lean techno – manufacturing service proposal · product costing client prospective leading to...

LEAN TECHNO –

Manufacturing Service Proposal

� MANUFACTURING

www.leantechnocrats.com

2 www.leantechnocrats.com

Who We Are

We are pleased to introduce Lean Techno… The Growth Accelerator as

Manufacturing, Consulting and Training Service provider. The wide spectrum of

hands on skills on various industry domains, helps us to reduce risk and offer

competitive cost.

� Vision:

To establish Lean Techno as a leading service brand of customer choice. We

aim to reach the unreached and provide seamless services with sense of

ownership for the growth of our customers, business partners, employees &

society.

� Mission 2020:

Building passionate empowered & accountable Lean Techno team for catering

long term customer base by instilling organizational values of

Care : for customer growth;

Challenge: the status quo

Courage: to take risk

Conviction: for success

We Accelerate Growth for the companies


Leadership Team

Sudipta is Lean Six Sigma Certified Black Belt with dynamic 18 years manufacturing career reflecting pioneering experience in mentoring high impact continuous improvement projects in the field of Quality, Cost, Delivery & People engagement. He has been involved in leading and implementing organization wide improvement initiatives like six sigma & different Lean management tools.

Sudipta Sarkar

Arun holds Engineering Degree in Electronics and Telecommunication from VNIT, Nagpur. 20+ years of cross functional experience across the verticals of Plant operations, Lean implementation, Supply chain & Logistic management and EMS set up. Working experience with reputed consumer electronics, automobile ancillaries and embedded product development companies. .

Arun Dakhole

We love what we do, we go for excellence not for success and our energies

are infectious…

What We Do

Manufacturing

Product designing & manufacturing are two unlike worlds. We connect designing & mass manufacturing through our extensive exposure & experience

Consulting

We interpret Lean as a culture, more than a set of efficiency and improvement techniques. We inculcate strategies & implement through practical hands on approach that help organization to deliver meaningful & measurable milestone

Daily Management System (DMS)

Design and software development of the Daily Management System to monitor the Operational Excellence Indexes

Training

We Customize 360 degree training programs targeted towards building lean culture, developing our client’s internal competencies & sustaining operational excellence.

In a short span of time, we are proud to get associated with various industry

domain through our service offerings

Q4’ 16 Q1’17 Q2’17 Q3’17 Start Q4’17

LEAN TECHNO –

Manufacturing Services

www.leantechnocrats.com


Domains of Manufacturing set up

1. People

Connect

2.Process

Engineering

3. Mgmt.

of Supply

chain

1. People Connect: Quality, productivity and elasticity come

from the willingness of staff rather than a

particular technique.

2.Process Engineering:

Each process must be :

simple (Lean Manufacturing)

reliable (Design For Six Sigma)

flexible (almost zero change over time)

elastic (very quick changes in capacity)

3.Management of Supply chain processes The design and implementation of the supply chain must meet the customer’s exact requirements Delivery :When they want it. Quality :Get what they order and it works Design :Meets their requirements


Challenges in Supply Chain

� Managing key

supplier for delivery

timeline

�Transport

productivity de-growth

� Lack of Quality

standard during mass

production at supplier

� Very low material

productivity y-o-y for

lack of benchmark of

standard data

� Not capable of

product costing

Client Prospective

Lea

din

g t

o

� Tailor supply chain for

key clients

�Managing stocking

policy & healthy stock

� Managing process

robustness of supplier.

� Aggregate supplier

data

� Product costing

through standard time &

RMC benchmark

Lean Techno Prospective

Collaborate with Lean Techno Platform (LTP)

� A new client, is new

process audit & new set

of qualification

�Demand fluctuation &

resource management

� Lack of Quality

standard for skill

competency retention

� Very low productivity

year on year cost

reduction pressure

� Not capable of

product costing through

standard methodology

Supplier Prospective


Blue Print of Lean Techno Platform

Tailor Supply Chain

• Process mapping for specific characteristic of client

• Healthy stock, Stocking policy, simplify Information flow

• Demand management, Production control

Cost Benchmark

• Product costing through standard time

• Aggregate cost of standard parts

• RMC database

Process Robustness

• Quality assurance through RCA methodology, CAPA, FMEA

• PCS control

• Autonomous operator

• Pokayoke & Jidoka

Adhere to Just-in-time principles, ride through zero defect but goal is

Cost benchmark …..

LSL USL Average

Target

Capable and on target $


Challenges in People - Process

� Market fluctuation,

Volume pressure from

supplier

�Weak link in value

chain

� Lack of commitment

in Quality & Delivery

� Product life cycle &

risk of obsolescence

Client Prospective

Lea

din

g t

o

� Cellular layout &

process design, Flow

bottleneck, Quick

changeover, flexible &

ergonomic workstations

� Competency

development, succession

planning, KPI tracking

�Design of supermarket

with PULL trigger

� Smart warehouse

�Lean Logistic system

�Ramp up – Ramp down

policy

Lean Techno Prospective

Collaborate with Lean Techno Platform (LTP)

� Capex investment is

key unless volume

confirmation

�Capability & Flexibility

issues

� People competency &

retention issues

� Unhealthy stock,

dead inventory

Supplier Prospective


Blue Print of Lean Techno Platform

Line Architecture Design

• Removing conflict flow

• Lean line architecture

• Low cost automation, Jig fixture introduction

• Time trap & SMED

Key resource pool

• Competency & Succession plan

• Dynamic management, Escalation matrix

• Multi-skill & Versatility

• Employee suggestion scheme

Lean Logistic

• Supermarket sizing

• Visual Control

• Just-in-time operation

• Warehouse design & smart MPH system

Engage people with simple layout to achieve speed in logistic …..


Benefits – Lean Techno Platform

Process Area Indicator Benefit Realized Quantum of Improvement

Procurement Inventory turns Improved By 30%

Planning Lead time Reduced By 50%

Planning On time delivery Improved By 20%

Quality Non Quality cost Reduced By 50%

Operation Time spent/ unit Reduced By 40%

Operation Logistic Efficiency Improved By 30%

Business (P&L) Raw material cost Improved 2-5%

Business (P&L) Variable cost Reduced 2~5%

Business (P&L) Gross Margin Improved 1-2%

Gross Margin improved by 2% after 12 months of Lean Techno platform collaboration and restore resources energy

Domain 1

• Reliability - The ability of an organization to consistently perform its intended or target mission on demand without failure

Domain 2

• Capability – Measure of the ability of an entity to achieve its objectives, specially in relation to its overall mission

Domain 3

• Flexibility – Ability to change easily according to customer need

Domain 4

• Information – It is a paradigm of supporting users in doing their work by delivering them information proactively related to the current working.


Why Lean Techno…

Now- In build criteria

The four domains which are to be focused for top line growth are:

Quality Cost Delivery

Traditionally Quality, Cost and Delivery are the deciding criteria for becoming a

supplier of choice. Today with fundamental change in customer satisfaction

definition these are rather intrinsic requirements.

We don’t compete with others , we only compete with ourselves…. Our energies are infectious

13

Lean Technocrats India Pvt. Ltd. Plot 79, H. No. 15‐15/79, Sudarshan Nagar Colony, Opp: HCU Bus Depot, Serilingampally,

Hyderabad, Rangareddy, Telangana, PIN‐ 500019, India. Contact No: +918978993358 Email Id: [email protected]

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