#kaizen implementation company in bangalore

[7stepsglobal]

What is the Need for Standard Operations?

It  happens that the most important elements in the daily activity of manufacturing begin with the letter “M.” In factories, we are trying to find the best possible combination of Men, Materials, Methods, Measurements, and Machines, so that we can make the best products while spending less cost. Standard operations can be defined as an effective mode of workers, materials, and machines for the sake of making high-quality products at low cost, quickly, and safely.

Standard operations comprise the backbone of JIT(Just in Time) production. Many people make assumptions that standard operations are nothing more than standard operating procedures (SOP’s). But this is not True, Standard operating procedures have to do with specific standards for individual operations in the line and are just part of what we mean by standard operations. Standard operations involve the participation of individual operations in a specific order to achieve an effective combination for manufacturing products.

Another name for standard operations would be “Standard Work Instructions. Let us suppose that we have asked some manufacturers to do some manufacturing for us for a particular product. The person probably asks such questions as: “How do you manufacture these products? How much time and cost does it take to make them? and When will you deliver them? Why does the other manufacturer need to know all these things every time? Because they need to set the work we have asked them to do into their current production schedule

[tpmconsulting]

Theory of Constraints

Theory of Constraints

TOC- Theory of Constraints is a methodology developed by Eliyahu Goldratt. It is a methodology for identifying the constraint, most important limiting factor that stands in the way of achieving a goal and then systematically improving that constraint until it is no longer the limiting factor. Constraint is also referred as bottleneck. Bottleneck management is widely used terminology in manufacturing, services, construction, hospitals, retail..

Some of the benefits that TOC can bring to organization are:

Increase in capacity through bottleneck management

Reduction of inventory

Reduction in Manufacturing Lead time

Effective utilization of resources

Improvement in On time supplies

Reduction of defects

Increased profit

Fast improvement

TOC is used as one of the methodologies by Seven Steps along with Lean, TQM, Six Sigma , TPM etc., in facilitating Journey of Excellence as organization wide initiative.

For more information on how we can support your organization or if your have any specific business problems to be solved, please get in touch with us.

Read More: https://bit.ly/3dKI4EU

[leanconsultingblog]

Five Phases of Lean Roadmap – A Thousand Step Journey

Quality is the result of collective effort of every employee in an organization. Quality cannot be achieved only through stringent quality control methods and use of sophisticated instruments or by highly competent quality department. Dr. Deming claims that 85 % of quality problems are created by people who never touch the product. Also quality cannot be achieved using flavor of the month approach. When individuals make quality as a habit, it becomes a culture at organization level. In this paper we are making an attempt to summarize traits of an organization where quality is a culture.

Read More: https://bit.ly/3c3WGxx

[topmanagementconsultingfirm-blog]

Implementation of Applied 5S 

[sevenstepsglobalbangalore]

When an “Abnormality” Occurs, Corrective action (To Prevent Recurrence) and Preventive Action (To prevent Occurrence of Similar abnormality) Needs to be taken………!

How?

CAPA includes control points, control levels, etc. This step is the key to the improvement of your performance.

To Prevent recurrence of the abnormality, you need to understand the situation in great detail, analyze the causes at a deep level, and take action to eliminate the cause.

To prevent the occurrence in similar areas, you need preventive actions. These actions include revision of SOP’s, control points & control levels along with regular skill updation of the concerned.

Also, Read Implementing Lean Maintenance System to Improve Factory Performance

Abnormality Analysis Framework

When any abnormality occurs, the root cause(s) of this abnormality must be known or analysis to be done & necessary corrective actions are required to be taken to prevent the recurrence of this particular abnormality. This corrective action brings in a gradual improvement in the performance level.

The occurrence of the abnormality can happen due to the following reasons:

SOP’s are not available

SOP’s are available, followed by the people but still, abnormality occurred.

SOP’s are available but not followed by the people

Analyze Abnormalities in the Industry Through Daily Management- Once an abnormality occurs, an analysis of the same must be done to conclude one of the above reasons due to which the abnormality happened.

