Operational Excellence
We provide a long-term sustainable operational excellence program
Our philosophy of operational excellence in manufacturing industry revolves around three major components i.e., Inventory Management, Waste Control and Process Improvements. We provide a framework to improve performance and productivity continuously through improved processes. Our methodology is focused to eliminate waste across the value chain which ultimately drive costs down and deliver quality goods and services.
We believe that the Lean Manufacturing Style brings dramatic results with discrete production systems. The key focus of operational excellence is to reduce the manufacturing throughput time from the raw material receipt till the finished product is ready for dispatch.
Our Process
Our first step is to access the current processes, systems, resources & operations to identify and prioritize the potential areas of improvement.
Based on our assessment, we provide a full diagnostics to the management with alternates for areas of operational improvements.
After management approval, we implement the plan by deploying our resources, incorporating SOPs and work with the management for organization-wide changes to achieve the desired results.
After implementation, we train the relevant teams on the new processes, resolve issues, clear bottlenecks and continue reviewing the post implementation situation to ensure smooth running of the operations.
WIP Inventory Management
Review existing levels of inventory at each step of processing, find the areas of improvements and recommend practical solutions.
Reducing manufacturing work in process (WIP) leads to higher liquidity, better cash flow, enhanced customer service and diminished business risks. Large benefits can be gained when WIP is reduced significantly, focusing on raw materials as well as finished products. WIP can affect various areas in the manufacturing process, like labor productivity and line efficiency. These are typically important bottlenecks in a manufacturing operation.
Improving Waste Management Practices
Propose Actions
Such as on-site wastewater recycling and other systems that change the way wastes are managed,
Employee Training
Training and awareness may be required to successfully implement actions and support the introduction of new equipment or processes, such as (in textile) better segregation of wastes into fiber types, colors and processes that maximize recycling opportunities and ‘waste’ value.
Written Plan and Clear Targets
Results are more likely to be achieved and maintained with written plans and clear targets agreed by all areas of management. Prioritize actions and consider beginning with the ‘low-hanging fruit’ for fast gains and to generate enthusiasm.
Monitoring waste generation and disposal
Such as checking collection contractors’ invoices or benchmarking production against raw material purchases, is important for environmental compliance, stock control and to measure (and reward!) improvements.