Smart factory Creation

Strategy

How a Capital Equipment Manufacturing company digitized their factory operations.

About the customer

Mumbai, Maharashtra

Capital Equipment Manufacturing

Fabrication, Installation and Commissioning of Water and Wastewater Treatment Plant

50+ Shop Floor Staff

Primary customer base: Food and Beverages industries

25 Years in Business

Problem as visible to the customer

Problem 1: Decreasing Net Profit despite Increase in Revenue
Problem 2: Delayed Key Projects leading to customer dissatisfaction
Problem 3: Unorganized shop-floor and highly cluttered stores
Problem 4: promotor of the organization has to get involved in every decision making

Root Cause Analysis

Lack of documentation

Inventory data was manged in Hard copies
No GRN
No record of purchases

Undefined Job
roles / dept.
heads

Undefined Purchase
mechani

Undefined performance
measurement mechanism

No demarcation on
shopfloor
area

“In a manufacturing company, information flow between multiple departments can happen only by adopting technology”

Tools & Techniques used

Supply chain management
5s Techniques
Performance Management
System
Kaizen identification and implementation

The Intervention

Entire Factory was virtually put for revamp. Various data collection opportunities were identified like RM Stock, Purchase, GRN etc. Entire data collection mechanism was set up with an excel based inventory management tool. Detailed 5s was conducted on the shopfloor, various areas were identified and designated. Various job roles were identified, right people were interviewed and respective responsibilities were given to them.

A glimpse of Intervention

Tools & Techniques used

Safety Guidelines
Sexual Harassment Policy Making
Attendance and leav and
many more

Employee Engagement

Activity: Physical Check up

Stores after 5s Activity

Results

Significant drop in stock-out situations
Better availability of material at site for implementation
On-time project completion leading to bonus pay-outs from the customer
Better cashflow management, due to enhanced visibility of stock holdings
Increased morale of the employees on the shop floor where employees are willing to learn new skills, taking new initiatives etc.

" From a data blind company, setting up the entire supply chain mechanism has put XYZ Pvt. Ltd. on its course for a relevant ERP adoption thereby moving towards a data driven company. "

Strategy