The leandrive
- 1. Contact : madhupchaturvedi@rediffmail.com +91 9909959838 +91 124 4213026
- 2. Current Industrial Situation Medium & Small enterprises • Most organizations are struggling/preoccupied with short-term target achievements like daily production, monthly revenue with fluctuating demands • Long term focus & efforts needed to sustain in competitive and international arena are neglected • Some organizations launch operational excellence initiatives with great enthusiasm but over a period of time it becomes a flavor of the month program • Due to lack of road map for coordination between stakeholders within & outside manufacturing unit
- 3. Service offered Coaching for organization build around high performance work teams Lean Drive Coach Facilitator Result Catalyst Awareness Business Analyzer Barrier Buster • Lean / World class manufacturing, Business / Operational excellence • Industry : Coaching, hand holding & management consulting • Institute to Industry program • Lean Manufacturing awareness & products
- 4. Industry : Coaching, hand holding & Management consulting • Provide operational excellence insight to Industry owners • Support business heads for business excellence • Coach in-house functional teams for Lean / World Class Manufacturing • Team leaders and operators for 5S & TPM
- 5. Operational Excellence Achieving Operational Excellence requires the successful implementation of a integrated Business Execution System that effectively and seamlessly integrates the following four building blocks: Strategy Deployment, Performance Management, Process Excellence, and High Performance Work Teams. Strategy or Policy Deployment is the process that aligns and links business strategy and execution. Performance Management is the process that translates strategic initiatives into measurable objectives and goals. Operational Excellence can be achieved and sustained with the right attitude, the right mindset, and the right competencies. Well designed, efficient, and effective Management, Value Chain, and Support Processes are necessary to deliver world-class results.
- 6. k Business Purpose Profitability QDC Quality: Zero Defect Delivery on time. Maximize revenues Cost optimum : accurately controlled Business Excellence
- 7. k Business Goals People morale, QDC, Improvements People involvement,safety Quality: Zero Defect Delivery on time. Maximize revenues Cost optimum : accurately controlled Improvement culture Business Excellence
- 8. k TPS/Lean House People, Safety Quality: Zero Defect On time delivery. Maximize revenues Cost optimum : accurately controlled Improvement culture JIT Right part, Right amount, Right time • Takt • Continuous flow • Pull system • SMED •Integrated logistics Highly Motivated People JIDOKA (Built in quality) • Automatic Stop • Andon • Poka Yoke • Person Machine separation • In station Quality • 5 Whys Operational Stability Visual Management Standardized work Level Production 5S Total Productive Maintenance ( TPM ) Standardization Business Excellence Consistent availability of •Manpower •Machines •Materials •Methods Continuous Improvement Absolute Waste Elimination
- 9. Elements of World Class Manufacturing
- 10. Lean manufacturing 5. Pursuit Perfection 2. Map Value Stream 3. Create Flow 4. Establish Pull 1. Define Value Lean Principles
- 11. 8 Motion गति Unnecessary movement of materials or people within a process. Physical movement of people Inventory इंवैंट्री Any supply in excess of what is required. Having too many of the wrong thing in stock Waiting प्रिीक्षा Idle time created when material, information, people, or equipment are not ready. People or things waiting around for the next action Rework- रीवर्क Work that contains errors, rework, mistakes, or lacks something necessary Over-processing अतिसंसाधिि Additional effort that adds no value to the product or service from the customers’ viewpoint Over-production अति-उत्पादन To produce sooner, faster, or in greater quantities than actual customer demand Intellect प्रतिभा The waste of not leveraging peoples’ full talents and capabilities Transportation पररवहन Unnecessary movement of materials or people between processes k Wates Identification
- 12. k Input Waste Lean Tool Man • Motion • Walking • Waiting • Searching • Untapped Potential • Standard Work • 5S • Product Preparation Process ( Heijunka) • Kaizens Machine • Motion • Changeover • Breakdown • Product Preparation Process ( Heijunka) • SMED • TPM Material • Inventory • JIT Method • Batch Production • Transportation • Flow production • One Piece Flow Lean tools to remove waste
