© Indian Centre for Manufacturing Excellence
VISION
ICME visions to develop 1000 SMEs of India by 2022, making them
‘Best in Class' which in turn will contribute towards the Growth of Indian
GDP, help in New Employment creation and Making the Dream ‘Make
in India’ a Reality.
© Indian Centre for Manufacturing Excellence
MISSION
To build a World Class SME-University that will provide End to End
solutions to the Industry, covering all aspects of Business from New
Plant Designing (Green Field Project), R&D Support, Plant & Process
Layouts Designing, Technology & Machine Selection, Manpower
Recruitment, Lines setup, Key Skill Development, Trainings, Market
Research and Branding.
© Indian Centre for Manufacturing Excellence
OBJECTIVE
Support in the growth of GDP of Manufacturing sector from 16%
to 25% & 100 million Job Generation
Growth & Profitability Improvement of Manufacturing Industry
Man Productivity & Quality Improvement, Cost reduction/ unit,
R&D and NPD
Skill Upgradation
Senior Management
Middle Management
Junior Management
Faculty
Students
University Industry
© Indian Centre for Manufacturing Excellence
APPROACH
ICME is working together with Manufacturing Industries in different
Sectors to Make them Competitive, so that they can Grow from Small
to Medium and Medium to Large with Increase in Profitability via -
Trainings
Handholding
Plant Layout Designing with Process Engineering
Cluster Programs
Conferences and Summit
© Indian Centre for Manufacturing Excellence
FOUNDER
Ravinder Kumar is the Executive Director of Indian Centre for
Manufacturing Excellence (ICME). With more than 17 years of
experience as a Principal Counselor at CII-AVANTHA Centre for
Competitiveness, Chandigarh and practical auto sector working
experience, he has been able to translate his skills and knowledge in
field of TQM implementation into impeccable solutions through his
Practical training, Counseling and Mentoring.
© Indian Centre for Manufacturing Excellence
B.Tech in Mechanical Engineering, Certified TPM Facilitator from
JIPM, Japan and Certified Business Manager from Federal Ministry
of Commerce & Technology, Germany
Conducted 150+ Programs imparting training to more than 5000
professionals for improving Operational Excellence via tools &
techniques like 5S, 3M, Kaizen, TPM, SMED, Poka-Yoke, TPS,
Value Stream Mapping, Flow Manufacturing, Inventory
Management, Jishu Hozen, Integrated Quality Management, QCC,
LCA, 7 QC tools & Problem Solving tools
FOUNDER
© Indian Centre for Manufacturing Excellence
Served 100+ Organizations PAN India covering Indian, American
and German MNCs ranging from 10cr turnover to 20,000cr turnover
Reported savings for more than 5000 millions
Exposure to Benchmark Plants & Practices in detail with companies
like Toyota, BMW and Mercedes
Assessor for CII / ACMA / IMTMA Annual Awards at National Level
FOUNDER
© Indian Centre for Manufacturing Excellence
Customized 4-Year
Integrated Roadmap
(as per diagnosis)
© Indian Centre for Manufacturing Excellence
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24
Stability in process
Reduced Lead Time
Customer Satisfaction
Productivity improvement
WIP reduction
Manpower Optimization.
