Case Study

Case Study

Planning, Scheduling, BPR, Method Analysis and Multi skilling

Engineering - Machine Building - MSE

Stream lining of Planning processes
Improvement in scheduling
Development of Multi skilling through on Job Training
Identification, Exhaust and removal of Constraints
BPR
Continuous measurement of Productivity, output, process timings and throughput, initiate corrective actions and measure effectiveness.

Production Enhancement - from 60 Lacs a Month to 200 lacs a Month.

Time and Motion Study

Petrochemical ‐ Large Scale

Take an inventory of the total process
Total process is sub divided in a set of small measurable activities
Each activity was measured in terms of Method, Time consumed for various activities and involvement.
On conducting a time study we got a range of times for an operation depending on the number of cycles captured.
A Lean analysis was carried out for the operation.
VA, NVA and required NVAs are identified.
Process reengineering was carried out.
Improvements on the working methods are done to remove/reduce the identified NVA's
Work load balancing is done to maximize the utilization of the workforce and achieve the desired productivity levels

Total No of Processes - 185 Processes
VA identified - 106 Processes
Required NVA identified - 24 Processes
NVA identified - 55 Processes
Manpower restructuring - Reduction of 20% Manpower from the existing processes, training imparted and place them in other processes.
Total cost saving - @192 lace per annum.

Training - Knowledge and Practical

Engineering - Rail coach Manufacturing

Electricals for non electrical

40 Ladies were selected - Basic qualification Std 10 Pass.
Class room Training provided on Basics of Electrical Engineering.
Total Training Tenure - 120 days
Target production per person per day was fixed, Ladies are trained for making panels, wire harness and assembly.
Project completed