Agile Profile 20160614
- 1. Business Excellence through People Excellence www.albs.co.in Agile Lean Business Solutions (ALBS) Introduction Flat No. 108, Sri Srinivasa Mansion, 5th Block, 1st stage, 19th Main, 38th Cross, HBR Layout, Bangalore – 560043, India. e-mail - abhayasangal@gmail.com abhaya@albs.co.in +91 – 99019 60727 (Abhaya) +91 – 94480 41782 (Abhaya)
- 2. Business Excellence through People Excellence Page 2 of 6 www.albs.co.in Our Background & Experience ALBS is a team of professionals with more than a fifteen years of experience in associating ourselves as catalysts with organizations with a view to facilitate their team members to start using Lean Thinking as a means to awaken their dormant strengths to meet ever increasing market challenges. As a matter of this catalytic approach the organizations learn to implement Japanese Lean production techniques such as 5S (Safety Included) / JIT / SMED / KANBAN / TPM / TPS etc. The extensive experience of each member of our team has been in a variety of High Volume and Low Volume Electrical, Electronics, Engineering, Automotive, Telecommunication, Machine Building, Continuous Process and many other Industries where Lean / Kaizen application has lead to the business bottom-line benefits and improved service to customers. Our consulting philosophy and approach is, two prongs: a. Bottom-Up: “GO & SEE at the work place (Genchi Genbutsu)” combined with “Hands-on-implementation” philosophy to induct lean among all front-liners b. Top-Down: Simultaneously to Bottom-Up we apply “Thinking-with-hands” approach, to introduce Lean among rest of the organisation. In both the situations we get things done by heading straight to the shop-floor, dirtying our hand along with all the team members and thereby setting an example. We have a background of associating with well-known corporations to assist them in implementation of Lean / Kaizen / Lean Sigma. We are constantly on call by organizations and many professional event organizers to conduct in-house workshops on Lean Manufacturing, 5S, TQM, SMED and TPM and conduct public training programs. How ALBS Can Support you? 1. ALBS through their unique catalytic approach can help you develop a. Self Managed Teams (thru’ Total Employee Involvement) at your work place. b. Self motivated employees at all levels having a deep urge to identify and remove waste from day to day shop-floor activities c. Deep rooted culture of Continuous Improvements (Implemented Kaizens). This approach is expected to create Lean Thinking individuals at all levels of organizations which then ensures that Lean implementation in the organization is sustainable, even after hand-holding of teams by ALBS has stopped. 2. ALBS can act as a catalyst in creating an in-house culture and capability at all levels to solve problems internally rather then depending on external agencies – In today's business situation the difference in a “GOOD” & “BETTER” organization is the SPEED at which solutions to problems are implemented. This also determines your “Business Velocity & Customer Service”. 3. ALBS may help you identify the skill gaps and create a training programme to enable you face the challenges of employee absenteeism during difficult times (Multi-skill) 4. ALBS will work with your teams in reducing the long set-up times for the bottleneck machines – This will help increase your Business capacity forever in future and almost at no-cost.
