indian centre for manufacturing excellence - icme online ppt61.pdfindian centre for manufacturing...


About ICME


VISION

ICME visions to develop 1000 SMEs of India by 2022, making them

‘Best in Class' which in turn will contribute towards the Growth of Indian

GDP, help in New Employment creation and Making the Dream ‘Make

in India’ a Reality.


MISSION

To build a World Class SME-University that will provide End to End

solutions to the Industry, covering all aspects of Business from New

Plant Designing (Green Field Project), R&D Support, Plant & Process

Layouts Designing, Technology & Machine Selection, Manpower

Recruitment, Lines setup, Key Skill Development, Trainings, Market

Research and Branding.


OBJECTIVE

Support in the growth of GDP of Manufacturing sector from 16%

to 25% & 100 million Job Generation

Growth & Profitability Improvement of Manufacturing Industry

Man Productivity & Quality Improvement, Cost reduction/ unit,

R&D and NPD

Skill Upgradation

Senior Management

Middle Management

Junior Management

Faculty

Students

University Industry


APPROACH

ICME is working together with Manufacturing Industries in different

Sectors to Make them Competitive, so that they can Grow from Small

to Medium and Medium to Large with Increase in Profitability via -

Trainings

Handholding

Plant Layout Designing with Process Engineering

Cluster Programs

Conferences and Summit


FOUNDER

Ravinder Kumar is the Executive Director of Indian Centre for

Manufacturing Excellence (ICME). With more than 17 years of

experience as a Principal Counselor at CII-AVANTHA Centre for

Competitiveness, Chandigarh and practical auto sector working

experience, he has been able to translate his skills and knowledge in

field of TQM implementation into impeccable solutions through his

Practical training, Counseling and Mentoring.


B.Tech in Mechanical Engineering, Certified TPM Facilitator from

JIPM, Japan and Certified Business Manager from Federal Ministry

of Commerce & Technology, Germany

Conducted 150+ Programs imparting training to more than 5000

professionals for improving Operational Excellence via tools &

techniques like 5S, 3M, Kaizen, TPM, SMED, Poka-Yoke, TPS,

Value Stream Mapping, Flow Manufacturing, Inventory

Management, Jishu Hozen, Integrated Quality Management, QCC,

LCA, 7 QC tools & Problem Solving tools

FOUNDER


Served 100+ Organizations PAN India covering Indian, American

and German MNCs ranging from 10cr turnover to 20,000cr turnover

Reported savings for more than 5000 millions

Exposure to Benchmark Plants & Practices in detail with companies

like Toyota, BMW and Mercedes

Assessor for CII / ACMA / IMTMA Annual Awards at National Level

FOUNDER


Clients Served


LARGE


MEDIUM


SMALL


Customized 4-Year

Integrated Roadmap

(as per diagnosis)


0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24

Stability in process

Reduced Lead Time

Customer Satisfaction

Productivity improvement

WIP reduction

Manpower Optimization.

High ITR

Working capital management

In house rejection reduction

Warranty claim Reduction

Customer complaint reduction

Incoming part rejection Reduction

Zero Breakdown

Zero defect

OEE increase

1. Basic 5 S Operator Ownership

2. QCC Team involvement

3. Waste Elimination Cost reduction

4. Safety Safer Workplace

5.Suggestion / kaizens Total employee involvement

Time in Months : 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24

1. Takt Time

Work place

Improvement(Impro

vement culture)

ROAD MAP

Time in Months Deliverables

Road Map for Competitiveness : Foundation cluster

4. 7 QC Tools

Inventory Management

(Improved cash flow)

Lean

(Introduction)2. kanban Linkage

1. My Machine-Step 1 ,2,3

2. Prev. Maintenance

3. Daily work management

workplace

Ownership(Paradigm

Shift)

Quality management (Quality

excellence)

1. SOPs

2. Process Quality

3. Poka Yoke

Productivity

improvement(Productive

work culture)