- 13. MURI = Overburden क्षमिा से अधिर् र्ार्क MURA = Unevenness, Variation, Fluctuation ववषमिा, ववभभन्निा, अस्थिरिा MUDA = Waste रद्दी (वेथट) No MURI, MURA and MUDA मूरी, मुरा और मुदा नहीं है The MURI, MURA and MUDA
- 14. Visual Management Display Metric Control Displays To make staff aware of related data and information – charts, graphs etc Controls To guide the action of staff members – sign boards, dos and don’ts signs Information is shown Displayed Information is acted upon Metrics Path to targets for success See the performance Visual Management
- 15. Literal Translation Operational Translation Indicator Seiri Arrange Clear out rarely used Items by Red Tagging Reduce search Seiton Put in place, Arrangement Organize and Label a Place for Everything Reduce motion Seiso Clean-up Clean up the workplace and look for ways to keep it clean. Reduce rework Seiketsu Neat, Tidy Create Rules to Sustain the first 3 5’S Reduce Variation Shitsuke Education Follow the rule to keep the workplace 5S-right. Hold the gain Reduce investment loss "Every day, our priority is 2s. (Sort & Set In Order) With a good 2s environment, we easily prevent accidents, create a good space for efficiency, avoid clutter, save time when locating items, and maintain a positive atmosphere and employee motivation, and easily distinguish the right from the wrong conditions which is key for the elimination of waste." 5S
- 17. USP : What’s in it ? MNC : • Integration of MNC’s Global best practices into local scenario • Support in setting up skill schools as per specific requirements • Resources to support urgent requirements during project set ups OEM : • Interface for supplier improvements • Corporate training programs • Step towards awards like Deming Medium, small & micro enterprises : • Capability rating improvement for customers • Customer Quality performance improvement • Step towards Clusters, QMS, EMS, OHSAS, IATF, ZED compliances
- 18. Institute to Industry program • Facilitate aspiring students with Industry ready skills • Meaningful summer trainings • Improved chances and better placements • Career growth • Paid freelance assignments • Client deal referral bonus • Lean manufacturing bulletins & events discount
- 19. Lean manufacturing awareness & products • Train The Trainer packages, presentation slides, games, learning kits, videos • Tags, transparent warning film, shadow board tool sheets, tool kit foam, kaizen diary, TPM inspection card set, forms, posters, rails & hangers • Product Lifecycle Management (PLM) & Quality Management software for Auto parts manufacturing industry • Leverage IoT, mobile, Cloud & Big Data to engage shop floor employees (welders, fitters, operators, admin staff etc)
- 20. Achievements • Guided plant teams for 90% rating of Standardization Principle with excellent people involvement in calibration by external Global Manufacturing System team at General Motors. • Lead for General Motors India being first plant in Asia Pacific Region to achieve full compliance in direct run process for First Time OK quality. • Planned, negotiated and implemented productivity linked wage agreement with works committee based on MOST standards • Achieved 30% improvement in efficiency, delivery on time from 65 to 95 % and reduction in quality non conformities from 0.6 to 0.1 defects per product in a year • Vertical ramp up of simultaneous new production launches along with improvement in running models operations of new manufacturing plant • Planning and execution of greenfield & in-house expansion projects
- 21. Companies served by Founder coach General Motors Tata Motors Al Shirawi Hero Honda AMW Dulsco Gunnebo Escorts Munjal Auto Prabha Engineers Calcom Electronics
- 22. Founder & Coach : Madhup Chaturvedi • 30+ years experience at Automotive MNC’s, OEM’s, International assignments and ancillaries • Systems & Process transformations for operational / business excellence, world class / lean manufacturing, projects planning & executions • BE Industrial Engineering • Diploma in Management • World Class Trainings
- 23. So, Why Lean Drive ? • Single window subject matter expertise for sustainable Industrial excellence • Committed to Make a Difference with innovative, proven, practical concepts applied successfully in multi cultural scenarios • At a good economic sense for required days instead of full time hiring
- 24. We would love to serve you Please share your details. We will share our proposal to serve you. • Company / name : • City : • State : • Country : • Pain point / requirement / interest / comments / suggestions : • email : • Mobile # : • Landline # :
- 25. Thank you very much Seeking your valued enquiry Comments & suggestions are welcome Request to share in your network