- 3. Business Excellence through People Excellence Page 3 of 6 www.albs.co.in 5. ALBS can look at product in-house quality issues and help develop processes so that organization is always getting the first time right quality. All improvements in this direction add value directly to the Business Bottom Line (TQC) 6. With the help of ALBS your team members will learn to identify and prevent the machine break downs among crucial machines. This, therefore, will improve machine utilization of such crucial machines (TPM) 7. ALBS will make aware supervisors at shop floor to learn “How to finish more number of pieces per hour” without asking for more machines and more helpers. This may also help you increasing your business capacity. This is done by introduction of Lean concept of Cell Manufacturing, Single piece flow; PULL Production, Standard WIP etc. 8. In case if you are concerned about your inventory carrying costs and inventory turns ALBS can work with your team to implement any or all the following Lean concepts: a. Raw Material Kanban or JIT supplies combined with PULL procurement and Vendor partnership, b. Finished Goods Kanban to improve product availability with a view to reduce customer order fulfillment time delay, c. Consumable Kanban combined with Vendor Managed Inventory (VMI) to eliminate production stoppages on account of simple consumables. This will help you reducing bank loans in terms of Working Capital by increasing Business Turns. 9. ALBS can even help you to take up re-designing of your products / tooling in a manner that manufacturing of the products take less time to manufacture without affecting the quality & performance of the same. This will facilitate your ability to serve a customer at a faster pace. Lean name for this is Design for Manufacturing (DFMA) 10. In order to achieve all the above it often helps to study and map the current state of the business (Value Stream Mapping) with in-depth identification of the hidden waste (from the point of view of customer) in the system and wherefrom emerges a Future State (Vision State) which then becomes a systemic approach to implement lean in a very deep rooted manner. For the organizations who wish to take a deeper plunge in benefits from Lean usually take help from ALBS in taking up this systemic approach. To conveniently unearth the above and much more hidden treasure in your business - the usual recommended starting point is by helping your staff and employees to understand some basics through simple house-keeping (5S) and attitude building (TEI) activities and exercises with a view to begin seeing the “HIDDEN TREASURE IN BUSINESS” AND SERVE AS A FOUNDATION FOR DEEPER LEAN IMPLEMENTATION
- 4. Business Excellence through People Excellence Page 4 of 6 www.albs.co.in Your Benefits thru’ ALBS Why ALBS as Consultants? “Rich experience of the consultant creates an opportunity to critically examine in my organization whatever appears ‘Normal way of life to me and my colleagues. “A consultant may risk his engagement with us to identify and highlight gaps and weaknesses in my organization without any fear of being reprimanded. “My consultant can help enforce the discipline I need and thereby keep me alert on many business aspects. In addition he can make me search for new ways to improve my real effectiveness as a leader / manager. “A consultant can be my Coach, Sounding Board, Mentor and a Good Friend.”
- 5. Business Excellence through People Excellence Page 5 of 6 www.albs.co.in Bio-data: Abhaya Sangal Working as a Lean Consultant at Bangalore for last fifteen (15) years Abhaya has acquired total hands on experience in implementation of all aspects of Lean and contributing to improve the Business Results of many organizations such as: Aster Teleservices, Hyderabad Aster Teleservices, Raipur Bharath Magnetics, Bangalore DISA India Limited, Tumkur, Hosakote Elastrex Polymers, (Paragon Footwear), Peenya & Nelamangala FOURESS Engineering, Peenya Harsha Engineering, Bangalore Ingersoll Rand, Ahmadabad Ingersoll Rand, Sahibabad Integrated Electric, Bangalore Kar Mobiles Ltd., Peenya & Tumkur Kennametal, Bangalore Linea Fashions, Chennai Motor Industries Company – MICO, Audgodi, Bangalore Motor Industries Company – MICO, Nagnathpura, Bangalore Paragon Polymers, Hyderabad, Kottayam Maruti (Trainings Bangalore, Kochi) MTAR, Hyderabad Pearl Insulations (vonRoll), Bangalore Rishi Consfab, Bangalore, Rapsri, Harohalli, Karnataka Sahney Commutators, Bangalore, Saint Gobain – Grindwell Norton Limited, Bangalore Saint Gobain –Vetrotex India Limited, Hyderabad (Now a part of Owens Corning) Sobha Developers Limited, Bangalore Solectron, Bangalore and Solectron, Malaysia Stumpp, Schule, and Somappa, Bangalore, Ananatpur and Gurgaon, Titan Jewelry Div at Hosur Tyco Electronics, Bangalore Aditya Birla (Madura Exports), Bangalore Some of the typical results achieved by Lean Implementation have been like: Improvement in House Keeping >25% (Based on 5S audit score) – Typical 5S, Machine 5S (Autonomous Maintenance), 3D Concepts, Visual management Space Released >20%, - Re-layouts, 5S, Kanban etc. Capacity/Sales improvements >50%, QCO/SMED & Machine 5S, Standardization, Lead Time Reduction by >50% - Cell Manufacturing & Pull Production, Load Leveling, Small Batch Production, Raw material Kanban, Inventory reduction >30% - Kanban for Raw Material & Finished Goods, Milk Van Run, Pull Procurement, Material Flow, Reduction in the distance moved for material up to 80% - Relocation of facilities across departments and joining by cell & Kanban (CONWIP) Waste Reduction – Value Stream Mapping & design, Inventory Control – Kanban & Pull Procurement Cost Reductions thru’ Design for manufacturing and assembly (DFMA) also known as Value Analysis and Value Engineering (VA/VE) Immediately prior to working as Lean Consultant Abhaya has been working as General Manager (Works) with EID Parry (I) Ltd at their Alwar, Rajasthan Plant. His other past experiences were in companies such as Larsen & Toubro Limited, Bombay; ITW Signode (I) Ltd, Hyderabad; Signode Kenya Limited, Nairobi; Munak Galva Sheets Limited, Delhi etc. Presently Abhaya has a total experience of 38 years. This experience besides Lean Consulting covers the areas such as General Management, Industrial Engineering, Marketing, Production, Planning & Control, and Green Field & Brown Field Project Management etc. By education Abhaya has done his M.Tech from IIT, Kharagpur in Industrial Engineering in 1977 and graduation from University of Roorkee (now IIT, Roorkee) in 1975.