Let’s Understand all the above three reasons:

a) If the conclusion is that the abnormality occurred because the SOP for doing the job was not available and the job was not done as per the standardized way, requisite standards operating procedure must be prepared by the concerned persons, all the people who are required to do this particular job must be trained and a system should be incorporated to ensure that jobs are done as per the standardized procedures.

b) While standards are available and followed, these are not adequate to achieve the desired level of performance. Therefore, these standards should be reviewed for adequacy and requisite modification should be made in these standards & training to be provided to all the concerned members.

c) While Standard operating procedures are available, these were not followed by operating people, further analysis should be done to find out the reasons behind people not following the standards

Also, Read How to Address Cost of Poor Quality and Customer Complaints in Manufacturing, Logistics, Supply Chains, Retail, Hospitality, Hospitals.

These reasons Can be:

People are not aware of the standards.

Standards are too difficult to follow.

People are aware of the standard but difficult to follow.

People are aware of the standards but knowingly not following.

Also, Read How To Sustain Daily Operations In Lean Practicing Companies Through Application Of Standard Work Methodology

Seven Steps Business transformation is a member of Seven Steps Group helping organizations in their journey of Operational Excellence.

We have Specialized TPM consultants who work across India, UAE, Srilanka, Bangladesh, Vietnam, Nepal, Indonesia, Middle East, Africa. In India, we support the entire country and our customers are across India which includes places like Hosur, Bangalore, Mysore, Shimoga, Tumkur, Calcutta, Jamshedpur, Pune, Mumbai, Vadodara, Gurugram, New Delhi, Pant Nagar, Vishakapatnam, Vizianagaram.

Please get in touch with us if you are looking for

Total Productive Maintenance consultants, trainers, and coaches in India for Automotive, Pharmaceuticals, FMCG, Oil and Natural Gas, Continuous Process Industries, Food Industry, Forging, molding, stamping, fabrication, and assembly.

Lean-Kaizen consultants and trainers for manufacturing, hospitals, healthcare, retail, supply chain, FMCG, agriculture products, warehouse, apparel, automotive, construction, fabrication, and assembly.

5S consultants for banking, manufacturing, warehouses, retail,  hospitals, healthcare services, food chains, restaurants, central kitchens, oil fields, etc.,

Quality consultants

[sevensteps1-blog]

There used to be a time when certain jobs are considered as dream jobs and highly respected such as Telecom new connections and ticketing clerk in a reservation counter, teller in banks. These were all niche jobs and posts. What happened to those jobs?  Are they still in demand or the demand has reduced?  Many of those who did not want further learning or skill enhancement were left behind as clerks with same pay or lost their jobs.

[uniquejobs]

Automotive Company Jobs | Tenneco Company | QA & QC Engineer Vacancy | Chennai location

Automotive Company Jobs | Tenneco Company | QA & QC Engineer Vacancy | Chennai location

