Results Achieved by Us

For Which Company/Business?

Here are the Samples of Results2 we achieved

1) Overall productivity improved e.g. One type of alternator output improved by 200 %. 2) The lean effort helped accommodate the increased output in the same square feet space.   3) Employee Involvement - Improved to Near 60%On-going.

Some interim improvements in the process of targeting 100 % reduction in Electricity power restoration time are as follows. 1) SCADA control panel operations made Error free. 2) Cycle time reduced from 2-minutes To ½ minute. 3) Search time for tools reduced from 5-minutes to 1-minute. 4) Employee Involvement - Near 90% in some locations

1) En-route LEAN Production System, some ppm Improvement/s achieved are e.g. Gun Drill Breakage in DSLA –100% Improvement, Nozzle damage – 100% Improvement 2)Employee Involvement - Improved to Near 30%. Balance internally scaled-up.

1) Productivity up 33% in Gear pumps 2) Inventory reduced- 200 % in Gear pumps 3) Some Set-ups crashed (from 300) to 1 minute 4) OEE Improved (From 43 to 83% on Model Machines) 5) Engine Test bed - Flexible to take 3 models(that previously used to test only 1 model), - Productivity up 100% 6) Won CII award for above achievements

1) Productivity increase 56% in center section 2) Set up time reduced - 78% on bottleneck m/c 3) OEE Improvement (From 39% to 85% on VMC) 4) Capacity Increased by 100 % 5) Reduction in Material movement – 66% 6) Overall Lean score in Gear Pump improved from 1.4 (Apr’03) to 3.1 (Jul’04)

7) Employee Involvement – Improved to Near 90% 8) Before ppm – 5 digit, After – 4 digit (3months)

1) Company-wide Kaizen implementation by us enabled producing culture change evidence at grass root level (for theDeming Award process) 

2) Employee Involvement -Improved to Near 90%

3) Before – 5 digit ppm Defectives

After – 4 digit ppm Defectives

First-pass Results compared to old-plant: 

Transportation steps reduced from 49 to 25

WIP storing stations reduced from 41 to 20

FloorSpace per Unit production reduced from 35 Sq.Mtr to 25 Sq.Mtr

Cleanliness-n-Ambiance 5”S” score improved from 50 to 80+

(US multinational)

Business (Large Scale, 2500+ people) - Electricity generation – Hydro, Thermal, Location – All India (Indian multinational)

Business (Large Scale, 2400+ people) - Fuel injection equipment. At Nasik (German multinational)

Business (Large Scale, 2500+ people) – Diesel Engines,

Location – Pune (US multinational)

Business (Large Scale, 500+ people) – Hydraulic systems, 

Location - Pune

(US multinational)

Business (Large Scale, 2500+ people) – Tractor Farm equipment, 

Location – Nagpur

Business - Alternators/Generators 

Location- Pune (US multinational)

 (Indian multinational)