High ITR
Working capital management
In house rejection reduction
Warranty claim Reduction
Customer complaint reduction
Incoming part rejection Reduction
Zero Breakdown
Zero defect
OEE increase
1. Basic 5 S Operator Ownership
2. QCC Team involvement
3. Waste Elimination Cost reduction
4. Safety Safer Workplace
5.Suggestion / kaizens Total employee involvement
Time in Months : 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24
1. Takt Time
Work place
Improvement(Impro
vement culture)
ROAD MAP
Time in Months Deliverables
Road Map for Competitiveness : Foundation cluster
4. 7 QC Tools
Inventory Management
(Improved cash flow)
Lean
(Introduction)2. kanban Linkage
1. My Machine-Step 1 ,2,3
2. Prev. Maintenance
3. Daily work management
workplace
Ownership(Paradigm
Shift)
Quality management (Quality
excellence)
1. SOPs
2. Process Quality
3. Poka Yoke
Productivity
improvement(Productive
work culture)
1. Cell layout
2. single piece flow
3. Multi machine manning
3. Logistics
1. Quality of Inventory
2. SMED
3. Containerization
FOUNDATION CLUSTER ROADMAP
© Indian Centre for Manufacturing Excellence
ADVANCE CLUSTER ROADMAP
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24
EEC
Sustenance
Clarifications
Future Plans
1. Value adding Management (Concepts , Design & Implementation) VAPCO
1.1 implementation of 14 steps of Lean VAR
1.2 Production Balancing and Leveling
2. Integrated Cellular Management ( implementation & Practice )
1. Concept of Cell design and implementation Lead time
1.1 SMED (Integrated to SPF) ITR
1.2 LCA (Integrate to operator Fatighue / Stresses ) Process Stability (Quantity and Quality)
1.3 integrtaed Quality control (Poka -Yoke, Vision Control) Customer Quality (PPM)
2. Equipment Miantenance OEE /OLE/ OPE
2.1 Step 1 2 3 (Implementation and Video training) Cost Losses
2.2 Preventive Maintenance (Implementaion and practice)
2.3 Organization / Management
2.4 Cost loss Analysis
1. Institutionalize all 5 S Basics Advance 5 S : Audit Score
2. 6 M Concept Design , Process Mapping and Implementation PQC improvement
3. Holding Gains and Corrective Actions
Total Employee involvement
Employee satisfaction Score
Participation Kaizen / QCC
Training Modules
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24
3. Future Plans
Advance 5 S (sustenance culture
through Discipline)
TEI (Continuous
Improvement Culture
Through TEI)
Introduction to Engg. Cluster
1. Refreshing of All Training and Learning's
Integrated Flow Manufacturing
(Bussiness Culture)
3. Material Handling
5. 7 Management Tools
1. Introduction of Engineering Excellence Cluster Contents
Cellular Manufacturing (Productivity culture)
Road Map for Competitiveness : SME Advance course
Re-training
(Sustenance Culture)2. Sustenance Plans
5 . FIFO
5.1 First in First produced -Integerate to Quality Traceability
3.1 Material Handling Management and Control
4. FPS (forecasting Planning & Scheduling)
ROAD MAP
Time in Months Deliverables
1. kaizen
2. QCC
3. QC Story
4. 7 QC Tools
6.Talent development and Retention
7. Satisfaction Survey
Time in Months :
© Indian Centre for Manufacturing Excellence
Creation of Model Handtool SME with Cluster inputs:
HR International reduced 50% Manpower in Jalandhar (Appx.350
Persons at Plant Level)
Eliminated complete one Shift (Saving of 3 Crore/annum)
See-through Layout- Godrej, Mohali
Shining Model Lines via 5S
Jogging Track around complete Plant
WCP and Gate Meeting via TEI
Hospital Clean inside and Garden Green Outside
Coconut to Car Parking
Standardized Display Boards- Demag Cranes, Pune
Integrated Inventory Mgt, Material Handling & Control- TVS, Hosur
Scrap Management & Control- TVS, Hosur
INNOVATIVE CHANGES
© Indian Centre for Manufacturing Excellence
INDIAN PRODUCTION SYSTEM
Present System New System
Grinding Machine
Magnetic separator
Paper band filter
Coolant tank
Grinding Machine
Double Magnetic separator
Cyclone
Coolant tank
© Indian Centre for Manufacturing Excellence
RESULT
Not Environmental Friendly
Present System New System
100% Environmental Friendly
© Indian Centre for Manufacturing Excellence
INDIAN PRODUCTION SYSTEM
Present System New System
Machine
FAT Electrical Panel
AC for cooling
Machine
Lean Electrical panel
© Indian Centre for Manufacturing Excellence
RESULT
Not Environmental Friendly
Present System New System
100% Environmental Friendly
Panel Size : 1000mm (W) x 1000mm (H) x 300mm (D) Without AC
Panel Size : 2800mm (W) x 1700mm (H) x 500mm (D)
With AC
© Indian Centre for Manufacturing Excellence
INDIAN PRODUCTION SYSTEM
Present System New System
Machine
FAT Power pack
Chilling unit
Machine
Lean Power pack
© Indian Centre for Manufacturing Excellence
RESULT
Not Environmental Friendly
Present System New System
100% Environmental Friendly
Hydraulic Power pack : 220 Liters with Chilling Unit
Hydraulic Power pack : 70 Liters without Chilling Unit
© Indian Centre for Manufacturing Excellence
MANUFACTURING PLANT
Along the
Wall
Men / Material
Movement
Jogging Track See Through Layout
AIS
LE
FO
R
MA
N M
OV
EM
EN
T
© Indian Centre for Manufacturing Excellence
MANUFACTURING PLANT
OUTSIDE INSIDE
Hospital Clean Garden Green
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