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Photos 08-Jan
Lean Manufacturing - DN Jewels

In the year 1995, DNJ established an in-house Jewellery manufacturing unit in Seepz (Mumbai), India, as D. Navinchandra Jewels. Today, DNJ emerged as one of the fastest-growing jewellery manufacturing and exporting companies from India Over the years, the group has been honoured with many awards and citations from the Gem & Jewellery Export Promotion Council of India. One of the early members of the Responsible Jewellers Council, utmost care is taken for excellence in the area of quality, environment, safety and social responsibility.

 

Sector: Jewellery Manufacturing

Engagement:  3.0 years

Workplace:  1 Facility

Website: http://www.dnavinchandra.com/

 

Objectives:

  • Workplace improvement
  • Improve supply chain
  • Reduce lead time
  • Quality improvement
  • Standardize the operations
  • Business growth  

 

Problems:

  • Long Order registrations & approval process
  • Long design concept to Model / Sample making process
  • Long order registration to the diamond procurement process
  • The long manpower recruitment process
  • Lack of information on daily, weekly work loading and actual performance in every department
  • Peak Loading in season, uneven loading
  • Long lead time in diamond procurement & bagging process
  • Long lead time in Pre-casting process
  • Long lead time in Post- casting processes
  • Rework & rejection in the manufacturing process

 

Approach:

  • VVM design
  • Streamline the process
  • Layout design
  • Cell formation
  • Daily morning standup meeting in the cell
  • Merging of design, CAD & CAM department together
  • Automate Production Planning

 

Outcome:

  • Complete alignment in the organization through VVM
  • Productivity Improved by 19%
  • Lead time reduced by 33%
  • WIP reduction by 66%
  • Rework & Rejection reduced by 10%
  • Increase in on-time delivery to the customer from 60% to 90%
  • Business Growth from 35 m$ to 55 m$ in 3 years

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