MANUFACTURING EXCELLENCE CONSULTING
Total Productive Maintenance, Total Quality Management, World Class Manufacturing
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
Employee Awareness
Achieving Zero Defect Condition
Productivity Improvement
Manufacturing Cost Reduction
Zero Effect Environment
Delivery Improvement
Industries We Serve
Industrial
Food & Beverage
Automotive
Medical
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
Our 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.