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Manufacturing Operations


Problem Statements

  • Regularly missing shipment dates
  • High WIP and FG Inventories
  • Frequent replanning

Methodology

  • Simplified Drum-Buffer-Rope
    (S-DBR)

Expected Benefits

3 to 4 months; significant results in a few weeks
  • Sharp increase in due date performance (>99%) & reduction in lead times ( 30%)
  • Reduction in inventories (50%) & hidden capacity (20%)

Distribution /Procurement


Problem Statements

  • Inventory shortages & surpluses in supply chain and need to improve availability at demand points
  • Supply side disruptions
  • High RM inventory / EC

Methodology

  • Pull-based replenishment

Expected Benefits

6 to 12 months; significant results in few weeks
  • Substantially increased availability
  • Reduced inventories (typically by 30%)
  • Reduced expediting costs

Projects(EPC, Capital, R&D)


Problem Statements

  • Unable to manage New products introduction on time
  • Less ROI on Projects
  • Significant project delays

Methodology

  • Critical Chain Project Management

Expected Benefits

Within the duration of project
  • On time completion / reduction in project lead time (typically 20%)
  • Robust mechanism to anticipate & act on problems

OE reduction


Problem Statements

  • Low utilization of capacity
  • High set up time
  • High COPQ
  • Less OEE

Methodology

  • SMED / Problem solving techniques

Expected Benefits

Within 60 to 90 days
  • Additional capacity exposed (30%)
  • Reduce Operating expenses (20%)
  • OEE improvement

Perfect synergy with Lean, Six Sigma & Re-engineering principles at strategically chosen time & areas