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Optimizing Steel Utilization
A project was done for the construction division of a conglomerate. The construction company was involved in construction activities at multiple sites within close proximity. It faced significant wastage of steel reinforcement bars, averaging about 6% of total steel usage due to inefficient cutting practices and poor inventory management due to decentralized administration of sites. To address the issue, project team consolidated the cutting of the steel bars at one location, implemented standardized cutting plans optimized through software to minimize offcuts, introduced strict inventory controls, and coupling techniques to use the uncut pieces. As a result, steel wastage was reduced from 6% to 3%, saving approximately 250 tons of steel annually. This reduction translated into cost savings of around INR 43 lacs per year, significantly lowering material expenses and enhancing project profitability.
Lean HR > HR Analytics
Project ManagementAutomating Time Tracking and Billing
A project was done in a BPO/ITES company that struggled with manual time sheet entries, resulting in inaccuracies, limited visibility into employee time allocation, and incorrect billing to clients. The project team implemented an automated time-tracking system integrated with project management and HRMS software. Employees’ work hours (irrespective whether they worked from office or home) were automatically recorded and assigned to specific tasks and projects. This automation reduced time entry errors by 96% and improved billing accuracy by 90%. The company recovered approximately INR 15 lacs annually in previously lost revenue due to billing discrepancies. Additionally, managers gained better visibility into time spent on tasks, enabling more effective resource planning and increased productivity.
Optimizing Packaging Line Maintenance
A project was done in a packaged food manufacturing plant. The key issue faced was frequent machine downtimes, costing approximately INR 50 lacs annually. To address this, the project team implemented a Predictive Maintenance System using IoT sensors on critical machinery. These sensors monitored real-time performance metrics and alerted the maintenance team of potential failures. The solution included integrating IoT platforms with existing ERP systems. As a result, unplanned downtimes reduced by 40%, saving INR 30 lacs annually and enhancing overall production efficiency. Additionally, the data collected enabled better resource planning, extended machinery lifespan and uninterrupted continuous manufacturing.
Quality Control/ Quality Assurance > DOE
Integrating Quality by Design
A project was done in a pharmaceuticals company which was struggling with inconsistent product quality and lengthy development times due to insufficient process understanding. To address these issues, the project team adopted the Quality by Design (QbD) approach. This involved identifying critical quality attributes (CQAs) and critical process parameters (CPPs), conducting risk assessments, and utilizing design of experiments (DoE) to optimize manufacturing processes. By integrating quality considerations from the outset, the company built robustness into the product design and manufacturing process. As a result, the company achieved improved product quality, reduced batch failures by 30%, and shortened development time by 25%. Benefits included enhanced regulatory compliance, reduced time to market and cost savings from fewer rejected batches.
Maintenance > Asset Management
Implementing RFID for Inventory Control
A project was done in a warehouse that struggled with inaccurate inventory tracking and frequent theft, resulting in annual losses of approximately INR 6 lacs. As a part of the project, the team integrated a Barcode/RFID Tracking System. The implementation involved tagging all inventory items, installing RFID scanners at key access points, and training staff on the new system. This solution enhanced inventory accuracy by 98%, reduced manual stock-taking time by 35%, and streamlined inventory management processes. Additionally, the system’s real-time tracking capabilities decreased theft incidents by 95%, preventing potential losses of INR 4.5 lacs annually.
Training > Business Excellence
Boosting Training Engagement
A project was done in an organization to improve the training delivery and engagement. The key issue was low completion rates hovering around 55%. The team developed an interactive e-learning platform , featuring gamified modules and mobile accessibility. This platform increased training completion rates to 80% and boosted employee engagement by 25%. Additionally, the team standardized training materials across departments, ensuring uniform skill development and reducing knowledge gaps. The enhanced training program led to a 12% improvement in overall employee performance and productivity.
Financial Process Improvement > AR
Reducing Days Sales Outstanding
A project was done in the offshore support center of a global oil and gas company to reduce Days Sales Outstanding from 60 to 42 days. Key actions taken included real time and automated invoicing as per the terms and conditions of sales and reducing the dispute resolution time by 80%, from 10 to 2 days. This project improved the cash flow of the company and helped them manage their working capital requirements efficiently.
Admin > Health and Safety Compliance
Strengthening Health & Safety Measures
A project was done to improve the employee preparedness during a health or safety incidence. The key issue identified was confusion and lack of knowledge in the event of a safety incident like fire or water ingress etc. The project involved identifying floor wardens, using better visual aids to identify locations of safety equipment, training and spot checks for employees to gauge their level of knowledge and preparedness in case of an incident. The project helped reduce the incident reaction time from 35 minutes to 15 minutes.