Productivity Portal » Case Studies

Tata electronics – Non Auto Sector

Abhishek D — Tue, 11 Mar 2025 22:59:24 +0000

Brief Description of the Project

Tata Electronics pioneers in the EMS Industry with the vision to develop a strong supply chain base for Electronics Manufacturing Services in our nation, creating more job opportunities to benefit the nation's economic growth.

In the EMS industry, new product development and mass production sustenance need to be carried out in a very short span to cater to customer demand. Tata Electronics had to face challenges and risks involved in the conventional method of production ramp-up. The demand for digital gadgets is exponential. To meet the global supply chain demand, Tata Electronics planned a massive factory setup with a capacity of 1 lakh mobile enclosures per day in two phases, i.e., three enclosures can be made every second. Factory readiness is expected to be completed in a very short span of six months.

TAFE – Non Auto Sector

Abhishek D — Tue, 11 Mar 2025 22:57:24 +0000

Brief Description of the Project

In response to the growing demand for New model of tractors (NPI tractors) from 5% to 45% in the market and to uphold its commitment to customer centricity, our company is embarking on a project to optimize the delivery process of tractors to dealers. The challenge lies in ensuring the right model of tractor reaches the right dealer at the right time. This necessitates a thorough assessment of manufacturing plant capacity to accommodate new product adoption without compromising regular production volume. Hence This project will be focusing the bottleneck areas within the production process and implement targeted improvements to reinforce our dedication to exceed the customer expectations to uphold organization core value and to play a market leader in the industry.

Synergy Engineers and powder – SME

Abhishek D — Tue, 11 Mar 2025 22:55:15 +0000

Brief Description of the Project

We were on the path of CII zero defect cluster, and our goal was to eliminate the defects. There were several defects as a result of the human-centric approach and the absence of equipment/system upgrades.We concentrated on powder coating plant kill live defects, which were mostly human-centric. We used zero defect cluster learning to identify as many as 42 pokayokes to manage these faults and were successful in eliminating them by deploying pokayokes. These pokayokes are used in numerous stages of the powder coating facility, including pre-treatment, powder spraying, the baking cycle, and the packaging section. We are dealing with 14 live defects which we have divided into two categories: live defects and dormant defects.

Lucas TVS – Auto Sector

Abhishek D — Tue, 11 Mar 2025 22:51:30 +0000

Brief Description of the Project

INDER ENTERPRISES is a CNC Machining job shop that caters to high mix and low volume precision component of sizes ranging from 1m up to 9m. Being a family run business, we have over 40 years of manufacturing complex and precision components for regional and domestic customers belonging to industries like Aerospace, Defense, Industrial Automation and Robotics, Printing machinery, Machine tools and SPM etc. You can find our company profile here. Being a job shop, our order book is highly dynamic and unpredictive and our customers being SMEs themselves lack the systems, forecasting capabilities and financial headroom to have a smooth flow of orders. This leads to highly variable order flow on our shop floor causing delays, errors and rejections leading to less than expected top line performance. To Alleviate this, our management took the decision of systemizing all our process and build a custom Enterprises Resource Planning (ERP) Software in-house that can cater to our specific needs.

Inder Enterprises – SME

Abhishek D — Tue, 11 Mar 2025 22:47:34 +0000

Brief Description of the Project

Hero-MotoCorp – Auto Sector

Abhishek D — Tue, 11 Mar 2025 22:42:53 +0000

Brief Description of the Project

From Hero-MotoCorp Haridwar plant, HUNK160 R model is exported to 4 Continents and 17 countries based on the requirement and facilities equipped at dealer’s end in the form of CBU (Complete build Unit), CKD (Complete Knock-down) & SKD (Semi Knock Down). Out of 17 countries, in 11 countries SKD packaging is used as per facilities equipped at dealer’s end. As contribution of SKD was around 65%, so we analyzed detailed costs involved in SKD and found that the logistics costs were contributing to 76% of total export costs. After finalizing the project from the above trigger points, we listed down the below parameters that are to be fulfilled by this project. To reduce the cost, we needed to improve our productivity by increasing no. of vehicle per container.

Ashok leyland

Abhishek D — Tue, 11 Mar 2025 22:27:42 +0000

Brief Description of the Project

Ashok Leyland is having 7 manufacturing units in India. We are from Hosur plant - II, Tamil Nadu producing very wide range of products. Our unit is the only plant amongst Ashok Leyland and competitors producing vehicles of all segments including Light, Medium & Heavy commercial vehicles.

Paint shop is a common facility to produce Cabins for LCV, M&HCV & Specialty vehicles, whereas other shops like Weld, Trim & Chassis are having multi lines to meet the production demand.

Installing a new Paint shop requires huge Capex and also operational expenses will become double. Due to cyclicity of Automobile it is advisable to have single Paint shop with improved productivity & capacity.

With this project, team has increased the cabin paint capacity from 125K/annum to 199K/annum through by Process Innovation and developing new Paint and chemical along with material supplier to fulfil the requirement.

The uniqueness & complexity of the project was that it needed to be completed in same building without stopping regular production.

TAFE

Abhishek D — Wed, 06 Mar 2024 22:33:14 +0000

Brief Description of the Project

TAFE has been working on many continuous improvement projects over the years to make available, the right model of tractor at the right dealer point at the right time to the Domestic market customers which is 80% of the TAFE Volume. But always there had been instances of mismatch of the Customer need and tractor models available at the Dealership. In view of the highly competitive market scenario, customers were not willing to wait for the right model be made available to him in some days, due to this there had been opportunity loss of a sale. So it became necessary to look at opportunities for improving the full cycle of Sale to Production process and consequently making the tractor available at the dealer ship end.

Hero MotoCorp Ltd

Abhishek D — Wed, 06 Mar 2024 22:28:26 +0000

Brief Description of the Project

Objective: “To Create Future Ready Workplace” by adopting Operational Excellence practices involving World-class Manufacturing Methodologies.

Scope: This Project articulates the essential for a Cost Competitive Plant with Productivity improvement as the primary objective and applies to all the processes of the plant.

Context Setting: Plant has an installed daily Production Capacity of 9500 Vehicles, where Market demand is fulfilled as per the forecasted demand. So, to grow productivity with fluctuation in market demand, we need to optimize the Resources by identifying & eliminating waste in our processes.

Challenges: Some of the challenges include high labor intensive assembly areas, age factor of the employees in coming years, partially skilled work force for Automations related improvements.

Tata Motors

Abhishek D — Wed, 06 Mar 2024 22:25:24 +0000

Brief description of the project.

Nexon is the first compact crossover SUV from Tata that was first displayed as a prototype in 2014 at the Auto Expo before being launched in 2017. Tata had bought out the Land Rover and Jaguar brands, leveraging their attention to design, quality and detail, to produce the Tata Nexon and introduce it to the Indian Automotive market. It proved to be a masterstroke and a breath of fresh air capturing the hearts and minds of the public at large. The Tata Nexon entered a market segment that was highly competitive and could even be said to be saturated today. Yet it found its way to becoming a bestseller. Its sales figures have risen year on year with the pandemic proving to be just a blip on the radar.

The Nexon Weld Body (BIW) was planned on the same shop where earlier models like Tata Zest were produced by refurbishing these lines to keep minimum investment as investing on new shop will ask for huge investment for non-reliable Market .