Manufacturing Operational Excellence Consultant
Minimize Manufacturing Waste & Increase Productivity
Our Operational Excellence Consultant will help you with a holistic approach to achieve the desired Mission Objective and Goals of your organization by a series of tools and techniques that align the organization’s culture, enable employees, and sustain all implemented initiatives. The Manufacturing Excellence programs are also used in different formats in part or whole with names like Operational Excellence, World Class Manufacturing (WCM), Business Turn Around, Total Productive Maintenance (TPM), Total Quality Management (TQM), and many more.
To stay ahead of competitors and drive desired business outcomes, companies must reimagine their operations and processes holistically in response to evolving marketplace competition and digital technology disruption.
Our Operational Excellence and practice assists organizations in meeting these challenges by architecting and delivering world-class business capabilities, while also serving as lean manufacturing consultant and a critical pillar in any successful business transformation.
Objective of Manufacturing Excellence
Challenges of Manufacturing Companies
Manufacturing Companies have been witnessing challenges for their survival in these areas :
Increasing Man Power Cost
Increasing Input Material Cost
Changing Customer Requirement
Cut Throat Supply Chain
Legal & Statutory Compliances
Though these challenges are external factors and can’t be controlled by any company, the one and only way to remain sustainable is by a structured Manufacturing Excellence Approach.
Energy Management System drives performance levels that really change the company’s competitive position in the marketplace. It helps the organization to challenge itself and achieve its optimum potential.
Process Improvement V/s Manufacturing Excellence
Most of the time organizations confuse between these two terms and under the false impression of Driving Manufacturing Excellence while implementing Process Improvement Kaizens.
So What shall the organization go for a Kaizen/Improvement Program or Drive a Manufacturing Excellence Program?
The answer is simple → Both of these are required.
Material Handling and Process Automation
(India’s Largest Precious Metal Exporters)
-Extremely labor-intensive operations resulting in high costs
-High pilferage of precious raw materials
-Quarterly INR 40 Lacs of raw material unaccountable or pilfered
Tetrahedron helped the company to turn around the operations of the company in an industry which resistant to change. Following results have been achieved:-
-15% reduction in Manpower; 20% reduction still ongoing
-Truck Loading Time Reduced by 28% Contract Worker Cost Reduction by 42% (18 to 10)
Manufacturing Excellence in Flock Manufacturing
(India’s Leading Velvet Cloth Manufacturing)
-Low Productivity Leading to Lower VAPE
-High WIP and Inventory due to improper Planning
-Manual Loading leading to high labor and time
Tetrahedron implemented SOP to improve the Production planning reduce WIP reduction due to reduce order production mismatch, Designing of low-cost automation for material handling.
-VAPE improved by 17%
-WIP reduction by 23%
Benefits of Manufacturing Excellence
Manufacturing Excellence Implementation Process
Total Employee Engagement: It aims to develop a culture in which Employees care about their work that could make a difference & hence increase the performance of the company.
♦ Workplace Visual Management (Visual Factory)
♦ Kaizen Strategy
♦ Suggestion Scheme
♦ QC Circles
♦ DWM – Daily Work Management Development
♦ KPI (Managing Point & Checkpoint)
♦ VMO (Vision Mission Objective)
Zero Breakdown: Maintenance is all about working for the ultimate goal with a winning maintenance strategy.
Key Tools :
♦ My Machine Campaign
♦ Machine Utilization Monitoring
♦ Machine Losses Reduction
♦ Breakdown Analysis
♦ Preventive Maintenance
♦ 3S for Machine MTTR, MTBF, CBM
♦ MCA (Machine Criticality Analysis)
♦ Spare Part Criticality Analysis
Zero Waste: To eliminate waste across entire value chains to the fullest extent possible through Lean Manufacturing tools.
♦ Time & Motion Study
♦ Lean Layouting
♦ ZCA (Zero Cost Automation) & LCA (Low-Cost Automation)
♦ Material Handling Optimization
♦ OEE/ OLE
♦ Lean Study
♦ Arrow Diagram
Zero Accident: The risk of falling, risks related to electricity or handling of machinery, road hazards, and more. Every day, the awareness of each and every employee is essential to avoid accidents in the workplace and to prevent occupational illnesses.