Company Name : Tenneco

Automotive Company Jobs Our Latest YOUTUBE Videos Link : https://www.youtube.com/channel/UCZYt-jtPk975fMuI6tLpUEg Our Telegram Channel Link: https://t.me/employmentjobs Related Jobs : - Sharda Motors Company Jobs - Hyundai Supplier Company Jobs  -  Nissan Company Jobs In Chennai  Job Interview in Pegatron Company – Diploma & B. E. Engineers | Mahindra World City | Chengalpattu Designation: Engineer & Sr.Engineer                                 Educational Qualifications: B.E. Engineer & Diploma Role: Permanent                           Year of Experience: Min Experience             Job Location: Mahindra World City – Chengalpattu                                 Apply link - Click Here BEL Recruitment 2023 | BEL நிறுவனத்தில் Apprenticeship Training அறிவிப்பு Designation:  Apprenticeship Training                                 Educational Qualifications: B.E, B.Tech Engineers Role: Trainee                          Year of Experience: Fresher                  Job Location:  Bangalore                                 Salary Details: 17,500 /- Per month Apply link - Click Here Latest Jobs By :         Chennai JobsClick HereCoimbatore JobsClick HereBangalore JobsClick HereHyderabad JobsClick HereAndra Pradesh JobsClick HereSalem JobsClick HereMadurai JobsClick HereTrichy JobsClick HerePondicherry JobsClick HereAcross India JobsClick HereOther Cities JobsClick HereAutomotive Company Jobs Designation: QA / QC Engineer                               Educational Qualifications: B.E. Mechanical / Automobile Role: Permanent                           Year of Experience: Min Experience                   Job Location: Chennai , Tamilnadu                                  Salary Details: As per the Company Standard Mechanical JobsClick HereELE / ECE  JobsClick HereCivil JobsClick HereIT / Software JobsClick HereBPO / Call Centre  JobsClick HereH/W & Networking JobsClick HereHuman Resource Jobs  Click HereAcc/Fins JobsClick HereArts & Science  JobsClick HereAutomotive Company Jobs Automotive Company Jobs Job Description :                   Responsible for Customer Quality and Process Quality  Monitor monthly PPM, FTT and kaizen Do internal audit and close the observation Good knowledge in PPAP, 8D, QC tools and QC story  Implement poka-yoke in the process to eliminate defects Monitoring Quality inspector skill Matrix and focus on development of team  Do continuous Quality improvement activities Complete customer PPAP as per timeline Following daily KPI and achieve the target. Meet APQP timeline and address all the failure mode during NPD  Achieve zero customer PPM and Maintain zero warranty PPM How to Apply for this Job?           Details & Apply link : Click Here Titan Company Jobs | Hosur Location Designation: Mechanical Engineer                                 Educational Qualifications: B.E.Mechanical Engineer Role: Permanent                           Year of Experience: Min 2 Years                  Job Location: Hosur , Tamilnadu     Apply link - https://myemploymentjobs.com/titan-company-jobs-hosur-location-b-e-mechanical-engineer/ Foxconn Company Off Campus Drive 2023 Designation: Trainee                                  Educational Qualifications: Mechanical , EEE , ECE & Arts and Science Role: Permanent                           Year of Experience: Fresher                    Job Location: Sriperumbudur , Chennai                   Apply link : https://myemploymentjobs.com/foxconn-company-off-campus-drive-2023/ TATA Auto Jobs | டாடா நிறுவன நிரந்தர வேலை வாய்ப்புகள்  Designation: Engineers                                  Educational Qualifications: B.E , B.Tech , M.E, M. Tech Role: Permanent         Year of Experience: 1 – 8 Years Experience                   Job Location: Chennai , Bangalore & Pune                Apply link : https://myemploymentjobs.com/tata-auto-jobs-permanent-job-openings-2023/ For more Job info, subscribe to our website & and check our website daily. Join Our youtube ChannelClick HereJoin Our Telegram ChannelClick HereOur linkedin PageClick HereOur Quora PageClick Here Read the full article

[harrymartine]

https://www.crescendo-global.com/jobs/supply-chain-management

Job!!!!

City Manager- Dark Store Ops -Multiple Locations -3 -5 years

​

 Location: Gurgaon /Delhi/Mumbai/Bangalore

The individual will be responsible for end to end operations of Dark Store Order Fulfillment

Your future employer – A fast growing company in Logistics Industry which facilitates most of the companies in the country to aggressively expand their distribution channel.

 Key Responsibilities:

 Leading the end-to-end operations of Dark store Order fulfilment.

 Leading all aspects of dark store operations including but not limited to inbound, inventory, outbound, manpower planning, rostering, training, and employee engagement.

 Managing all aspects of rider’s operations pertaining to deliveries, including but not limited to rider planning, onboarding, QMS, productivity, training and engagement, & inventory hygiene.

 Leading and executing the dark store capacity planning with respect to infrastructure and manpower.

Contributing towards development and implementation of SOPs.

Building culture of continuous improvement through lean practices, Gemba Kaizen and other productivity improvement tools.

Ensuring Dark Store Quality Control, Manpower Training & Development & overall hygiene of the Store.

Institutionalizing the processes to delivery strong customer experience - Work cross functionally with peers who will empower you to do your best work

[leansixsigma11-blog]

How to implement Kanban and supermarket system for Inventory optimization (Case study)

ABC company is a home interior products manufacturing company located in Bangalore

Company produces for around 40 clients) in a month

Types of furniture manufactured are wardrobes, kitchen cabinets, TV cabinets etc.