1. Cell layout

2. single piece flow

3. Multi machine manning

3. Logistics

1. Quality of Inventory

2. SMED

3. Containerization

FOUNDATION CLUSTER ROADMAP


ADVANCE CLUSTER ROADMAP

0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24

EEC

Sustenance

Clarifications

Future Plans

1. Value adding Management (Concepts , Design & Implementation) VAPCO

1.1 implementation of 14 steps of Lean VAR

1.2 Production Balancing and Leveling

2. Integrated Cellular Management ( implementation & Practice )

1. Concept of Cell design and implementation Lead time

1.1 SMED (Integrated to SPF) ITR

1.2 LCA (Integrate to operator Fatighue / Stresses ) Process Stability (Quantity and Quality)

1.3 integrtaed Quality control (Poka -Yoke, Vision Control) Customer Quality (PPM)

2. Equipment Miantenance OEE /OLE/ OPE

2.1 Step 1 2 3 (Implementation and Video training) Cost Losses

2.2 Preventive Maintenance (Implementaion and practice)

2.3 Organization / Management

2.4 Cost loss Analysis

1. Institutionalize all 5 S Basics Advance 5 S : Audit Score

2. 6 M Concept Design , Process Mapping and Implementation PQC improvement

3. Holding Gains and Corrective Actions

Total Employee involvement

Employee satisfaction Score

Participation Kaizen / QCC

Training Modules

0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24

3. Future Plans

Advance 5 S (sustenance culture

through Discipline)

TEI (Continuous

Improvement Culture

Through TEI)

Introduction to Engg. Cluster

1. Refreshing of All Training and Learning's

Integrated Flow Manufacturing

(Bussiness Culture)

3. Material Handling

5. 7 Management Tools

1. Introduction of Engineering Excellence Cluster Contents

Cellular Manufacturing (Productivity culture)

Road Map for Competitiveness : SME Advance course

Re-training

(Sustenance Culture)2. Sustenance Plans

5 . FIFO

5.1 First in First produced -Integerate to Quality Traceability

3.1 Material Handling Management and Control

4. FPS (forecasting Planning & Scheduling)

ROAD MAP

Time in Months Deliverables

1. kaizen

2. QCC

3. QC Story

4. 7 QC Tools

6.Talent development and Retention

7. Satisfaction Survey

Time in Months :


EDUCATING INDUSTRY


Case Studies


Creation of Model Handtool SME with Cluster inputs:

HR International reduced 50% Manpower in Jalandhar (Appx.350

Persons at Plant Level)

Eliminated complete one Shift (Saving of 3 Crore/annum)

See-through Layout- Godrej, Mohali

Shining Model Lines via 5S

Jogging Track around complete Plant

WCP and Gate Meeting via TEI

Hospital Clean inside and Garden Green Outside

Coconut to Car Parking

Standardized Display Boards- Demag Cranes, Pune

Integrated Inventory Mgt, Material Handling & Control- TVS, Hosur

Scrap Management & Control- TVS, Hosur

INNOVATIVE CHANGES


INDIAN PRODUCTION SYSTEM

Present System New System

Grinding Machine

Magnetic separator

Paper band filter

Coolant tank

Grinding Machine

Double Magnetic separator

Cyclone

Coolant tank


RESULT

Not Environmental Friendly


100% Environmental Friendly




Machine

FAT Electrical Panel

AC for cooling

Machine

Lean Electrical panel


RESULT




Panel Size : 1000mm (W) x 1000mm (H) x 300mm (D) Without AC

Panel Size : 2800mm (W) x 1700mm (H) x 500mm (D)

With AC




Machine

FAT Power pack

Chilling unit

Machine

Lean Power pack


RESULT




Hydraulic Power pack : 220 Liters with Chilling Unit

Hydraulic Power pack : 70 Liters without Chilling Unit


MANUFACTURING PLANT

Along the

Wall

Men / Material

Movement

Jogging Track See Through Layout

AIS

LE

FO

R

MA

N M

OV

EM

EN

T


MANUFACTURING PLANT

OUTSIDE INSIDE

Hospital Clean Garden Green

indian centre for manufacturing excellence - icme online ppt61.pdfindian centre for manufacturing...

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