Key Tools :
♦ OH & S Management System Implementation
♦ Safety KPIs
♦ Safety Signage Standardization
♦ ISO 45001:2018
♦ Safety, Gemba Walk
♦ Tool Box Talk (TBT)
♦ MEEBS Study
♦ Hazop Study
Zero Fatigue: Fatigue is a workplace hazard and can be associated with the safety and health of the worker. It affects the health and safety of the employee.
Key Tools :
♦ Scope Defining
♦ Workplace Ergonomics Analysis different Technical Score (REBA, RULA, WAS, HARM, NIOSH, JSI, KIM, EAWS, RAMP)
♦ OFI (Opportunities of Improvements) Points Sharing
♦ Support in Workplace Design Modification
♦ Final Audit
Zero Effect: To make the production process, product, environment friendly and good enough for social well being and sustainability of the environment.
Key Tools :
♦ Environment Policy
♦ Effect Impact Analysis & Life Cycle Assessment
♦ Energy Cost Optimisation
♦ Waste Management & Control
Zero Defect: Developing a product that has no defects but ensuring the quality standards and reducing the defects to a level of zero in the projects.
Key Tools :
♦ Quality Management System Awareness
♦ Quality Performance (Quality KPI Development & Tracking )
♦ Non-Conformities Identification & CAPA Implementation
♦ Workplace Audit
♦ 5 Core Quality Tools
♦ 7 QC Tools & 7 New QC Tools
♦ ISO 9001:2015
♦ Poka Yoke
♦ Root Cause Analysis
Zero Loss: Zero Loss is an aim/attempt to overcome such losses or minimize their effect up to great extent in order to reduce the manufacturing cost.
Key Tools :
♦ Advance Lean Practices Implementation
♦ Manpower Rationalization
♦ Design & Process FMEA
♦ Production Planning
♦ Line Balancing
Zero Delivery / Failure: To accomplish the task within the lead time without failure in Inventory time, WIP storage, Logistics cost, and mapping of the steps a company takes to complete a certain process.
Key Tools :
♦ Value Stream Mapping
♦ Value Supply Chain Management
♦ Inventory Analysis & Management
♦ Process Mapping (BPM/BPR)
It aims to successfully sustain the lean Manufacturing Processes.
Key Tools :
♦ Employee Roles & Responsibility
♦ Company Manual
♦ Competency & Skill Mapping
♦ Sustenance Audit check sheet
♦ Audit Schedule
♦ Employee Training, Re-Training & Right Training
♦ DOJO Set-up
What is Operational Excellence in manufacturing?
Operational Excellence in Manufacturing generally means to apply Lean Manufacturing Techniques. This includes workers at all levels focusing on enhancing business processes in order to achieve long-term profitable growth. The phrase is strongly related to Toyota’s Lean Manufacturing Methodology. Today, it aids in minimizing operational risks and costs in Lean operations.
Why is Manufacturing/Operational Excellence important?
Due to the enormous Competitive advantage it provides, Operational Excellence is crucial. Any quality improvements, no matter how small, have a significant impact. According to a study published in the Harvard Business Review, businesses with the highest levels of Operational Excellence had 25% greater growth and 75% higher productivity.
What are the benefits of Operational Excellence?
Here are some of the advantages of Operational Excellence that are frequently mentioned:
• Effective resource usage and process efficiency
• Cost reduction or containment
• A motivated, reliable workforce
• Consistent management
• Significant shareholder return
• High-quality standards
• Successful collaborations with suppliers
What are Operational Excellence goals?
Operational Excellence Goals are:
• lower accident rates or less time missed due to injuries
• Decreasing the defect or inaccuracy rates
• Less regulatory or compliance problems
• Greater client satisfaction
• Reduced waste in the value stream
• Lessening of environmental impact
• Minimized downtime
• Increased client loyalty
• Increased production or productivity
What are the KPI for Operational Excellence?
A corporation utilizes a discrete measurement known as an operations key performance indicator (KPI) or metric to track and assess the effectiveness of its ongoing operations. These KPIs aid management in determining which operational initiatives benefit the organization and which hinder it.