Study was done to streamline material procurement, storage, issue procedure & inventory management

Number of vendors – Raw material ~ 25, Hardware~10

Lead time – imports ~ 4 weeks, local ~ 1 week

Total inventory was around Rs. 60 lakhs

Major operations are:

Head office

Client interaction & Design

Approval from client

BOQ (Bill of qty preparation)

Material Purchase

Preparation of CAD drawing

Factory

Receiving, storage & issue  of material

Production

Quality checking

Packing

Dispatch

Study was done to standardize/simplify material procurement, storage & issue system

Before implementation of Kanban system:

Main three types of raw materials are used – Boards, Laminates & Edge banding (around 250 types)

Laminates were stored in bundled form as it come which was occupying lot of space & also very difficult to retrieve.

Boards were store horizontally – which was leading high retrieval time

Edge banding – not stores colourwise/widthwise leading to high retrieval time and also using mismatch color many time.  For reordering, it was difficult to know the stock of different materials available

Without getting 100% material for client, there used be pressure to take it for production and many times there used to be two batch production for the same client leading to lot of confusion in the shop floor in locating items & they used to miss many items

In hardware store, there were three types of material, Common items (classified from used in more than 5 clients in a month), unique items for clients & non moving & slow moving items

Non moving items accumulated, because of purchase of items without proper planning

Total inventory was around INR 20 lakhs, out of which around INR 10 lakh was non moving

All items were mixed up in storage and no clear identification.  Only when items are required to dispatch during installations, they used to find out some items have not yet received & there used to be delay in installation

Once items become non moving, it is very difficult to use it.  Only if few items are left out, it cannot be used for other clients as client requirement qty & available qty may not match & difficult to use it.

Also these items are stored in factory & designers sit in office in a different location, very difficult to coordinate with designers to use these items & there is no compelling on them to use these items

Hardware & accessories are ordered once a month

Inventory classification is done through Kanban analysis:

Sample Analysis For Feb 2018

on analysis of the items, it was decided to group items in to three categories & arrange accordingly:Based on logic of items used for number of customers & taking items used for more than 5 customers as common items, it was found that 60% of unique material & 40% are common materials

Based on analysis of the items, it was decided to group items in to three categories & arrange accordingly:

Common items where Kanban can be implemented

Unique items which can be kept clientwise when received

Extra/non moving items which are leftover either from extra ordering or MOQ restrictions

Extra racks were procured and items are arranged accordingly.

Kanban is a Lean tool to

              – optimise inventory

              – prevent stock out situation

              – visual control for ordering

Above sample calculation for Hardware & Accessories shows it is possible to reduce inventory & easy procurement process for Common items

Hardware & accessories arrangement in stores :

Hardware & Accessories will be arranged in to three groups :

Common items (around 50) will be arranged in to two bin Kanban system with each bin qty 15 days.

Unique items will be arranged customer wise

Leftover items (from MOQ ordering)

Material ordering :

For common items, Two bin Kanban system is introduced. Each bin will have Kanban card & when items are over in one bin, Kanban card is placed in “For Ordering” box.  Order to be done for these items weekly twice/weekly once.  These items are not ordered along with other BOQ items.  This method will optimise inventory, ease of ordering & visual system.

Presently all items ordered once a month.  In the new system, common items are ordered separately through card triggering mechanism.  Weekly bucket ordering system to be implemented.  For the ordered closed during the week, next week beginning order to be placed where production will be taken after 2 weeks.  Lead time for procurement taken as two weeks.

There are certain items because of MOQ, more than actual required for the customer order will be purchased.  The left out items to be kept separate so that they can be visually identified & while ordering items during next week for other customers, stock of these items to be seen & available items should not be ordered.

Kitting system is introduced:Benefits:

Inventory was reduced from Rs.60 lakhs to Rs.40 lakhs  (33% reduction)

Retrieval time reduced drastically due to new arrangement

Future generation of non moving items reduced because of new system

Testimonial from customer:

“We  were very much happy to associate with Seven Steps for the implementation of Lean Project at our Factory.