- 6. Business Excellence through People Excellence Page 6 of 6 www.albs.co.in Bio-data: S. Kannan Kannan is a specialist in implementing 5S, TEI, TPM, and Machine 5S (AM), SMED, KANBAN, and Visual Factory. Kannan gained this experience during last 15 years by working as a WCM / Lean / Kaizen practitioner in different industries. Kannan had the good fortune of learning the deeper meaning of WCM / Lean / Kaizen by closely associating and “hands-on” working, shoulder to shoulder, with large community of true practitioners of Lean / WCM / Kaizen. All Kannan's learnings are heuristic and therefore Kannan enjoys ‘thinking with his hands’ besides mind. We are sure you will not miss to experience Kannan's passion for Lean/5S, once you witness it. Kannan is a Graduate from St. Joseph’s College, and have imbibed from many Lean Gurus the consulting philosophy, “HANDS THAT HELP ARE HOLIER THAN LIPS THAT ADVISE”. Kannan practice this philosophy by using bottom-up approach, heading straight to the shop - floor and getting things done by setting an example. Kannan has improvised the first of its kind in the world, highly practical, fulfilled, “JIT-GAME” (Lean Simulations). Kannan also help organizations in developing a Kaizen culture through a unique program in Total Employee Involvement (TEI). To implement this he works with ease at all levels in an organization, right from the unskilled level to the Board level. Kannan is frequently invited by other organizations / Institutes to conduct TEI Workshops. Following are some of the organizations Kannan have been associated during last 15 years: Aster Teleservices, Raipur & Hyderabad Bharath Magnatics, Bangalore Centum Electronics (Solectron), Bangalore Centum Industries, Bangalore DISA India Limited, Hosakote DISA India Limited, Tumkur and FOURESS Engineering (India) Limited, Peenya Gokaldas Exports, Bangalore Harsha Engineering, Bangalore Integrated Electric, Bangalore Kar Mobiles Ltd., Peenya Kennametal India, Bangalore Khimjee Hunsraj, Chennai Linea Fashions (MAS Holdings), Chennai Magnatech, Bangalore MTAR, Hyderabad Elastrex Polymers, (Paragon Footwear), Peenya & Nelamangala RubFila, Palghat Newcast Die Casting, Peenya NTTF, Bangalore (client organizations) Pearl Insulations (vonRoll), Bangalore Paragon Polymers, Hyderabad Rishi Consfab, Bangalore Rishi Laser, Bangalore Sagar Rubber Products, Ahemdabad, Sahney Commutators, Bangalore Saint Gobain – Grindwell Norton Limited, Bangalore Saint Gobain – Vetrotex India Limited, Hyderabad (Now a part of Owens Corning) SLD Auto Ltd (Sandhar Group), Bangalore Sobha Developers Limited, Bangalore TOYOTA (Training thru' NTTF, Bangalore) Tyco Electronics, Bangalore Aditya Birla (Madura Exports), Bangalore THANK YOU