MANUFACTURING EXCELLENCE CONSULTING

Manpower Cost Optimization

OEE Improvement

Productivity Improvement

Execution Time-Line

S.No. Goal Deliverable
     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
    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
     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
      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
5.

Zero Loss

  • Advance Lean Practices Implementation
  • Manpower Rationalization
  • Design & Process FMEA
  • APQP
  • Line Balancing
  • Manufacturing Cost Reduction %
  • COPQ
  • Line Efficiency Improvement
      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
    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
     8.

Zero  Effect

  • Environment Policy
  • Effect Impact Analysis & Life Cycle Assessment
  • Waste Management & Control
  • Carbon Foot Print Reduction
  • % of Cost Reduction
     9.

100% Sustenance

  • Employee Training and Re-Training
  • DOJO Set-up
  • Training Content

  • Audit Plan
  • Training Calendar
  • Sustenance Plan

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

  • Exceeding Organizational Target
  • Sustenance of Improvement
  • Improving Employee Engagement
  • Achieving Zero Defect Condition
  • Improving Productivity
  • Manufacturing Cost Reduction
  • Achieving Zero Effect Environment
  • Achieving Zero Delay in Delivery

To adhere Manufacturing Excellence in your organization

Gallery

Our Clients

Client logo manufacturing excellence

Testimonials