formats and CLIT (Cleaning, Lubrication, Inspection, Tightening) sheets for all machines. Additionally, we conducted abnormalities identification campaigns, maintained abnormalities trackers, and implemented corrective actions for machine abnormalities and hard-to-access areas (HTAA).

Planned Maintenance:

We developed a maintenance dashboard and implemented PM plans for all machines. We conducted breakdown analysis, calculated MTTR (Mean Time to Repair) and MTBF (Mean Time Between Failures), and performed SMED (Single-Minute Exchange of Dies) studies for time optimization.

Focused Improvement:

We identified and implemented over 500 KAIZENs, achieving a 93% sustenance rate. We conducted root cause analysis and implemented corrective actions for identified issues. Additionally, we monitored Overall Equipment Effectiveness (OEE) and conducted loss analysis for critical machines.

Quality Maintenance:

We established standardized quality checks and maintenance procedures, conducting regular audits and maintaining records to track improvements and address issues promptly. These measures enhanced operational efficiency and reliability, ensuring consistent high standards were met.

Results will achieve after TQM Implementation

5S Implementation:

Physical condition and 5S scores improved significantly from 30% to 86%.
Cross-audit scores and visual management systems were fully implemented.

Autonomous Maintenance:

Identified 555 abnormalities and corrected 526, resulting in reduced equipment failures.
Implemented CLIT practices and improved machine maintenance routines.

Planned Maintenance:

MTTR reduced significantly, with notable improvements in MTBF across all departments.
Breakdown percentages reduced to well below targets in PVC, IMD, and HDPE departments.

Focused Improvement:

Over 500 KAIZENs identified and 357 implemented, saving Rs. 22,16,65,378.
Sustained high-quality improvements and continuous monitoring of OEE.

Quality Maintenance:

Improved quality maintenance practices and reduced variability in production processes.