Manufacturing Operational Excellence Consultant

Reduce Manufacturing Cost & Increase Productivity

Productivity Improvement

Delivery Performance Improvement

Quality Improvement

Safety Improvement

Manufacturing Cost Reduction

Manpower Optimization

Operational Excellence Consultant & Lean Manufacturing Consultant will help you with a holistic approach to achieve the desired goals of your organization. Tetrahedron deploys various tools and techniques, those align the organization’s culture, enable employees, and sustain all implemented initiatives. The Manufacturing Operational Excellence programs are also used in different formats in part or whole with names like Operational Excellence, World Class Manufacturing (WCM), Total Productive Maintenance (TPM), Total Quality Management (TQM),  and many more.

Main motive of a operational excellence consultant is to reduce cost with improvements with the primary objective being to increase growth and gain a competitive edge.  By improving operational speed, agility, and responsiveness, Tetrahedron enables you to grow your profitability (Bottom Line) five times faster than your revenue (Top Line). With lean manufacturing consultant, businesses and industries can experience our sustainable approach to scale their business.

Operational Excellence Consultant

To stay ahead of competitors and drive desired business outcomes, companies must imagine their operations and processes holistically in response to evolving marketplace competition and digital technology disruption.

Our Operational Excellence in Manufacturing approach helps organizations to overcome challenges by developing and deploying top-tier business skills. As a lean manufacturing consultant, we play a pivotal role in successful business transformations.

Objective of Manufacturing Excellence

Employee Engagement

Employee Engagement

Profitability Improvement

Profitability Improvement

 Business Sustenance

 Business Sustenance   

Challenges of Manufacturing Companies

Manufacturing Companies have been witnessing challenges for their survival in these areas : 

Manufacturing consulting by increase manpower cost

Increasing Man-Power Cost

increasing input material cost

Increasing Input Material Cost

changing customer requirement

 Changing Customer Requirement

Cut throat supply chain

Cut Throat Supply Chain

legal & statutory compliances

Legal & Statutory Compliances

Though these challenges are external factors can’t be controlled by any company. The one and only way to remain sustainable is by a structured Manufacturing Excellence Approach.

Manufacturing Excellence V/s Process improvement

Manufacturing Excellence Process Improvement
Focuses on Gain and Sustain Focuses on Gain only
Strengthening of organization Strengthening of process
Include the whole organization Include a person/ Small team
Top-Down Approach Bottom-Up Approach
Scope extends to customers & suppliers Scope mostly limited to a dep/ section
Aligned with organization vision mission Aligned with processes’ cost, safety, quality
Unique and can’t be copied for other organization Can be replicated/copied to another
Works like an immune booster to face challenges Works like medicine to relieve pain quickly

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 with the right context and requirement.


Case Studies

Material Handling and Process Automation

(India’s Largest Precious Metal Exporters)

Challenges : 

-Extremely labor-intensive operations resulting in high costs
-High pilferage of precious raw materials
-Quarterly 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:-


-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)

Challenges : 

-Low Productivity Leading to Lower VAPE
-High WIP and Inventory due to improper Planning
-Manual Loading leading to high labor and time

Approaches : 

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.

Results : 

-VAPE improved by 17%

-WIP reduction by 23%

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
    • Achieving Zero Harm in Workplace

To adhere to Manufacturing Excellence in your Organization

Manufacturing Excellence Implementation Process

Objective : 

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.

Key Tools:

♦ Work place  Management: 5S

♦ Workplace Visual Management (Visual Factory)

♦ Kaizen Strategy

♦ Suggestion Scheme

♦ QC Circles

♦ DWM – Daily Work Management Development

♦ KPI (Managing Point & Checkpoint)

Objective : 

Zero Breakdown: Maintenance is all about working for the ultimate goal with a winning maintenance strategy.

Key Tools :

♦ My Machine Campaign

♦ CLITA (Cleaning, Lubrication, Inspection, Tightening, Adjustment)

♦ Machine Utilization Monitoring

♦ Machine Losses Reduction

♦ Breakdown Analysis

♦ Preventive Maintenance

♦ 3S for Machine MTTR (Mean Time to Repair), MTBF (Mean Time Between Failures), CBM (Condition-Based Maintenance)

♦ MCA (Machine Criticality Analysis)

♦ Spare Part Criticality Analysis

Objective :

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 (Failure Mode and Effects Analysis)

♦ Production Planning

♦ Heijunka

♦ Kanban

♦ Line Balancing


Zero Waste: To eliminate waste across entire value chains to the fullest extent possible through Lean Manufacturing tools.

Key Tools:

♦ Time & Motion Study

♦ Lean Layouting

♦ ZCA (Zero Cost Automation) & LCA (Low-Cost Automation)

♦ Material Handling Optimization

♦ OEE (Overall Equipment Effectiveness) / OLE (Overall labor effectiveness)

♦ Lean Study 

♦ OAT (Overlay Authoring Tool)

♦ SOCC (Standard Operation Combined Chart)

♦ VSM (Value Stream Mapping)

♦ Arrow Diagram

Objective :

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

Objective :

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 (Business Process Management)/BPR (Business Process Re-engineering))

Objective : 

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

♦ HIRA (Hazard Identification & Risk Assessment)

♦ Safety Signage Standardization

♦ ISO 45001:2018

♦ Safety, Gemba Walk

♦ Tool Box Talk (TBT)

♦ MEEBS Study

♦ Hazop Study

Objective : 

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

Objective : 

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

Objective :

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

The sequence of the tools are customised as per customer’s business requirement and pain points.Tetrahedron first conducts an detailed audit/observation of existing operation before designing the implementation process.

Our Clients

ME_Client Logo


What is Operational Excellence in manufacturing?

Operational Excellence in Manufacturing generally means to apply Lean Manufacturing Techniques in 4Ms i.e. Machines, Manpower, Material/Inventory, Method/System

Manufacturing Excellence is a Top-to-Down approach which includes both Senior Management as well as Line Operator, focusing on enhancing business processes in order to achieve long-term profitable growth and sustenance

The phrase is strongly related to Toyota’s Lean Manufacturing Methodology, WCM,OpEx TPM, TQM

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:

 • Increased production or productivity

 • Reduced waste in the value stream

 • Decreasing the defect or inaccuracy rates 

 • Minimized downtime
• Less regulatory or compliance problems

 • lower accident rates or less time missed due to injuries
• Greater client satisfaction
• Increased client loyalty
 • Lessening of environmental impact

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.

Best Manufacturing consulting firms in India

Tetrahedron is best Manufacturing consulting firms in India having worked on 100+ projects in India till date. In Manufacturing Operational Excellence we have given our best in the projects of TPM, TQM, Lean Manufacturing, Zero Waste, Zero Accident, Zero Defect, Zero Loss, etc.