Kaizen, a term of Japanese origin, is defined as continuous improvement aimed at optimising quality in the manufacturing sector. However, from an Indian manufacturing perspective, Kaizen should also incorporate self-discipline as an important element.
Process adherence for operational success
In India, technical excellence in manufacturing mainly stems from strong engineering skills. However, many plants struggle with shop floor discipline, partly due to cultural tendencies questioning why a task needs to be done rather than strictly adhering to the processes.
Compromising any one of these elements can lead to failure. In a manufacturing environment, it is essential to maintain instruments and machines are in optimal condition because poorly maintained equipment results in breakdowns and reduced productivity.
Our extensive experience in India has demonstrated to our clients that using broken or compromised tools directly affects profitability. Ultimately, respecting and maintaining tools and processes is critical for operational success.
How to achieve manufacturing excellence in India
To bridge the gap between technical skills and consistent shop floor discipline, companies must embrace a holistic approach combining Kaizen principles with self-discipline. Here are three key actions to help achieve excellence:
1. Install Management Control Systems to ensure Process Adherence
Poor process adherence or lack of discipline in operations can lead to poor control over operating expenses, waste and maintenance costs.
What You Can Do
- Implement systems for production, maintenance, and procurement by creating clear work processes, roles, and responsibilities. Establish KPIs at all levels, from the shop floor to senior management. This clear accountability among employees improves coordination and minimises errors.
- Conduct regular review meetings supported by data-driven dashboards and reports. These meetings can help you to monitor performance against targets and enable you to take timely corrective action. These will lead to better management of operating expenses and lower maintenance costs.
- Introduce Short Interval Control (SIC) mechanisms on the shop floor to monitor real-time performance. SIC mechanisms ensure that processes stay on track and that issues are addressed immediately.
Cost savings through operational efficiency for manufacturer
Paper mill cuts material loss by 300% with maintenance planning
Cost savings through operational efficiency for manufacturer
Paper mill cuts material loss by 300% with maintenance planning
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2. Optimise Equipment and Process Performance
Poorly maintained or misused equipment causes unexpected breakdowns and production delays, directly impacting profitability.
What You Can Do
- Implement preventive maintenance (PM) management systems and condition-based monitoring. Use data-driven analysis and planning to identify and address the root causes of potential breakdowns and inefficiencies. It could help address issues before they cause failures and ensure smoother productions.
- Eliminate non-value-added (NVA) activities through detailed process mapping and analysis. This can cut cycle times, reduce waste, and prevent costly rework.
- Implement real-time digital dashboards and Management Information Systems (MIS) to gain visibility into operational status, preserving machine condition, extending its life, and reducing capital expenses.
3. Develop Workforce Capability and Promote Continuous Improvement
Achieving manufacturing excellence requires building capabilities from within and ensuring that employees at all levels are not only trained but also actively involved in the change process.
What You Can Do
- Provide comprehensive training programmes combining classroom sessions with intensive on-the-job coaching and mentoring. These initiatives can improve workers’ technical expertise and problem-solving abilities for higher-quality output.
- Train promising employees to become internal change champions who can sustain and lead continuous improvement initiatives long after external support concludes.
- Create multi-functional task forces to identify issues, develop solutions and drive implementation. In the long run, it will better equip your organisation to respond to changing market demands.
Renoir has over three decades of experience working with more than 300 companies to help them achieve operational excellence. Some of these are repeat engagements from the same company. We work closely with our clients’ employees to assess their as-is situation before providing customised solutions.
Control Processes, Cut Waste, Boost Profits