The dedicated efforts by you and your team are very commendable and down to earth.

My Shop floor teams are well trained by you on 5S, Kaizen, Kanban, Error Free Delivery, Kitting,etc which helped us in improve On Time Delivery,Reduce Lead time,100% Fulfillment and tracking of inventory at different stages.”

Seven Steps Business Transformation Systems is a Bangalore based consulting company for manufacturing, services, retail, logistics, construction, Education, hospital, hospitality.  Kanban system implementation is done as a combination of other tools and methodogies such as 5S, Value Stream Mapping, Cellular Manufacturing, Total Productive Maintenance, Six Sigma etc., Through their group vertical – Seven Steps academy, various training programmes are also offered for both onsite and public programmes.

Some of the flagship training programmes conducted at Seven Steps Academy of Excellence are:

Six sigma Green Belt

Six Sigma Black Belt

Six Sigma Yellow Belt

Skill development programme – Campus to Corporate – Precision Engineering

Applied 5S

TPM

Lean Experimental Learning Programme

[sixsigmacertificationinbang-blog]

Quality Culture in an Organization | Quality Improvement in the Workplace

Quality is the result of collective effort of every employee in an organization. Quality cannot be achieved only through stringent quality control methods and use of sophisticated instruments or by highly competent quality department. Dr. Deming claims that 85 % of quality problems are created by people who never touch the product. Also quality cannot be achieved using flavor of the month approach. When individuals make quality as a habit, it becomes a culture at organization level. In this paper we are making an attempt to summarize traits of an organization where quality is a culture.

1: What is Quality Culture and how we measure it?

During one of the plant visit, we entered their canteen and found beautiful visuals for keeping the used food plates, cups, waste food etc…And in practice most of the employees mixing cups and plates, partially clearing waste foods from plate etc… We came to a conclusion that this company may be having serious concerns of quality. When we expressed our view with one of the manager he was not convinced. Then we explained him the concept of culture. If your employees not serious about mixing cups and plates, what is the guarantee they are serious about mixing of parts in the shop-floor? Later he was convinced with our logic. In the next stage we observed employees not following lane principle while going out of canteen. They suppose to walk in the left hand side but most of them were not complying with the rule. Simple examples like this will tell us if quality is a culture in an organization.

Below is the Wikipedia definition of Organization culture as a summary.

Organizational culture is  collective behavior of people belonging to organization and the meanings that the people attach to their actions. organization values, visions, norms, working language, systems, symbols, beliefs and habits are part of its culture.

It is also the pattern of such collective behaviors and assumptions that are taught to new organizational members as a way of perceiving, and even thinking and feeling. the way people and groups interact with each other, with clients, and with stakeholders depends on its Organizational culture.

If we extend this definition to include quality, it becomes, “Organizational culture affects the way people and groups interact with each other, with clients, and with stakeholders and ultimately quality of the product

That means “Quality Culture depends on Organization culture”

Now let us look at the other side. Imagine that you entered an organization where quality is a culture; you feel the difference right from security gate. The way security personnel interact with you, the systems they maintain, the time management etc… gives you a feel of world class organization. Once you enter the reception, you will continue to experience the difference. The courteousness of receptionist, the self help displays, hassle-free path ways etc… You will appreciate how much attention given even for micro level things. No need to explain about the behavior of rest of the organization.

Once a company was audited by its Japanese customers for Quality System implementation. The auditors specifically wanted to visit three areas which took the company management by surprise. According to them, the areas customers selected were nothing to do with their quality systems.

The three areas selected were; Security, Scrap yard and workers toilets. Later during the closing meeting, one of the auditors explained to top management about the reason behind selecting those three areas. The logic is, most of the companies give least importance to these areas. According to them, if any company gives importance to these areas, it is obvious that they are serious about other areas.

