Mopex model From Mattcons
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Operational Excellence Model (MOPEX) DEVELOPED BY :- Mattcons Services Private Limited
description
Mattcons Operational Excellence Model shortly (MOPEX) is the systematic management approach to achieve world-class performanceby focusing operation optimization, safety, environment, reliability and efficiency. Value Proposition from Mattcons IncreasingProfitability and Cash Flow. Driving CultureChange. SupportingGrowth initiatives and New product development. Beyond theBasics. Supply ChainManagement: The Real Improvement. Focus onMaintenance: Key for enhancing Profitability. Where will your Operational Excellence journeytake you? Reduce ManufacturingCost by 20 % Number of Breakdownreduced by 50% OEE improved by 30 % Reduction DefectiveProducts by 50% Customer Complain downby 60% Inventory down by 30% Major Accidents reducedby 100% Improvement ofSuggestion 10 times Improve 5S score by 80% Machine Changeover timeby 40% Reduce EnergyConsumption by 20%
Transcript of Mopex model From Mattcons
Operational Excellence
Model (MOPEX)
DEVELOPED BY :-
Mattcons Services Private Limited
ABSTRACT
What is Operational Excellence and our Process.
Key Results from Operational Excellence
Time line for OE Model.
Methodologies we used.
Sector’s that MOPEX model Cover.
Our Client Achievements
About Mattcons
Mattcons Client’s
Contact us
Bakery Industry
OPERATIONAL EXCELLENCE
Operational excellence model helps achieve
business goals while lowering costs and
improving cycle times.
It standardizes processes and integrates
operations across multiple channels of supply
and distribution, supporting high-volume, low-
margin business strategies.
MOPEX Model
KEY RESULTS FROM OE Reduction of Manufacturing Cost by 20 – 30 %
Improve the Net productivity up by 30 - 60 %
Number of Breakdown reduced by 10 - 80%
Overall Plant Effectiveness by 30 - 50 %
Reduction Defective Products by 50%
Customer Complain down by 40 - 60%
Inventory (Only Spare parts) down by 30%
Major Accidents reduced by 50%
Minor Accidents reduced by 40%
Enhance the Employees Moral by 5 times
Improvement of Suggestion 10 times minimum.
Workforce uncertain absent-ism down by 5 times.
Benefit’s
INTANGIABLE BENEFIT’S
Benefit’s
Achieving full Self Management – Operators have ownership on their equipment.
Enhancing skill and knowledge of workforce by training.
Building CANDO attitude by eliminating breakdowns and defects.
Enhancing the communication among all team members.
Make the workplace clean, bright and lively and Giving plant visitors a better image.
Making all losses more visible and enhance safety of plant.
Making the plant with more visual display.
MOPEX
Mattcons Operational
Excellence Model
PROCESS
Increase Profitability and Cash Flow
Driving Culture Change
Supporting the Growth initiatives
New product Development
Supply Chain Management
Focus on Maintenance
Beyond the Basics
OE Process
Increase Profitability and Cash Flow
OE Process
Mattcons strategies, tools and techniques and
our methodologies designed for
Improving business performance.
Improve equipment uptime (OEE).
Reduce scrap.
Improve yield.
Improve quality & productivity.
Accelerate set-up/change-over times.
Reduce lead times.
Optimize inventory.
Driving Culture Change
OE Process
Companies who successfully leverage operational
excellence as part of a strategic platform for
growth often achieve market performance well
beyond their nearest competitors.
We can help you how to expand continuous
improvement into non-manufacturing areas.
Enhance sales force productivity.
Optimize the maintenance activities.
Enforcing the employees in all level.
Supporting the Growth initiatives
OE Process
Creating growth initiatives without losing focus
on the core business.
We will share Industry best Kaizens, Suggestions
that really works and One point Lesson (OPL).
Help your bottom line to develop more small
ideas which will help ultimately transform your
business
New product Development
OE Process
We will share best practices for applying
process excellence to new product development
and commercialization, Efficient product
development processes closely integrated with
the operational processes .
You will gain important advantages, such as
reduced lead time to market, improved quality
and increased development capacity.
Supply Chain Management
OE Process
The complex and often costly internal supply
chain processes is one area that many
businesses seek to improve.
By “killing complexity” in the overall supply
chain system, companies will experience
better, faster delivery with lower costs.
Focus on Maintenance
OE Process
Proper maintenance of plant equipment can
significantly reduce the overall operating cost,
while boosting the productivity of the plant.
Hence another perspective of looking at
maintenance function is not only to maintain
but also to enhance the process or the plant
operation system as a result of turnaround
planning.
Beyond the Basics
OE Process
Many manufacturing organizations need to expand
continuous improvement throughout the enterprise
and seek training to expand capabilities into
marketing, customer service, engineering ,new
product development and quality control.
Mattcons web Matrix is the helps the organization
to increase web penetration, getting higher orders
from online, increase the site rank & traffic.
