Execution Time-Line
| S.No. | Goal | Deliverable |
| 1. |
100% Employee Engagement
|
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| 2. |
Zero Breakdown
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| 3. |
Zero Waste
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| 4. |
Zero Defect
|
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| 5. |
Zero Loss
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| 6. |
Zero Delivery Failure
|
|
| 7. |
Zero Accident
|
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| 8. |
Zero Effect
|
|
| 9. |
100% Sustenance
|
|
Manufacturing Excellence Time-Line Approach
| Stage | Description |
|---|---|
| Step 1 100% Employee Engagement -Basic 5S Awareness -1S Implementation -2S Implementation -Workplace Visual Management (Visual Factory) -Kaizen Concept -Suggestion Scheme -Innovative Leaders |
-5S Score -Total Space Recovered -Scrap Value -No. of signage implementation -No. of KAIZEN Implemented -No. of Employee Suggestion -Innovative Team Size |
| Step 2 Zero Breakdown -My Machine Campaign -CLIT -Machine Utilization Monitoring -Machine Losses Reduction -Breakdown Analysis -Preventive Maintenance -3S ,4S & 5S for Machine & Office area |
-No. of Machine Covered in Campaign -Preventive Maintenance Plan -Loss Reduction % -MTBF -MTTR |
| Step 3 Zero Waste -Time & Motion Study -Lean Audit -Lean Layouting -ZCA(Zero Cost Automation) & LCA(Low-Cost Automation) -Material Handling Optimization -OEE/ OLE |
-Total Distance Travelled -New Space Discovered Area -VA/NVA Ratio -OEE/OLE % -Productivity Improvement % -No. of ZCA/ LCA opportunities Identification |
| Step 4 Zero Defect -Quality Management System awareness -Quality Performance (Quality KPI development & Tracking ) -Non-conformities Identification & CAPA implementation -Workplace Audit -7 QC Tools & 7 Management Tools -Problem Solving & Poka Yoke -Root Cause Analysis |
-Production Yield -QMS NC identified & Closed -No. of Solved Chronic Quality Problems -Customer Quality PPM -No. of Poka-Yoke Implemented |
| Step 5 Zero Loss -Advance Lean Practices Implementation -Manpower Rationalization -Design & Process FMEA -APQP -Line Balancing |
-Manufacturing Cost Reduction % -COPQ -Line Efficiency Improvement |
| Step 6 Zero Delivery Failure -Value Stream Mapping -Supply Chain Management -Value Chain Management -Inventory Analysis & Management -Process Mapping (BPM/BPR) |
-Lead Time Reduction % -Inventory Cost Reduction -WIP storage reduction -No. of waste Process eliminated |
| Step 7 Zero Accident -Occupational Health & Safety Policy -Safety KPIs -OH& S Management System Implementation -Workplace Safety -Process Safety -HIRA -Safety Signage Standardization |
-No. of Safety KPI defined -No. of Near-miss reported & Closed -Medical Expenses Reduction -LTI Reduction % -LTIFR & LMHFR Reduction -No. of Hazard Identified & Closed -No. of Safety Signage Implemented |
| Step 8 Zero Effect -Environment Policy -Effect Impact Analysis & Life Cycle Assessment -Waste Management & Control |
-Carbon Foot Print Reduction -% of Cost Reduction |
| Step 9 100% Sustenance -Employee Training and Re-Training -DOJO Set-up -Training Content |
-Audit Plan -Training Calendar -Sustenance Plan |
| Stage | Description |
|---|---|
| Step 1 100% Employee Engagement -Basic 5S Awareness -1S Implementation -2S Implementation -Workplace Visual Management (Visual Factory) -Kaizen Concept -Suggestion Scheme -Innovative Leaders |
-5S Score -Total Space Recovered -Scrap Value -No. of signage implementation -No. of KAIZEN Implemented -No. of Employee Suggestion -Innovative Team Size |
| Step 2 Zero Breakdown -My Machine Campaign -CLIT -Machine Utilization Monitoring -Machine Losses Reduction -Breakdown Analysis -Preventive Maintenance -3S ,4S & 5S for Machine & Office area |
-No. of Machine Covered in Campaign -Preventive Maintenance Plan -Loss Reduction % -MTBF -MTTR |
| Step 3 Zero Waste -Time & Motion Study -Lean Audit -Lean Layouting -ZCA(Zero Cost Automation) & LCA(Low-Cost Automation) -Material Handling Optimization -OEE/ OLE |
-Total Distance Travelled -New Space Discovered Area -VA/NVA Ratio -OEE/OLE % -Productivity Improvement % -No. of ZCA/ LCA opportunities Identification |
| Step 4 Zero Defect -Quality Management System awareness -Quality Performance (Quality KPI development & Tracking ) -Non-conformities Identification & CAPA implementation -Workplace Audit -7 QC Tools & 7 Management Tools -Problem Solving & Poka Yoke -Root Cause Analysis |
-Production Yield -QMS NC identified & Closed -No. of Solved Chronic Quality Problems -Customer Quality PPM -No. of Poka-Yoke Implemented |
| Step 5 Zero Loss -Advance Lean Practices Implementation -Manpower Rationalization -Design & Process FMEA -APQP -Line Balancing |
-Manufacturing Cost Reduction % -COPQ -Line Efficiency Improvement |
| Step 6 Zero Delivery Failure -Value Stream Mapping -Supply Chain Management -Value Chain Management -Inventory Analysis & Management -Process Mapping (BPM/BPR) |
-Lead Time Reduction % -Inventory Cost Reduction -WIP storage reduction -No. of waste Process eliminated |
| Step 7 Zero Accident -Occupational Health & Safety Policy -Safety KPIs -OH& S Management System Implementation -Workplace Safety -Process Safety -HIRA -Safety Signage Standardization |
-No. of Safety KPI defined -No. of Near-miss reported & Closed -Medical Expenses Reduction -LTI Reduction % -LTIFR & LMHFR Reduction -No. of Hazard Identified & Closed -No. of Safety Signage Implemented |
| Step 8 Zero Effect -Environment Policy -Effect Impact Analysis & Life Cycle Assessment -Waste Management & Control |
-Carbon Foot Print Reduction -% of Cost Reduction |
| Step 9 100% Sustenance -Employee Training and Re-Training -DOJO Set-up -Training Content |
-Audit Plan -Training Calendar -Sustenance Plan |
Case Studies
Material Handling and Process Automation
(India’s Largest Precious Metal Exporters)
Challenges :
- Extremely labour intensive operations resulting to high costs
- High pilferage of precious raw materials
- Quaterly INR 40 Lacs of raw material unaccountable or pilfered
Approaches :
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 on going
- Developed In-House Machines with company’s engineers to Automate Workflows.
Manufacturing Excellence in Flock Manufacturing
(India’s Leading Velvet Cloth Manufacturing)
Challenges :
- Low Productivity Leading to Lower VAPE
- High WIP and Inventory due to improper Planning
- Manual Loading leading to high labour and time
Approaches :
Tetrahedron implemented S&OP 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%
- Truck Loading Time Reduced by 28%
- Contract Worker Cost Reduction by 42% (18 to 10)
Benefits of Manufacturing Excellence
To adhere Manufacturing Excellence in your organization
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