LEAN TECHNO – Manufacturing Service Proposal · product costing Client Prospective Leading to...
Transcript of LEAN TECHNO – Manufacturing Service Proposal · product costing Client Prospective Leading to...
LEAN TECHNO –
Manufacturing Service Proposal
� MANUFACTURING
www.leantechnocrats.com
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Who We Are
We are pleased to introduce Lean Techno… The Growth Accelerator as
Manufacturing, Consulting and Training Service provider. The wide spectrum of
hands on skills on various industry domains, helps us to reduce risk and offer
competitive cost.
� Vision:
To establish Lean Techno as a leading service brand of customer choice. We
aim to reach the unreached and provide seamless services with sense of
ownership for the growth of our customers, business partners, employees &
society.
� Mission 2020:
Building passionate empowered & accountable Lean Techno team for catering
long term customer base by instilling organizational values of
Care : for customer growth;
Challenge: the status quo
Courage: to take risk
Conviction: for success
We Accelerate Growth for the companies
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Leadership Team
Sudipta is Lean Six Sigma Certified Black Belt with dynamic 18 years manufacturing career reflecting pioneering experience in mentoring high impact continuous improvement projects in the field of Quality, Cost, Delivery & People engagement. He has been involved in leading and implementing organization wide improvement initiatives like six sigma & different Lean management tools.
Sudipta Sarkar
Arun holds Engineering Degree in Electronics and Telecommunication from VNIT, Nagpur. 20+ years of cross functional experience across the verticals of Plant operations, Lean implementation, Supply chain & Logistic management and EMS set up. Working experience with reputed consumer electronics, automobile ancillaries and embedded product development companies. .
Arun Dakhole
We love what we do, we go for excellence not for success and our energies
are infectious…
What We Do
Manufacturing
Product designing & manufacturing are two unlike worlds. We connect designing & mass manufacturing through our extensive exposure & experience
Consulting
We interpret Lean as a culture, more than a set of efficiency and improvement techniques. We inculcate strategies & implement through practical hands on approach that help organization to deliver meaningful & measurable milestone
Daily Management System (DMS)
Design and software development of the Daily Management System to monitor the Operational Excellence Indexes
Training
We Customize 360 degree training programs targeted towards building lean culture, developing our client’s internal competencies & sustaining operational excellence.
In a short span of time, we are proud to get associated with various industry
domain through our service offerings
Q4’ 16 Q1’17 Q2’17 Q3’17 Start Q4’17
LEAN TECHNO –
Manufacturing Services
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Domains of Manufacturing set up
1. People
Connect
2.Process
Engineering
3. Mgmt.
of Supply
chain
1. People Connect: Quality, productivity and elasticity come
from the willingness of staff rather than a
particular technique.
2.Process Engineering:
Each process must be :
simple (Lean Manufacturing)
reliable (Design For Six Sigma)
flexible (almost zero change over time)
elastic (very quick changes in capacity)
3.Management of Supply chain processes The design and implementation of the supply chain must meet the customer’s exact requirements Delivery :When they want it. Quality :Get what they order and it works Design :Meets their requirements
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Challenges in Supply Chain
� Managing key
supplier for delivery
timeline
�Transport
productivity de-growth
� Lack of Quality
standard during mass
production at supplier
� Very low material
productivity y-o-y for
lack of benchmark of
standard data
� Not capable of
product costing
Client Prospective
Lea
din
g t
o
� Tailor supply chain for
key clients
�Managing stocking
policy & healthy stock
� Managing process
robustness of supplier.
� Aggregate supplier
data
� Product costing
through standard time &
RMC benchmark
Lean Techno Prospective
Collaborate with Lean Techno Platform (LTP)
� A new client, is new
process audit & new set
of qualification
�Demand fluctuation &
resource management
� Lack of Quality
standard for skill
competency retention
� Very low productivity
year on year cost
reduction pressure
� Not capable of
product costing through
standard methodology
Supplier Prospective
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Blue Print of Lean Techno Platform
Tailor Supply Chain
• Process mapping for specific characteristic of client
• Healthy stock, Stocking policy, simplify Information flow
• Demand management, Production control
Cost Benchmark
• Product costing through standard time
• Aggregate cost of standard parts
• RMC database
Process Robustness
• Quality assurance through RCA methodology, CAPA, FMEA
• PCS control
• Autonomous operator
• Pokayoke & Jidoka
Adhere to Just-in-time principles, ride through zero defect but goal is
Cost benchmark …..
LSL USL Average
Target
Capable and on target $
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Challenges in People - Process
� Market fluctuation,
Volume pressure from
supplier
�Weak link in value
chain
� Lack of commitment
in Quality & Delivery
� Product life cycle &
risk of obsolescence
Client Prospective
Lea
din
g t
o
� Cellular layout &
process design, Flow
bottleneck, Quick
changeover, flexible &
ergonomic workstations
� Competency
development, succession
planning, KPI tracking
�Design of supermarket
with PULL trigger
� Smart warehouse
�Lean Logistic system
�Ramp up – Ramp down
policy
Lean Techno Prospective
Collaborate with Lean Techno Platform (LTP)
� Capex investment is
key unless volume
confirmation
�Capability & Flexibility
issues
� People competency &
retention issues
� Unhealthy stock,
dead inventory
Supplier Prospective
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Blue Print of Lean Techno Platform
Line Architecture Design
• Removing conflict flow
• Lean line architecture
• Low cost automation, Jig fixture introduction
• Time trap & SMED
Key resource pool
• Competency & Succession plan
• Dynamic management, Escalation matrix
• Multi-skill & Versatility
• Employee suggestion scheme
Lean Logistic
• Supermarket sizing
• Visual Control
• Just-in-time operation
• Warehouse design & smart MPH system
Engage people with simple layout to achieve speed in logistic …..
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Benefits – Lean Techno Platform
Process Area Indicator Benefit Realized Quantum of Improvement
Procurement Inventory turns Improved By 30%
Planning Lead time Reduced By 50%
Planning On time delivery Improved By 20%
Quality Non Quality cost Reduced By 50%
Operation Time spent/ unit Reduced By 40%
Operation Logistic Efficiency Improved By 30%
Business (P&L) Raw material cost Improved 2-5%
Business (P&L) Variable cost Reduced 2~5%
Business (P&L) Gross Margin Improved 1-2%
Gross Margin improved by 2% after 12 months of Lean Techno platform collaboration and restore resources energy
Domain 1
• Reliability - The ability of an organization to consistently perform its intended or target mission on demand without failure
Domain 2
• Capability – Measure of the ability of an entity to achieve its objectives, specially in relation to its overall mission
Domain 3
• Flexibility – Ability to change easily according to customer need
Domain 4
• Information – It is a paradigm of supporting users in doing their work by delivering them information proactively related to the current working.
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Why Lean Techno…
Now- In build criteria
The four domains which are to be focused for top line growth are:
Quality Cost Delivery
Traditionally Quality, Cost and Delivery are the deciding criteria for becoming a
supplier of choice. Today with fundamental change in customer satisfaction
definition these are rather intrinsic requirements.
We don’t compete with others , we only compete with ourselves…. Our energies are infectious
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Lean Technocrats India Pvt. Ltd. Plot 79, H. No. 15‐15/79, Sudarshan Nagar Colony, Opp: HCU Bus Depot, Serilingampally,
Hyderabad, Rangareddy, Telangana, PIN‐ 500019, India. Contact No: +918978993358 Email Id: [email protected]