TIME LINE FOR MOPEX MODEL
5S.
KRA Set up.
RCA .
Basic Training to Operators.
TPM Implementation.
Lean Manufacturing.
Quality Management.
Focus on Online Marketing.
TPM Certification.
ISO Certification.
GMP Certification.
Kaizen Award.
18 months
6 months
12 months
Time line
TOOLS THAT WE USED
TPM- Total Productive Maintenance and 5S.
SMED and RCA – Root Cause Analysis.
Kaizen and FMEA – Failure Mode Effect Analysis.
Lean Manufacturing.
Value Chain and Value added analysis.
Management System.
Strategic Alignment.
RCM and TQM – Total Quality Management.
Mattcons web matrix.
INDUSTRY COVER
Steel Plant
Cement Plant
Sponge Iron Plant
Power Plant (Coal Based)
Chemical Plant
Fertilizer Plant
Formaldehyde Plant
FMCG
Bakery Plant
Food Processing Plant
Pharma and Healthcare
Bottling Plant
Automobile Company
Glass Manufacturing
Oil and Gas
Textile Plant
Many more visit our Client Portal
for more details.
www.mattcons.com
CLIENT’S ACHIVEMENT
Formaldehyde Plant Located in Egypt
63 72
80
0
10
20
30
40
50
60
70
80
90
2010 2011 2012 (EXPECTED)
Plant OEE - Productivity
64
53
45
0
10
20
30
40
50
60
70
2010 2011 2012 (EXPECTED)
Avg. Delivery Lead Time
1,064
642
400
0
200
400
600
800
1000
1200
2010 2011 2012 (EXPECTED)
Machine Down Time
11756450
10804525
8000000
EGP 0
EGP 2,000,000
EGP 4,000,000
EGP 6,000,000
EGP 8,000,000
EGP 10,000,000
EGP 12,000,000
EGP 14,000,000
2010 2011 2012(EXPECTED)
R&M Budget
CLIENT’S ACHIVEMENT
Formaldehyde Plant Located in Egypt
28
83 90
0
10
20
30
40
50
60
70
80
90
100
2010 2011 2012 (EXPECTED)
5S Score
80
55
50
0
10
20
30
40
50
60
70
80
90
2010 2011 2012 (EXPECTED)
Inventory - Spare Parts
7873514 6782805
6500000
0
1000000
2000000
3000000
4000000
5000000
6000000
7000000
8000000
9000000
2010 2011 2012 (EXPECTED)
Energy Consumption - KWH
37
11
1 0
5
10
15
20
25
30
35
40
2010 2011 2012 (EXPECTED)
M/C Break Down(Major)
CLIENT’S ACHIVEMENT
Visit our website for
More details :
www.mattcons.com
10.8
73.6 95
0
10
20
30
40
50
60
70
80
90
100
2010 2011 2012 (EXPECTED)
Mattcons Web matrix
Formaldehyde Plant Located in Egypt
10
364
500
0
100
200
300
400
500
600
2010 2011 2012 (EXPECTED)
Number of Suggestions
19,785,320
5,421,678
800,000
0
5,000,000
10,000,000
15,000,000
20,000,000
25,000,000
2010 2011 2012 (EXPECTED)
Website Global Rank
ABOUT MATTCONS
The company was setup with the objective of providing
senior managers, Top management with a more effective
resource to help resolve complex strategic and operational
issues.
Our reputation and credibility have been built through
delivering practical and implementable solutions to clients –
both domestic and international covering both the
manufacturing and the service sector.
one stop company for all services that you need with most
cost effective way with higher return over investment value.
About Mattcons
MATTCONS OFFERINGS
Management Consulting
Green Consulting
Condition Monitoring
Project Management
Operation Outsourcing
Industrial Trainings
Maintenance Products.
For More details kindly visit our website www.mattcons.com or
Drop an email at [email protected]
About Mattcons
MATTCONS CLIENT’S
Some of the project was executed with the help of AMC - Asset Management
Consultant & TPMWAY - A subsidiaries of Mattcons. About Mattcons
Visit our Client
Portal for More
details
CONTACT US
Email :: [email protected]
Open Line :: +91 – 902 900 5850
Phone :: +91 – 22 – 412 36 302
Office Location
Mattcons Services (P) Limited. Waghbill Naka, Thane – West,
Mumbai – 400607 Email – [email protected]
Phone - +91 – 412 36 302
Mumbai - India BBSR - India Mansura - Egypt
Mattcons Services (P) Limited. Kalyan Nagar, Pallahat,
Khurda, – 752055 Email – [email protected] Phone - +91 – 986 101 5544
Mattcons – EMEA Region Business Development Center. Aga-Dakahlia–Egypt – 35516
Email – [email protected] Phone - +20 – 106 378 4682
www.mattcons.com THANK YOU
