MANUFACTURING EXCELLENCE CONSULTING

Total Productive Maintenance, Total Quality Management, World Class Manufacturing

Profitability Improvement

Cost Reduction

Sustainability

Manufacturing Excellence is based upon widely established set of tools and techniques, which all together make up a framework for Lean Manufacturing.

Manufacturing Shop floor performance is a challenge for today’s manufacturers who operate in an age of complex production system and supply chain environments. Business managers who oversee plant operations are not going to get the results when shop floor operations are not streamlined or optimized. Manufacturers are constantly looking for methods to increase productivity, accelerate operational output, and achieve sustainable manufacturing excellence.

Many manufacturing companies struggle to maximize quality and performance—while attempting to minimize costs. There is no “Hard & Fast rules” to achieve this excellence, but innovation can lead to excellence, and can be derived from various tools and techniques.

Manufacturing cost reduction project APPROACH

STEP 1

Target

-Productivity Improvement by 20% – 40%

Activities

-Units per man HR Analysis

-Units per Employee Analysis

-Time & Motion Analysis

-ZCA( Zero Cost Automation) & LCA (Low Cost Automation) Opportunity Identification

-Material Handling Optimization

-New Space Discovered

-OEE/OLE Identification

STEP 2

Target

-Quality Improvement by 20% – 50%

Activities

-Quality Management system Awareness

-Quality KPI Development & Training

-KAPA implementation

-Poka -Yoke Implementation

-COPQ – Cost of Poor Quality

( External + Internal + Appraisal + Prevention)

STEP 3

Target

-Zero Accident Condition

Activities

-No. of Safety KPI Identification

-No. Of Hazard Identification & Closing

-LTIFR & LMHFR Reduction

-OH & S Management System Implementation

-Safety Signage Implementation

STEP 4

Target

-Delivery Performance > 98%

Activities

-Value Stream Mapping

-Process Mapping ( BPM/ BPR )

-Lead time Reduction

-Inventory Cost Reduction

-WIP Storage Reduction

-Waste Process Identification

STEP 5

Target

-Manpower Cost Reduction by 10% – 20% 

Activities

-Total Salary vs Sales

-Value Add per Employee

STEP 6

Target

-Inventory Cost Reduction by 20% – 40%

Activities

-Inventory Turnover ratio / Dead Stock

STEP 7

Target

-Process Cost Reduction by 10% – 20% 

Activities

-Process Mapping ( BPM/ BPR )

-Value Stream Mapping

STEP 8

Target

-Production Plan Adherence > 95%

Activities

-No. of Defaults in Production Vs Plan

STEP 9

Target

-OEE Improvement by 30% – 40%

Activities

-( Availability + Performance + Quality )

STEP 10

Target

-SMED by 40% – 100%

Activities

-Setup Time Reduction

STEP 11

Target

-MTTR & MTBF Improvement by 40% [- 100%

Activities

-Units per man HR Analysis

STEP 12

Target

-Space Creation by 20% – 50%

Activities

-Sqft Creating n Existing Setup, Units per Sqft )

TPM Pillars

Autonomous Maintenance

Increase Efficiency by training operators to perform maintenance tasks

Planned Maintenance

Schedules maintenance tasks based on predicted and measured failure rates

Quality Maintenance

Design error detection and prevention into production processes

Focused Improvement

Provides team-based approach to elimination of losses in any process

Equipment Management

Directs practical knowledge and understanding of manufacturing equipment

 

Training and Education

Fill in knowledge gaps necessary to achieve TPM goals

 

Safety, Health, Environment

Maintain a safe & healthy, accident-free working environment

TPM in Administration

Apply TPM techniques to administrative functions like- Order Processing,Scheduling

Want FREE most accurate Operational Analysis of your Company and Competitive Benchmarking

Case Studies

Manufacturing Excellence in Hero Motors

( India’s Largest Automobile Manufacturing )

 

Challenges:

  • To identify unutilised area of the plant and remove the unnecessary items
  • High Inventory due to improper Line Balancing
  • Manual operation increases the cycle time of the process
  • Designing jobs and equipment which are fit for people according to Ergonomics

Approaches: 

  • Tetrahedron implemented 5S activity for workplace improvement
  • Process Line balance by using Time and Motion study approach
  • Provided Automation solution by which cycle time reduce and manpower saved
  • Provided solution which is Ergonomically best for the people to perform the operation

Results:

  • Area saved by 20 %
  • 100 + Unique posters suggested
  • 10 SOC per machine identified
  • 8 HTAA in each zone identified
  • Manpower optimisation by 30 %
  • Cycle time reduced by 15 %

 

Lean Production System Implementation

( Leading suspension, tooling and fixtures manufacturing )

 

Challenges:

  • No. of presses were more- More space Needed
  • No. of Changeover
  • Distance Travel by material was high
  • Tool Changeover time
  • High MTTR & Low MTBF
  • HIgh WIP Inventory

Approaches: 

Tetrahedron studied the entire production line, Value added steps , Changeover time, MTTB, MTTR and Material movement and found multiple areas of improvements, Implemented die standardisation and die dedication.

Results:

  • We managed to save/free two presses which is 9% of the total presses given to us for working
  • Daily Average Internal time waste (During SMED):- 8580 Sec (2.4 hrs. ) was saved through die standardisation
  • 83% improvement in distance travel by material
  • 41% reduction in tool changeover time
  • MTTR reduced by 86%
  • MTBF increased by 91% 

Benefits of Manufacturing Excellence

Exceeding Organizational Target

Sustenance of Improvement

Sustenance of Improvement

Improving Employee Engagement

Employee Awareness

Achieving Zero Defect Condition

Achieving Zero Defect Condition

Improving Productivity

Productivity Improvement

Manufacturing Cost Reduction

Manufacturing Cost Reduction

Achieving Zero Effect Environment

 Zero Effect Environment

Achieving Zero Delay in Delivery

Delivery Improvement

Industries We Serve

Manufacturing Excellence

Industrial

Food & Beverage

Food & Beverage

Automotive

Automotive

Life Science

Medical

Consumer Goods

Consumer Goods

Our Bold thinking of inspired consultants and their passion for result come together for extraordinary impact with consultative approach. we allow customers in all sectors of business to scale quicker with a customized, integrated system. We work with client who Strive not only to be a success, but also to be a value.

Why to Choose Us ?

Making Change Happen

We make change happen using our unique approach of combining practical training and implementation on-site

Collaboration

 

We engage and involve your people in the process of change applying simple, yet highly effective world class improvement techniques

Results driven

 

We will make your organisation more profitable and totally customer focused

Embedding change

 

We help embed and sustain a culture of continuous improvement across your workforce

testimonials

Testimonials

Testimonials

Testimonials

Our Clients

Tetrahedron Clients

What is Manufacturing Excellence ?

Manufacturing Excellence is the continuous improvement of your operations to Achieve Zero Breakdown, Zero Waste, Zero Fatigue, Zero Accident etc with quality and safety innovation. One common misconception about Manufacturing Excellence is that its focus is to maximize production throughput, but total Manufacturing Excellence refers to multiple pillars of the business. To achieve raising all pillars of operations, you also have a mix of a positive work culture, constant process refinement and supporting technology.

What is TPM?

Total productive maintenance (TPM) is the process of using machines, equipment, employees and supporting processes to achieve perfect production.

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