2: Factors influence Quality Culture

We asked a question to our linked-in group members. In the equation Y=F(x), where Y= organization culture and x1, x 2 etc… are factors influence the culture, identify those factors. Also what are the 3 xs strongly influence the culture? We received various answers like Geographic location, Value system, Vision, Constancy of purpose, leadership, Management commitment, external environment, Quality Management systems, Human Resource development etc…most of them are interrelated.

Example: Poor implementation of quality management system is reflection of poor management commitment and leadership and so on…  Let us discuss about three important factors which according to us have strong influence on quality culture. They are Leadership, Training and development and value system. One may argue that the second and third factors can be influenced by Leadership. However, for ease of analysis we considered three factors separately.

2.1 Role of Leadership for creating culture of quality – The tale of two leaders

One of the organizations was engaged in manufacture of electric motors. All the completed motors were required to go through final auditing process. It was a month end and the factory was yet to deliver more than 50 % of the orders. In such situation one of the quality auditors rejected the entire lot of motors due to abnormal noise. The plant manager was very upset hearing this. He called the particular auditor and asked what is the problem and after knowing the problem, he suggested to release products under deviation.

The reason given was – These motors are used in textile industry and the abnormal noise of this motor will not be audible in the huge noise created by textile machinery. You can imagine what will happen for the quality in future. The quality auditor next time takes his own decision to pass the defective parts and spread the wrong culture.

Another company was making fabricated structures for construction of bridges. CEO of this company used to do surprise audits at different stages to ensure delivery of quality products to customers. Once while doing one of such audit, he found one of the structure having abnormal bend being in the vehicle ready for dispatch. He immediately asked concerned people to stop the shipment and correct the problem. Not only that; he also asked his team to do a root cause analysis for such escape. Though it is un intentional, the response by leader shows his commitment to quality.

One of the key roles of a leader is “Lead by example”. In the above example, the company may lose one delivery but it sends a strong message to all the employees that any deviation to quality is not acceptable at any cost.

Another key point here is continuation of these leadership principles irrespective of change in leadership. This is a big challenge for many organizations.

2.2 Training and Development – Key in creating culture

Cultural transformation is a journey. Training and development plays an important role in creating quality culture. It should happen at all stages recruitment to retirement and for all level of employees from operator to CEO. Below is an example of Induction training topics of a new employee in an organization known for its quality culture. This is apart from her work related topics and this is mandatory for all employees.

Mission and Vision of organization

Values and Principles

Problem Solving

Kaizen and 5S

Quality and Environment Management Systems

Imagine an employee joins a company with great quality culture from a company which is mediocre. He has two choices a) Adjust to new culture OR b) quit the company. This is the power of culture.

Training and retraining should be a continuous process. Otherwise sustenance will be difficult.

2.3 Value System – Driver of Culture

Values of an organization communicate what is acceptable and what is not acceptable behavior. For example one of the companies had the following values

Quality First

Respect for people

Sense of urgency

Now this will be the guiding factors for every employee. They will be questioned by any one if they deviate from this. Like a compass in the ship showing direction to the captain, the value system tells organization the right and wrong direction. No one can question this including CEO. Once again, it depends on leaders, how they drive it and communicate it.

3: Quality Culture and Quality Management Systems

In our article “IS ISO 9000 CERTIFICATION LOSING ITS CREDIBILITY? We tried to demystify the various factors responsible for dilution of quality management system. It is quite obvious from our study that, organization which has poor quality culture give least importance to Quality Management Systems like ISO 9000. If the systems are weak, naturally product quality deteriorates. The following triangle illustrates the effects of deviation in quality systems.

4: Quality Assurance (QA) and Human Resource Development (HRD) should not just remain as nameplate change:

In the last two decades many organizations changed name of their two departments

Quality Control became Quality Assurance and Personnel department became Human Resource Development. Unfortunately many companies just changed the board and continued to function in the old way. Few companies adopted new philosophy and become very successful. We strongly recommend companies to adopt the philosophy of QA and HRD in true spirits to create Quality Culture.

Seven Steps Business Transformation System provides support in improving Quality Culture in any organization. We use a combination of tools such as Lean manufacturing, Lean Services, Lean Construction, Lean Hospitals, Lean Retailing. Seven Steps Global also conducts training programs on Various Quality tools which include ASQ Six Sigma Green Belt, ASQ Six Sigma Black Belt certification training, 7QC Tools, Experiential Learning on Lean, 5S, TPM, TQM, TOC ETC, through our group company Seven Steps Academy of Excellence.

