Challenge

To meet sudden increase in Customer demand, Ford (430 to 560 Nos) & 7 LPM (340 to 450 Nos)

Gaps in meeting customer demand is identified by comparing the actual demand to the current capacity and by improving the major losses like Model changeovers in the current capacity.

Data Collection

Keeping minimum investment in mind focused on-Machine utilization / Line Balancing – Existing Line, Machine utilization / Line Balancing – other similar lines and Major losses in current condition.

Project initiation date: 07/12

Challenge

Project: Improve productivity by ensuring end to end pull system in M&M bolero assembly. To meet the customer demand and management policy we have selected the theme of creating an Integrated cell.

For selecting this project, PQ analysis was done and found IFS Lower has the highest volume in production.

Project initiation date: 07/12

Challenge

NTBC oil pump (Cummins) requirement increased from 500nos. to 1800nos. per month. Assembly & testing is the identified system constraint. Existing productivity of assembly & testing was 18 & 38 nos. per shift respectively. To meet the increased demand, it was needed to increase the capacity of assembly & testing. Since management policy does not allow to increase manpower, without increase in productivity (without fully exploiting the constraint). Capacity addition without improving productivity would have increased the cost of manpower, other expenses like power bill & other overheads. This would reduced bottom line.

Project initiation date: 07/11

Challenge

Zero rejection was targeted for machine shop and on data stratification

It was found that the steel phase was the top contributor of rejection. In steel phase rejection of Crank Shaft Line was very high and also affecting the overall productivity of the line. Project was taken and TPM (Total productive Maintenance) was used as a broad management tool and Figure of Eight methodology was adopted to eliminate the defects.

Project initiation date: 03/12

Challenge

The refrigerator market in India is highly seasonal and peaks during summer and festive seasons installed capacity to meet this peak demand.

But, in today’s competitive market, manufacturers are offering customers a range of features to suit their needs. This range includes different sizes, colors, designs, interiors etc and each such variant becomes an SKU for manufacturing. We at Godrej also increased our range by 25 nos. over last three years.

In order to produce the large number of variants and SKU’s, needed to produce in multiple lots and keep changing models on the production lines which resulted in productivity loss and inefficiencies in capacity utilization.