Specials

Case Studies

• Maintenance – Paint Shop, Industry: White Goods
  PROBLEM : Client is a leading producer of white goods, having production facilities at three locations in India. Equipment breakdown time in one of the paint shops very high – 18% of the available time.
  Full Article>>
  
  
• Excessive Consumption OF Bom Consumable
  PROBLEM : Client is a leading producer of white goods, having production facilities at three locations in India. Consumption of refrigerant gas was found to be 26% more than the norms specified in the Bill of Materials. Therefore opportunity for cost saving exists if consumption can be brought inline to the BOM norms.
  Full Article>>
  
  
• Consistency of Dry Film Thickness (DFT) In Powder Coating Process
  PROBLEM : One of the leading home appliance manufacturers was facing problem with its powder coating process. Dry film thickness on product exteriors showed a lot of variation historically. With annual production of almost 1 million appliances, reducing coating thickness and variation presented company management with a lucrative opportunity for cost reduction. A Six-Sigma project team was setup with the objective of improving consistency of DFT & reducing the cost of powder consumption in the paint process.
  Full Article>>
  
  
• Reduction in Production Consumable Consumption
  PROBLEM : Client is a leading producer of white goods, having production facilities at three locations in India. In one of the plants production volumes are 0.7 million units per annum. Assembly Consumable forms a major cost head. Present consumption is Rs 8 million per annum.
  Full Article>>
  
  
• Reduction in The Noise Level Of A Refrigerator
  PROMBLEM : There are several complaints on high level of noise of the appliance during use at customer end. The tests carried out in the lab showed that the company’s product has noise level higher by 4 db compared to the best competitor.
  Full Article>>
  
  
• Ice Making Time
  PROMBLEM : Ice making time is one of the key performance parameters for refrigerators. A leading multinational home appliances company was facing aggressive challenge from one of its competitors on this front. A Six Sigma project team was setup with the objective of studying and neutralizing competitor’s advantage without adding any Bill of Materials (BOM) cost burden on the company.
  Full Article>>
  
  
• Improve Productivity of A Bottleneck Operation
  PROMBLEM : Low productivity in refrigerator door making area, leading to extra hours of operation in this work-area.
  Full Article>>
  
  
• Reduction in Visual Defects at Pre-Delivery Inspection (PDI)
  PROMBLEM : Client is a leading producer of white goods, having production facilities at three locations in India. Finished goods appearing with visual defects (dents, paint scratch etc) at final PDI inspection. Present level is very high.
  Full Article>>
  
  
• Reduce The Equipment Breakdown of Tandem Press Line
  PROMBLEM : The client organization has 4 presses running in tandem to produce large pressed parts for car industry. There are problems in on-time delivery commitment, due to high breakdown (more than 6% in 2001).
  Full Article>>
  
  
• Improving Accept Ability of Product by The Customer
  PROMBLEM : The plastic granule manufacturer based in South India had a problem of shade variation of a particular high volume color. The customers, both in automotive & electric supply were giving preference to competitor’s product despite the lower price offered by the company. As such, the company had high internal rejection (>6%) and also was losing market share.
  Full Article>>
  
  
• Packaging & Handling Improvement – Bought-Out Plastic Items
  PROMBLEM : Bought Out Plastic Items getting damaged during transit as well as during storage and handling. Cost of parts rejected due to these damages works out to Rs 17 Lacs annually.
  Full Article>>
  
  
• Component Cost Optimization – Motor Assembly
  PROMBLEM : Motor cost a major contributor to the BOM cost of the final product. Product placed in segment that is extremely price sensitive. Present cost of the motor is more as compared to the competitors. Reliability and other performance parameters are critical and cannot be lowered.
  Full Article>>
  
  
• Rejection / Rework Reduction – Compressor Assembly
  PROMBLEM : Compressor Assembly output presently is having leakages to the tune of 4%. Rework cost for these leaking systems works out to Rs 19.2 Lacs annually.
  Full Article>>
  
  
• Productivity Improvement in Switchgear Production
  PROMBLEM : Low productivity in Switchgear Manufacturing area, leading to delays in deliveries, increased cost of operation and high inventories.
  Full Article>>
  
  
• Improvement in Switchgear Design & Engineering Process
  PROMBLEM : In view of Non Standard requirements from Customers, lead time of Design & Engineering along with issue of Engineering information without deviation from requirements was a major concern in a switchgear manufacturing plant. A project team was set up to study these aspects develop and implement action plans.
  Full Article>>
  
  
• Improvement in Switchgear Business Procurement Process
  PROMBLEM : Business Procurement is a key process in Switchgear business. Customer satisfaction, cost and productivity are key performance characteristics in the business. A leading switchgear manufacturing company foreseeing a stiff challenge from it’s competitors set up a Project Team to improve its performance on these critical to quality and business characteristics.
  Full Article>>
  
  
• Performance Improvement in Filling Stations
  PROMBLEM : Filling stations is one of the key distribution channel for retail sales in Oil Industry. Customer satisfaction, cost, and productivity are key performance parameters in Filling Stations.A leading refined products distribution company in UAE was foreseeing a stiff challenge from it’s competitors on these aspects .A Project Team was set up to with the objective of studying and improving on these aspects of the business.
  Full Article>>
  
  
• Redution of Cord Stripping Waste in Looms
  PROMBLEM : The leftover butts on the bobbins before bobbins are released for twisting is called stripping waste. The client organization was facing high rejections on a continuous basis for last 4 years and were not to able to find a permanent solution.
  Full Article>>
  
  
• Financial Processes Improvement Projects
  PROMBLEM : Lack of consistency in primary financial processes (accounts receivable, accounts payable, financial reporting, and payroll) resulting in excessive cost and time interacting with internal domestic and international project offices, as well as external customers. Corporate finance function viewed as cost center with no ability to add value to business or customers.
  Executive decision-making hampered by delayed and inadequate financial reporting system.
  Full Article>>
  
  
• Medical Laboratory Systems Clinical Trials Kit Cost Reduction
  PROMBLEM : Higher cost thought to be a result of kit (clinical study medical supplies) waste. Major customers were asking for significant cost reductions in clinical trials materials costs. Data showed that study sites typically ordered excess supplies. Customers were dissatisfied with cost of service.
  Full Article>>