Seven Steps Business Transformation System is also a most sort after Lean Manufacturing Consulting companies in India through their operating locations from Bangalore, Chennai, Calcutta, Pune, Mumbai, Nashik, Pant Nagar, Gurugram, Ludhiana, Shivamogga, Hosur, Mysore, Hyderabad, Salem, Chennai etc.

[tpmconsulting]

With Lean Daily Work Management System at the core of its operations, an organization will be able to quickly identify deviation, start solving problems and make strategy deployment a success.

Lean Daily Management System (LDMS) comprises of fundamental components for dealing with the presentation of tasks from operations. LDMS helps in improving overall performance of the organization through effective management of key tasks and timelines.

With straightforward and powerful visual tools, you can streamline your operational exhibition by eliminating the sources of variation brought about by traditional management and oversight practices.

Lean Daily Work Management will assist you with establishing a precise way to deal with oversee the same affairs, delegate, empower and manage performance of business/process. Lean Start-ups for the most part centre more on boot tying and creating products and services utilizing Lean standards.

Traditional organizations try announcing their strategy by simply telling goals and expectations onto the different areas and levels of the business.  Command and control mode is introduced for “making the numbers” and monitoring the actions they are expected to carry out.

Read more: https://bit.ly/3k4txqi

[leanconsultingblog]

CAPA includes control points, control levels, etc. This step is the key to the improvement of your performance.

To Prevent recurrence of the abnormality, you need to understand the situation in great detail, analyze the causes at a deep level, and take action to eliminate the cause.

To prevent the occurrence in similar areas, you need preventive actions. These actions include revision of SOP’s, control points & control levels along with regular skill updation of the concerned.

Read More: https://bit.ly/3lcSRLs

[isevenstepsglobal]

World Class Manufacturing|WCM Companies in bangalore

WCM Company in Bangalore

World Class Manufacturing (WCM) is a methodology of improving manufacturing operations in terms of productivity, Quality, Cost, logistics, inventory etc., Key objectives of WCM are Zero defects, Zero breakdowns and Zero Inventory … towards ideal state.

The World Class Manufacturing is a concept developed by FIAT, Hajime Yamashina, Professor Emeritus at Kyoto Universality in Japan, played a key in development of WCM.

According to Fiat, WCM is started in year 2005 with the aim of improving the production system by reducing waste, increasing productivity and improving working conditions, World Class Manufacturing is not a project but rather a constantly evolution program that grows and perfects itself using the contributions of all involved each day World Class Manufacturing (WCM)

The pillars of World Class Manufacturing are specified in terms of Technical and Managerial pillars as below.

The Technical pillars of World Class Manufacturing:

Safety

Cost Deployment

Focused improvement

Autonomous maintenance and workplace organization

Professional Maintenance

Quality control

Logistics & Customer service

Early equipment management

People development

Environment

The Managerial pillars of World Class Manufacturing are:

Management Commitment

Clarity of Objectives

Route map to WCM

Allocation of Highly Qualified People to Model Areas

Commitment of the Organization

Competence of Organization towards Improvement

Time and Budget

Level of Detail

Level of Expansion

Motivation of Operators

[sevenstepsglobalbangalore]

Below are those 4 Cs

Crisis

Customer Demand

Competition

Chairman or CEO of Vision

Here the definition of Excellence, I am limiting to Business Excellence journey using strategies like TQM, TPM, Lean, Six Sigma, etc..

Why should some organizations start any of this journey?

Crisis

If the organization is in deep trouble, its profits are negative, Liabilities increasing, No demand for the product, etc.. we can consider that this particular organization is in Crisis.  The current scenario of COVID 19 puts many organizations in Crisis mode.  Many organizations thinking of adapting practices like Lean, 5S, Kaizen, etc.. to reduce their losses.

The problem with this driver is it works until the crisis ends. The later organization thinks about excellence only when another crisis hits!

