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Photos 07-Jan
Case Study – Lean Manufacturing-Bebitz

Bebitz Flange Works Pvt. Ltd. is a leading manufacturer of flanges and forged rings working on a multinational basis located in Boisar in the Thane District close to Mumbai in Maharashtra

Sector: Flanges, Fittings and Forged rings Manufacturer

Engagement: 1 year

Workplace: 1 Facility

Website:www.bebitz.de

Objectives:

  • Improve Quality of Work and Reduce Defects and Material Handling
  • Improve Flow and Pull-in Manufacturing, Internal Planning and Procurement
  • Create Workplace Excellence for Integrated Problem Solving at Gemba
  • Improve Equipment or Machine Health and Performance Consistency and Reliability
  • Establishing Strategic Framework

Problems

  • High Rework and Rejection
  • High Customer Complaints
  • Low Machine Availability
  • High Inventory and Workplace Improvement

Approach

  • Training, Coaching & Handholding of Operators, supervisors & managers on Lean Methodology
  • Establish Strategic Vision, Mission and Defines Values
  • Value stream mapping & Implementation of Lean methods and tools
  • Formulation of Cross-functional action team

Outcome

  • Reduction in Rework from 8.92 % to 3.46%
  • Reduction in Customer Complaints from 81 to 10 no's/month
  • Improvement in OEE from 60 % to 65 % in a machine shop
  • 5 'S' Score Improvement from 21% to 81 %
  • Reduction in Inventory from 1928 MT to 1279 MT
  • Improvement in on-time performance from 61.3 % to 82.37 %

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