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 inefficiencies—long lead times, untapped manpower, and excessive material movement—hindering their agility and profitability. Solution [...]
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 [...]
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 [...]
Introduction In the ever-evolving landscape of the manufacturing and processing industry, the quest for precision, safety, and efficiency never ceases. This case study unveils the remarkable journey of a manufacturing industry’s instrumentation workshop that harnessed the power of the workplace excellence methodology to not only optimize its layout but also [...]
The Need for Operational Excellence in Chemical Industries Welcome to the world of chemicals, where innovation meets precision. Today, we delve into the remarkable journey of a chemical company that transformed itself from good to great through the power of continuous improvement. The chemical industry is a complex and demanding [...]
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 [...]
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. [...]
4. Not keeping log of Red Tag items “You can’t manage what you don’t track – Valentino Crawford” In a large government utility once after doing a massive 5S campaign and removing a lot of items in 1s (Red Tag), the top management was reviewing the status. Suddenly a senior [...]
