Many small and Medium enterprises struggle in achieving the production targets, Quality levels and meeting the Delivery Schedules given by customers.

The primary reason being lack of planning and the lack of professionally trained shop floor engineers / supervisors.

The common issues faced in the shop floor are:

  1. Unable to meet the production targets
  2. High Rejection / Reworks
  3. Poor Delivery performance
  4. Raw Materials – not available on time
  5. Firefighting everyday – lack of planning / focus
  6. High Work-In-Progress
  7. Poor housekeeping in the shop floor – Lack of 5S
  8. Lack of space in the shop floor
  9. Frequent Machine Breakdowns
  10. High Setup times for machines – more than 10 minutes

What we do?


Phase 1: Understanding Current State (As-Is Situation)

We understand the current state (As-Is situation) in the unit in a detailed manner. Some of the key areas we observe are Production Planning, shop floor management, Communication among the team members, Quality and Productivity related issues. We normally take 1 month for this study. The outcome of this phase is a clear action plan on the various issues and the roadmap to solve them.

Phase 2: Focus and Stabilize

In this phase, we start various initiatives focusing on Production Planning, Resource Allocation in Shop floor, Communication among the team members (especially with the operators), Information Sharing, Initiating 1S and 2S at the shop floor, etc. These activities would reduce Firefighting on day-to-day issues, creates visibility in the shop floor and would help in smooth running of the shop floor and also prepare the unit and team members for the next phase. Phase 2 would last for 3 to 4 months.

Phase 3: Improve and Standardize

In this phase we initiate Lean Manufacturing activities like Single Piece Flow, Single Minute Exchange of Dies (SMED), 5S, Kaizen etc. Focus would be to improve the Productivity, Reduce Defects and improve On-Time Delivery Performance. We generally see 20% to 30% improvement in productivity during this phase. Phase 3 generally takes 4 to 5 months.

Phase 4: Sustenance

In this phase, we expect the team to work on Auto-Pilot mode where we handhold / support whenever any requirement arises. The team would sustain the initiatives done in Phase 2 and 3 and would continue to improve upon them. This phase lasts for around 2 months.