OEE Improvement for Non-Woven Pad Process Machine
Objective:
The objective of the OEE improvement for the Non-Woven Pad Process Machine project was to enhance overall equipment effectiveness from 43% to 60%, reduce costs of goods sold, eliminate rework in the spray coating process, and ensure uniformity in GSM for better product quality.
Overview:
We have undertaken a project to improve the Overall Equipment Effectiveness (OEE) of our non-woven pad manufacturing process at our plant in [City]. The current OEE stands at 44%, impacting the cost of goods sold (COGS) by 9%. The project aims to address inefficiencies in the fiber winding and coating stages, eliminate rework in the spray coating process, and ensure uniformity in GSM. By implementing separate systems for different resins and defining standards for nozzle cleaning, we aim to enhance production efficiency and achieve our OEE targets.
Key Achievements:
The project improved OEE from 43% to 60%, reduced COGS percentage, eliminated rework in the spray coating process, and ensured uniformity in GSM for non-woven pads.
JIT/VMI Implementation for Packing Material
Objective:
The objective of the JIT/VMI for Packing Material project was to alleviate warehouse capacity constraints, reduce inventory and pallet occupancy, streamline processes, and enhance efficiency through just-in-time and vendor-managed inventory systems
Overview:
We have initiated the JIT/VMI implementation for packing material at the manufacturing plant. This project aims to address warehouse capacity constraints that impact growth and operational costs. By optimizing warehouse space, we support new product launches and avoid additional investments in infrastructure. The initiative focuses on reducing process steps by 30%, implementing a 3-day rolling plan for VSM conversion, and standardizing packaging materials to enhance efficiency and enable self-certification.
Key Achievements:
The project reduced packaging inventory value by 87.5%, decreased pallet occupancy by 75%, cut process steps by 30%, and streamlined headcount deployment in the warehouse by 66.7%.
Zero Defect (ZD) Methodology Deployment
Objective :
The objective of the Zero Defect (ZD) Methodology deployment project was to eliminate surface imperfections, enhance operator skills, and achieve self-certification for Auto OEMs, ensuring high-quality aesthetic products.
Overview :
We initiated the deployment of the Zero Defect (ZD) methodology at our manufacturing plants located in Pune and Bengaluru. The project involves the application of [specific material or process], aiming to address and reduce surface imperfections, which are significant causes of rejection and affect customer satisfaction. By minimizing machine and human errors in our aesthetic products, we are developing comprehensive PFMEA for process conversion, utilizing the latest industry standards. Rigorous root cause analysis and periodic training are being implemented to sustain and enhance our quality practices
Key Achievements:
The project successfully achieved self-certification for Auto OEMs, reduced parts per million (PPM) at the customer, enhanced operator training and skills, and minimized unnecessary downtime.
Technology Upgradation in Cable Jointing Kit
Objective :
The objective was to upgrade technology and optimize manufacturing processes for cable jointing kits to improve production efficiency, reduce costs, enhance inventory management, and minimize lead times. This aimed to increase throughput, reduce dependency on imported materials, and streamline warehouse operations for a more efficient supply chain.
Overview :
The project aimed to enhance cable jointing kit manufacturing by upgrading technology and optimizing processes. By adopting chemical cross-linking, developing new formulations, and implementing VSM, inventory management, and DOE, the project improved roll throughput yield from 72% to 92%, reduced COGS from 62% to 56%, and cut inventory days from 100 to 10. Additionally, warehouse space usage decreased from 1,200 to 900 pallets, resulting in a more efficient and cost-effective supply chain.
Key Achievements :
The key achievements are the successful in-house development, execution of a 5.0 CR INR Capex plan, inventory reduction, improved yield, and reduced COGS.
Streamlining Complex Manufacturing Processes through Simplification and Innovation
Objective :
The primary goal of this project was to streamline and simplify complex manufacturing processes to enhance overall efficiency, reduce lead times, and optimize resource utilization.
Overview :
This project focused on the implementation of various improvement steps to address inefficiencies in a manufacturing setup. By adopting methodologies such as Value Stream Mapping (VSM), process flow improvement, KANBAN, inventory management, Kaizen, mass customization, and Just-In-Time (JIT) practices, the project aimed to achieve significant operational improvements.
Key Achievements :
Main achievements includes project streamlined production plans, increased output, enhanced SKU management, reduced lead times, optimized warehouse transactions, implemented JIT principles, and reduced dependency on skilled manpower.
