Introduction: Kanban Transforms Machine Manufacturing: From Chaos to Cost Savings. Our client Machine Manufacturing is a medium-sized company specializing in the production of industrial machinery for plastic processing. They have a diverse product line ranging from Extruder machines to automatic machines used in various plastic industries such as beverages, chemicals etc. Challenges: So, we took…
Introduction Have you ever considered the transformative impact that implementing 5S principles could have on the mining and mineral processing industries? Despite the inherent challenges of dusty environments and complex operations involving manpower, machinery, and materials, one of our clientsβa prominent player in this sectorβfaced inefficiencies in material management, space utilization, and procurement processes. These…
Introduction: Our client, a machine manufacturer, faced declining productivity due to rework, excessive worker movement, and space constraints. This resulted in wasted time and inefficiency and led to high throughput lead time. To address these challenges, the company adopted Kaizen, a continuous improvement philosophy. This case study explores how Kaizen techniques were implemented to streamline…
Introduction The machine manufacturing industry faces an increasingly competitive environment, grappling with several key challenges. Globalization has intensified competition, requiring manufacturers to constantly innovate and offer cost-effective solutions to stay ahead. Additionally, the rapid pace of technological advancements demands continuous investments in research and development to integrate automation, AI, and other cutting-edge technologies. Furthermore, evolving…
Challenges Our client, a leading manufacturer of machines used in the textile processing industries, faced a daunting challenge amidst escalating competition and heightened customer demands for quicker lead times. Our client’s machine-building process was marred by inefficienciesβlong lead times, untapped manpower, and excessive material movementβhindering their agility and profitability. Solution We introduced Value Stream Mapping…
Introduction In the competitive realm of textile manufacturing, the perpetual struggle to optimize efficiency and reduce costs is ever-present. However, our client, specializing in the machining of textile machinery components, has successfully navigated these challenges, rewriting its own rules through a series of impactful improvements by adopting the various tools of lean manufacturing. Challenges The…
Introduction In the relentless pursuit of operational excellence, every facet of a business comes under scrutiny. Inventory management, the lifeblood of smooth operations, is no exception. But simply stockpiling products isn’t enough. To optimize inventory, businesses must delve deeper, employing a variety of analytical techniques to understand, categorize, and optimize their stock. This is where…
This is a very famous case study of Ford transmission system vs Japanese transmission system. Both were manufactured as per drawing. But the difference was in the consistency. Japanese parts consistency was much higher. They were not just matching drawing specifications. But were very close to each other. Which means technically their process capability was…
5. No FPP (Fixed Point Photography) “You have to know the past to know the future – Carl Sagan” Taking before picture of your 5S activity is like keeping history of what was happening. Before you jump to 1S, 2S, 3S…… wait. Take time and capture current state in photographs. You have to be thoughtful…