Operations and Business Consulting
Lean Manufacturing Training & Implementation
Business Process Excellence
Factory Layout Designing
Lean Manufacturing at Preeti Engineering Works
With a keen approach process at SS Controls was studied and Diagnostic Study was completed.
Areas of improvements were identified and improvements were planned in a sequence considering priorities, financial situation and practicality.
Solution was highly customized to suit the challenge at hand and achieve targeted results.
Set up by thorough experts in silencer manufacturing, Preeti Engineering Works caters to various Genset Silencer manufacturers. It also supplies air housing units and certain press parts to OEM manufacturers.
At one point of time space constraint stood between growth opportunities as there was no space to produce more. Client was ready with orders but unit was unable to cope with additional demand.
Constraints identified were space, huge in-process inventories, lack of tracking, high changeover time, existance of all 7 wastes.
All of these were targeted gradually with a step by step approach. To increase production it was mandatory to increase capacity by shifting constraints and additional capacity.
By implementing 5S space was created for more machines. With re-layout of the shop, a cellular layout was implemented. Kaizens helped to eliminate 2 processes. Changeover time was brought down by implementing SMED. This all created a possibility to implement Single Piece Flow.
>75% reduction in changeover time
>200% improvement in monthly production
>40 % space created in the shop to accommodate more machines
>80% reduction in Cycle Time with Single Piece Flow
Priyesh Panicker
CEO, Preeti Engineering Works
Suresh Todkar
Director, SS Controls
At the time of joining the cluster we used to make around 5-10 thousand pieces a month for each variety. AB Associates consultants highlighed hige WIP inventories, poor internal OTD's. To all this they advised Single Piece FLow. We never thought we are a company that could implement something like SPF.
With improvements we are now highly responsive to customer orders. We have added 2 new product varieties and are supplying more than 60 thousand a month comfortably. At the same time we believe that we have additional capacity to make more 50 thousand parts in existing setup.
Priyesh Panicker
CEO, Preeti Engineering Works
Lean Manufacturing at Powerinst Electromagnets
Constraints identified were space, huge in-process inventories, lack of tracking, high changeover time, existance of all 7 wastes.
All of these were targeted gradually with a step by step approach. To increase production it was mandatory to increase capacity by shifting constraints and addition additional capacity.
Powerinst is a vibrant SME supplying high- quality electrical assemblies, solenoid coils to all the major electrical OEM's.
The Unit took up the implementation of Lean practices in 2011 and has been on a progressive track since then.
In the Lean Cluster program unit showed remarkable improvements by the implementation of Single Piece Flow.
The unit has many assembly operations producing a variety of parts. With Kanban system already in place along with regular process study, efficiency at each workstation was optimized.
However, still 1 FG used to take close to 9-10 days from material issue to dispatch.
This meant a lot of WIP and money & space blocked.
Single Piece Flow, formation of cells in the shop, multi skilled workforce, kaizens all these were implemented gradually.
By the implemetation of Single Piece Flow and horizontal deployment of same on similar product lines, unit achieved tremendous results.
>70% improvement in productivity
>80% WIP reduced
>99% OTD achieved
Almost doubled the turnover in a year without adding new resources.
Priyesh Panicker
CEO, Preeti Engineering Works
We implemented Single Piece Flow in almost 8 different areas in our company. Productivity increased from 50 to 100 % on different product lines. This has helped us to achieve higher turnover without adding any machinery or manpower. Importantly we were able to eliminate WIP in most of the places. Copper being a major part of RM, it is a major saving for the organization.
Ajit Kulkarni
CEO, Powerinst Electromagnets Pvt. Ltd.
With the rapidly growing market of the Optical Fiber and its applications, worlds leading Optical Fiber Cable (OFC) manufacturer wanted to double the capacity.
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Biggest challenge was to bring in better flow of material, improve efficiencies, accommodate 30 new machines and ensure some place for future expansion.
4 Stages processes, multiple WIP locations, multiple quality gates and storage requirement of more than 5000 pallets & 3500 cable drums.
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Project was carried out in 3 main phases: studying the entire process, understanding requirements at each stage and department in details, proposing multiple layout options and detailed comparison, selection of the most comfortable option and detailing of the final Layout.
Outcome: >25% space spared for future development
>50000 sqft of rented go downs rent
>15 low cost automation ideas delivered.
>50000 sqmt space managed under single roof
Lean Plant Layout at World's 3rd largest Optical Fiber Manufacturer
Ajit Kulkarni
CEO, Powerinst Electromagnets Pvt. Ltd.
Lean Plant Layout goes a long way in optimizing cost, streamlining operations, and arresting wastes at the stage at inception itself. AB Associates has vast experience of delivering Lean Factory Layouts for multiple product and process layouts of different sizes.