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The scientific approach to the Organization's
operational activities leads the Company to more profitable
and efficient operations i.e. PROFICIENT PLANT OPERATIONS.
The techniques include:
Ten commandments of Productivity improvement
* Eliminate Waste
* Minimize Inventory
* Maximize flow
* Pull production from Customer demand
* Design for Rapid Change Over
* Partner with Supplier
* Empower workers/ Multi-skill workers
* Meet Customers' requirement
* Do It Right For the First Time
* Create a culture of Continuous Improvement
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Five "M"s of Operational Activity : Material,
Man, Machine, Method, Money
MATERIAL
Wastage Reduction
Scrap Minimization
Cause And Effect analysis
Materials Flow Study
MAN
Manual operations Line Balancing
Man Power movement Analysis
Time Traps Crunching
Workstation Turn Over Time
Work Place Layout
MACHINE
Machine- Manual
operational effective line balancing
Rapid Setup Method
Minimizing Break-downs with Total Productive Maintenance
technique
METHOD
Manufacturing Process
Mapping
Manufacturing Cycle efficiency improvement
Visual Control and MIS systems
80/20 Rule of bottleneck Identification and Removal
MONEY
Throughput Time crunching -Working Capital
Cycle improvement
The concepts include proven effective improvement tools
of
* Lean Manufacturing
* Plant layout Re-engineering
* Value Engineering exercise
* Efficient Material Handling
* DMAIC (Define Measure Analyze Improve Control) technique
* Kaizen
# Conservation of Energy
Provide solutions to optimize consumption
of electrical as well as thermal energy
# Work In-process Inventory Control
Quantify Work in Progress Inventory
between bottleneck operations & crunching WIP inventory
to improve plant velocity.
# Seven Effective tools of Wastage Reduction
Over production, Defects, Transportation,
Motion, Waiting, Processing, Inventory
# POKA YOKE
Mistake proofing resulting to minimizing
Rejections
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