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Case Studies

Case Studies

This Graph is result of the our engagement with the client from Aug 23

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  • Boosted Employee Engagement:
    Fostered a motivated and dynamic workforce through strategic initiatives.
  • Cultivated Ownership:
    Empowered employees to take responsibility and pride in their roles.
  • Daily Morning Meetings:
    Established consistent, short meetings to kick-start the day with focus and alignment.
  • Structured Weekly Meetings:
    Held regular check-ins to track progress, address challenges, and maintain momentum.
  • Comprehensive Monthly Scorecard Reviews:
    Evaluated performance metrics to ensure continuous improvement and transparency.
  • Accountability and Responsibility Awareness:
    Promoted a culture of accountability, leading to increased productivity and commitment

Month wise Production Report 2023 - 24

Particulars APRIL MAY JUNE JULY AUG SEP OCT NOV DEC JAN FEB MAR TOTAL
Production 19,69,943.50 20,63,323.00 17,68,666.00 11,28,325.00 15,98,958.00 12,87,164.00 15,30,676.00 22,59,305.00 25,23,491.77 23,47,090.00 26,54,275.00 24,67,161.00 2,35,98,378.27
SERVICE 1 1,20,850.00 1,24,540.00 2,03,940.00 1,68,929.00 2,62,074.00 1,47,655.00 2,29,859.00 1,13,347.00 1,46,585.00 1,68,350.00 1,60,510.00 2,23,230.00 20,69,869.00
SERVICE 2 2,57,031.00 1,27,884.00 1,26,255.00 1,48,064.00 2,53,641.00 2,77,930.00 1,19,840.00 1,22,730.00 2,78,030.00 1,67,385.00 3,40,985.00 65,220.00 22,84,995.00
TOTAL 23,47,824.50 23,15,747.00 20,98,861.00 14,45,318.00 21,14,673.00 17,12,749.00 18,80,375.00 24,95,382.00 29,48,106.77 26,82,825.00 31,55,770.00 27,55,611.00 2,79,53,242.27
Gems Presentation Worksheet ->

Training Feedback

1. Visibility and Ownership
  • Increased visibility of tasks and ownership.
  • Greater awareness of individual responsibilities.
2. Accountability and Quality:
  • Enhanced accountability among team members.
  • Reduction in final rejection rates from 6% to 2%.
3. Responsibility and Communication:
  • Workers are taking more responsibility in their roles.
  • Improved interaction and communication between team members.
  • Narrowed communication gaps during Service Level Agreement discussions.
4. Team Dynamics:
  • Improved teamwork and collaboration.
  • Initiation of idea generation within teams.
5. Operational Efficiency:
  • Machine uptime has improved due to morning meetings.
  • Increased adherence to ABSA system and processes.
  • Reduced setup times and focused efforts on cycle time reduction.
  • A systematic approach towards SOP-driven work.
6. Skill Development and Continuous Improvement:
  • Adoption of a learning mindset among workers due to multi skilling chart visibility.
  • Implementation of one-page lessons to facilitate continuous improvement.

Production Capacity and Productivity Improvement

1. Understanding Bottleneck:
  • Identified critical bottlenecks in the production process.
2. Skill Set Analysis and Introduction of Robo Cell:
  • Introduced the first robo cell in control panels manufacturing.
  • Reduced dependency on skilled manpower.
3. Time Study and Production Increase:
  • Conducted a detailed time study.
  • Increased assembly production from 100 units per day to 300 units per day.
  • Improved output per man.(almost doubled)
4. Client Satisfaction and Future Plans:
  • Client's customer was extremely happy with the improvements.
  • Two new product lines are currently under discussion.