Lean implementation in Manufacturing, Apparel and Service Industries

Lean is a powerful concept pioneered by Toyota, which is now practiced by many organizations as a philosophy for Business Excellence. Both Six Sigma and Lean are adopted as strategies to achieve Business goals in most of the organizations.
Lean exposes waste and non-value adding activities in the organization and Six Sigma helps to reduce variation in the process. Together they help organizations to significantly improve their bottom-line results and satisfy employees and customers. In a typical organization less than 5% activities are value added!!! Rest of them are non-value added and increases product cost.
We have two strong approaches for lean implementation

• Use of value stream approach: Focus on big picture and to avoid isolated improvements
• Development of 100 % employees on lean: To build lean culture for sustaining results

Six Sigma Consulting

We recommend use of Six Sigma to solve chronic problems after building a strong foundation through TQM and lean principles. Otherwise many Six sigma projects end addressing basic issues like 5S, flaws in Quality Management systems etc.

Six Sigma is a mindset not just statistics

"I am solution finder” is a 32 hour problem solving program designed for all level of employees including manufacturing and service. This covers problem solving and basic 7 tools. This Japanese method helps to identify, analyse and solve the work place problems using systematic methodology. 80 % of day to day problems can be solved using this methodology. Only 20 % of problems which are chronic in nature (after screening through Quality Management systems) take Six Sigma rout. 1 days Yellow belt, 4 days Greenbelt and 8 days Black-belt courses enable people to solve chronic problems which are not able to solve through Quality Management systems OR "I have solutions"

TPM ( Total Productive Maintenance) Consulting

What: TPM is a culture that focuses on improving the effectiveness of the plant, equipment and processes through the empowerment of PEOPLE

How: Using 8 pillar model and methodology as suggested by JiPM.
Duration(Scope): We will help for min 2-3 years ie. till beginning of realization OR achievement of TPM excellence award from JiPM.
Benefits: Improvements in PQCDMS* results. Cultural transformation. Total employee involvement. Organizations can go ahead of competition and build a recession proof business
*PQCDMS – Productivity, Quality, Cost, Delivery, Moral, Safety

Company X production system design

What: Designing a customized production system like Toyota Production System, Ford Production system to suit your business model
How: Using our 7 Step process
Duration(Scope): 1 years, Design- Validate-Run- Sustain and improve
Benefits: Robust systems to suit business requirements. Achievement of expected financial and growth results