Customer Demand

Many organizations depend on a few key customers and those Customers mandate organizations on certain Systems. For example, some customers may ask its suppliers to implement Lean or TPM or Six Sigma. In such cases, suppliers have no options other than accepting it.

The problem with this driver is, it works only to satisfy customers.  So TPM- Total Productive Maintenance becomes Total Paint Management (Painting the factory during customer visits) or Total Presentation Management. ISO 9001 only lies in papers. So the organization will never reap the benefit of the business excellence journey.

Competition

Our competitor is practicing Six Sigma, so we also should launch it!  Some organizations closely follow their competition and copy whatever they do. They are too much obsessed with competition. The biggest danger in this approach is, what works for competition may not work for us.

CEO/ Chairman’s Vision

Very few organizations, Business excellence is driven by Chairman or CEOs vision. There is no crisis, no competition, no customer mandate but the leadership proactively implementing it keeping long term results in mind. They anticipate changes and prepare the organization for the same. It is these organizations which will survive even in Corona era

Let us look at some powerful tools offered by Lean, TPM, TQM, Six Sigma, etc..  and how they are helping organizations during Crisis

Lean thinking talks about doing more with less – fewer Efforts, Less Resources, Less space, Less Inventory, Less supervision, etc..  This thinking obviously brings the cost down and make the organization more profitable. To achieve this lean provides tools like 5S, Value Stream Mapping, Kanban, Quick Changeover, etc..

TQM organizations use a powerful tool called Hoshin Kanri.  This tool makes leadership anticipate changes and keep plan B and C in case of uncertainties. Unfortunately, very few organizations applying it . If it is used with Balanced Scorecard, the benefits will multiply.

Related Article– Hoshin Kanri – The Secret Behind Visionary Organizations

5S is a very effective tool to create a disciplined and organized workplace. It is the dream of many Leaders to create a good work culture and 5S is a simple but powerful tool to achieve it.

Related Article– What is Red Tag Strategy in 5S, its Application and Implementation Method

Kanban will ensure optimum inventory is maintained and improves cashflow. SMED (Single minute Exchange of Dies) or Quick Changeover (QCO ) is companion of Kanban and JIT ( Just in Time) Manufacturing

DMAIC, PDCA, QC Story all are various problem-solving methodologies which make organizations highly competitive and profitable by reducing the cost of poor quality (COPQ)

Related Article– How to minimize stock out and improve inventory – Kanban Training

The above table gives an idea about the power of Business Excellence tools.

Finally, if organizations realize the importance of the Business Excellence Journey and start now, there is a possibility of Foreseeing the future and prepare for uncertainties.  The fourth C – CEOs vision will help to Foresee the Cs like COVID 19 and helps to counteract the same

Related Article– TQM; TPM; LEAN; SIXSIGMA: What is the right strategy for my organization’s business excellence journey?

Seven Steps Business Transformation systems are a member of the Seven Steps Group company. specialized in Business turnaround facilitation. Our team of Business consultants is specialized in

Business Turnaround Facilitation.

Lean manufacturing

Total Productive maintenance

5S

Six Sigma implementation

Total Quality Management

Overall organization improvement.

Our services find useful in

Manufacturing industries

Service industries

Hospitals

Retail

Supply chain

Hospitality

Healthcare services

Construction Banking

Retail

Logistics

Facilities management

Schools and colleges

Some of the focused industries include

Aircraft manufacturing

Defense equipment production,

Food production,

Agriculture

Foundry

Pharmaceuticals

FMCG

Forgings

Warehousing

Transportation

Software

App development

Telecom

Government

Research organizations and

Service organizations

Also, Read Delivering High-Value Healthcare Through Lean Hospitals

Our consultants operate worldwide for online consulting.

Our regional presence in India for onsite- Gemba visit covers Bangalore, Hosur, Chennai, Mysore, Shimoga, Pune, Mumbai, Calcutta, Hyderabad, Salem, Tiruchy, Madurai, Tiruppur, Coimbatore, Hubli, Belgaum, Delhi, Chandigarh and another tier 1 and tier-II cities.