Table of Contents
Featured Case Studies
A Leading Foundry reduced 72% of WIP by MUDA Elimination
How a Leading foundry in South India removed Muda and improved its productivity and has drastically improved the throughput. The company underwent an 18
De-bottlenecking in a Furniture Manufacturer to improve output
A Leading Furniture manufacturer established operations in 2004 with a mission to design, manufacture and sell metal-based furniture that set new standards for aesthetics,
How 90% error reduced by Process Re-design?
How data entry error increased customer waiting time in billing counter & dissatisfaction and how 90% data entry error was reduced by re-designing the
Industry 4.0
Over the last 15 years, KIAP has developed and refined its own customized approach to operational transformation, leading to significant performance improvement in manufacturing organizations.
With the current rapid changes in manufacturing technology and information systems, there is a huge scope to complement lean implementation with a judicious deployment of Industrial Internet of Things(IIOT) solutions to multiply the business benefits in terms of improved productivity and OEE, throughput time and inventory reduction, enhancing quality and reducing costs. These solutions also enable ease of monitoring and tracking relevant process and performance parameters, ensure data sanctity for right decision making and error proof critical areas thereby avoiding catastrophic process and delivery failures. Studies show that,
“When either approach, Lean or IOT applied alone, it can reduce conversion cost by 15%,whereas the integrated partnership approach reduces conversion cost by 40%, Cost of Poor Quality(COPQ) by 20% and Work in Process (WIP) by 30%”
It therefore makes sense to seamlessly merge the Lean philosophy with Industry 4.0 and we call this integrated approach Lean 4.0.
IOT solutions can be deployed at each phase of a typical lean implementation cycle as we can see from this diagram. The callouts show IOT interventions typical of each implementation phase.
KIAP has a proven track record of delivering phenomenal results to clients. With the current rapid changes in manufacturing technology and information systems, there is a huge scope to complement the gemba approach with a judicious deployment of relevant Industrial Internet of Things(IIOT) solutions to further multiply the business benefits in terms of improved productivity and OEE, throughput time and inventory reduction, enhancing quality and reducing costs. These solutions will also enable ease of monitoring and tracking relevant process and performance parameters, ensure data sanctity for right decision making and error proof critical areas thereby avoiding catastrophic product and process failures.
Our Approach
Over the last 15 years, KIAP has developed and refined its own customized approach to operational transformation, leading to significant performance improvement in manufacturing organizations. However studies show that,
“When either approach, Lean or IOT applied alone, it can reduce conversion cost by 15%,whereas the integrated partnership approach reduces conversion cost by 40%, Cost of Poor Quality(COPQ) by 20% and Work in Process (WIP) by 30%”
It therefore makes sense to seamlessly merge the existing consulting approach with the new technological advancements to multiply value to businesses. The diagram below shows our well defined consulting as well as typical IIOT solutions currently offered by technology providers that synergize at specific points in the cycle.
Design
- Make a technology / Low Cost Automation plan while making the Lean roadmap
Prepare
- Data needed for improvement projects can be related to machines / lines / materials
- Appropriate devices for computing OEE / line stops / rejections can be introduced at this stage
Improve
- LCA for improvements such as Jidoka (line stop), error proofing to avoid defects
- Analysis and alerts for line stops, bottleneck identification, deviations
- Monitoring and deviation alerts for process, machine conditions
- Material flow – kitting, pull based WIP management can all be electronically done
Standardize
- Validating the results of improvements made requires continuous monitoring of data
- Electronic SOPs both for display as well as guidance, also for deviation monitoring
Sustain
- Various OPEX assessment checklists and scores can be digitized and visually displayed
- Monitoring can help in continual improvement journey as data is now readily available for next round of diagnosis
KIAP is working with select technology partners who have developed robust solutions that complement our gemba implementation. The solutions can be customized depending on specific needs of the process and KIAP experts are on site to ensure proper fitment. We also help our clients utilize the deployed IOT solutions and realize the full benefit through further process improvement and standardization.
Please contact us for state of the art industry specific integrated Lean IOT solutions.
