Testimonials

Our throughput time reduced from more than 10 days to 2 days. Apart from the tangible benefits, lean implementation has also helped to change the culture of working in the unit. Our team is now always exploring ways and means of improving the methods of working which will serve us for a long time.

Our throughput time in post molding operations has come down by 60%. This has enabled us to reduce our lead time to the customers thereby providing us a unique selling proposition to get more orders. We have now learnt the methodology of problem solving which has given out team the confidence to address our quality problems. Non-value-added activities eliminated which reduced our cycle time.

The lean implementation in our unit was a healthy, economical and a sensible change in our shop floor. Our operator movement was controlled within the cell and concentration was increased towards production. Monitoring became simple. Simple automation was implemented. Packing time reduced by 50%. Coil fixing time reduced by 75%.

We have reduced internal movement of components for 850 ft. to 460 ft. We have seen a good improvement in reduction in rejection. By layout modification in machine shop we were able to get better productivity. Over all we have seen a good improvement in the implementation of lean.

Through SMED, average setting time was reduced by 30-40% and this has improved our OEE significantly. 50% reduction in throughput time for our runner product. The development time of NPD has reduced by 33.3%. After layout change additional space created in the shop floor which helped us to plan for two more machines.

Our output has increased drastically. We now able to produce double that of previous output per line. In spite of increased output, we have been able to reduce manpower in all the assembly lines. Our potential financial benefit has been increased.

Lean workshops resulted in 30% reduction of our floor space which was used for adding further machines in same floor space. Implementation of SME has reduced setting time drastically which enabled us to reduce the delivery time. We have implemented online quality inspection in all shifts which has decreased the in-house rejection percentage.

Line concept has reduced inventory level drastically. Dispatch per month improved by 33.33% than before lean implementation. Fettling throughput time reduced by 60%. Inventory stock reduced by 56%.

The lean implementation overall changed the working mechanism of our works, its one herculean task which we are happy with. The working pattern changed and they approach new assignment is now meaningful.

Our labor productivity improved & rejection reduced. Changeover time reduced from 90 mins to less than 50 mins. Reduction in rejection percentage from 5.7% to 0.6%. Problem handling techniques has improved to all top level & middle level employees. WIP stock reduced from 10 days to 3 days. Production cost reduced.