Operational Excellence

A mature organization is one whose operations have stabilized, has consciously developed a clear strategy for further growth, and is now looking to move to the next level. Such organizations seek to develop their internal capability as a means to achieve operational excellence. In the long term, the organization expects to become a learning and continually improving entity. We offer a comprehensive, long-term solution for such clients.

The OPEX initiative, aligned with business goals and strategy, is built on a theme to catch the attention of and create excitement among employees. The key to success is the involvement of people at all levels of the organization. Goals are set by the business owners or CEOs, based on which a Lean strategy and improvement roadmap is firmed up by the functional and operational heads. Improvement projects from the roadmap are then executed by line managers through cross-functional teams. Finally, improvements are standardized through mass programs such as 5S, Autonomous Maintenance, and Visual Management involving every employee.

Operational Excellence

Outcomes

  • Common goal orientation across all layers of the organization.

  • Tangible results with respect to the stated goals.

  • Internal champions capable of identifying and managing the implementation of improvement projects.

  • A spirit of continual improvement and concepts inculcated into the majority of employees.

Client Stories

Consistent Quality for Customers

India’s largest biscuit company operates over 50 owned and contract manufacturing units across the country. The theme “One Britannia, One Biscuit” focused on ensuring product consistency across geographies. This theme was translated into a measurable goal of reducing customer complaints by 50%.

Through our customized OPEX intervention, we worked with each factory for three years, during which processes were improved through Kaizen and sustained through Autonomous Maintenance (AM) and Planned Maintenance (PM). A comprehensive measurement framework was then established to monitor process enablers such as Kaizen, SOP adherence, and maintenance systems, as well as product outcomes such as complaints, defect rates, and product parameter scores.

These scores are compared within and across units, enabling internal teams to regularly develop and implement improvement roadmaps.

Rockwell – Lean is a Way of Life

Rockwell manufactures commercial freezers and bottle coolers, supplying both OEMs such as Coca-Cola and Pepsi, as well as the retail market. Initial constraints in the factory prompted the company to implement Lean-based improvements.

In the first year, the company doubled its output and reduced lead time by 75% through Lean initiatives. This success motivated Rockwell to continue its Lean journey year after year.

Refrigeration is a seasonal industry. At the end of each season, Rockwell’s teams assess their processes and identify opportunities for improvement. Based on this assessment, managers develop a Lean roadmap for the off-season period. Cross-functional teams are then formed to work on these initiatives, with plant trials and production ramp-up completed just before peak demand begins in January.

Over a period of five years, the company tripled its output and designed and established a new world-class single-piece-flow production line.