Operations / Metals [ India ]

8 Months

SHOP FLOOR WORKFORCE PRODUCTIVITY AT ONE OF INDIA’S LARGEST INTEGRATED STEEL PLANTS

CLIENT:
A boutique consulting firm specializing in strategy and execution projects
End Client: A large integrated steel manufacturing company, with annual turnover of 5000 cr
CONSULTANT:
Lean Manufacturing Consultant with Expertise in Operational Excellence, Productivity Improvement & Value Stream Mapping. Specialises in overall operational improvement at grassroots levels in industries, Workforce Productivity, Total Operational Improvement, and applying Lean principles for Manufacturing Excellence. Has worked for Fishfa Rubbers, Macpower CNC Machines Mahindra Gears & Transmissions Pvt Ltd and has consulted numerous MSME's in the manufacturing sector.
ASSIGNMENT:
 Co-ordinate and facilitate the task force team for doing studies, preparing implementation plans, and presenting the case studies to departments as well as senior management
 Optimize the manpower productivity and achieve a 20% improvement from the current ratio
 Prepare the improvement plan and strategize the same for the end client
 Study the plant from raw material to final product and identify areas for productivity improvement
OUTCOME:
1. Recorded an average productivity optimization of 20%
2. Training and upgrading the task force to perform basic studies for further analysis
3. Covered raw material preparation to the final product section to study bottlenecks wrt to productivity
4. Prepared action plans for all functions on the projects required to achieve the target and plan of action
5. Co-ordination with various functions on improvement drive implementation plan and ensured that all activities are in line with the project timeline and meet the deadlines without any firefighting
6. A total of 10 functions were studied, analysed and set for the optimization plan