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Photos 08-Jan
Lean Manufacturing - Asian Paints (ESSESS)

Asian Paints has engaged in the business of manufacturing, selling and distribution of paints, coatings, products related to home decor, bath fittings and providing of related services.

 

Sector: Home Improvement

Engagement:  2 years

Workplace:  1 Facility

Website: https://www.asianpaints.com/

 

Objectives:

  • Improve Productivity
  • Improve throughput time
  • Reduced WIP
  • Improve Quality
  • Create Workplace Excellence

 

Problems:

  • Long lead time
  • Long-distance traveled by parts, material
  • Customer complaints
  • Traditional business process
  • High WIP

 

Approach:

  • Training to all staff & workers on Lean-Kaizen principles
  • Mindset change program & cultural change
  • 5 S implementation
  • Streamline the process flow
  • Time motion study
  • Layout design & rearrange
  • Structured problem solving & root cause analysis for continuous improvement
  • Low-cost automation

 

Outcome:

  • Output increased by 52% in the assembly section
  • Throughput time reduction by 50%
  • WIP reduction by 48%
  • Rework & rejection reduced by 20%
  • Improved work culture
  • Improve customer satisfaction & moral of personal
  • Workplace excellence
  • The business grew from 170 Cr to 240 Cr in two years

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