Downtime Reduced from 14.67 to 5.33

Work Efficiency Improved by 63.66 %

Area Saved by 2380 Sq. Fit

About Industry

A noted Manufacturer, Exporter and Supplier, ABC Industries deal in a wide array of Self-Adhesive Tapes, Packing Tapes, Clear Tapes, which are manufactured in their in-house automatic production setup. The production process is conducted with extreme vigilance and focus towards quality which includes selection of the potential vendor for the supply of raw material and the production process itself. Supervised by our industry experts, these processes are carried off flawlessly reducing the human errors to a bare minimum. The products we offer are known for their excellent finish, adhesiveness and appropriate thickness along with other excellent qualities.

Basic Challenges of Company

  • Labour Productivity is low
  • Too Much Rejection is there
  • Document Management is poor
  • No Monitoring System of Energy Consumption
  • Machine Downtime is high
  • Inventory is Higher
  • Space Constraints are there
  • Unorganized Working Method
  • No Worker Participation in improvement

Project Implemented: LEAN Manufacturing Practices

  • To implement 5S practices & Visual Control to organize Workshop area
  • To Improvise Document Management system
  • Space management through the 5s Implementation and improving layout
  • To Implement Kaizen Improvement
  • To Increase sales
  • To Reduce rejection
  • To suggest scope of improvement in energy efficiency by Energy audit
  • Inventory management

Implementation method

  • Analysis of Present Situation
  • Data Collection & Analysis
  • Identification of Projects
  • Presentation & Approval
  • Phase wise Training & Execution
  • Phase wise Reporting of Outcome
  • Overview


  • 5S
  • 7 QC Tools
  • Kobetsu Kaizen
  • Pareto Analysis
  • Visual Control
  • Jishu Hozen
  • PokaYoke
  • Problem Solving Tools

Quantitative Benefit

  • 2500 kg. Scrap Removed.
  • 2380 Sq. Fit Area Saved.
  • Total 22 number Of Kaizen Implemented.
  • Increased IT ratio from 7.87 to 10.30.
  • 4 % of reduce retrieval time.
  • 2 days Delivery days Reduce.
  • Machine downtime reduces from 14.67 to 5.33.
  • Work Efficiency improved by 63.66 %
  • 23 % reduced Energy Consumption.

Qualitative Benefits

  • Wastage removed
  • Non-moving item remove
  • Improving material movement
  • Smooth working & time saving due to quick retrieval
  • Accidents and mistakes minimize
  • Results in place easy to manage
  • A clean& tidy work place leads together well being and increased motivation
  • Creates workplace ownership
  • Company image improves
  • Improvement in safety conditions in workplace
  • Increased Worker Participation in Improvement
  • Awareness about Lean Tools Created
  • Improved Employee morale

Duration: 1 year

Monetary Benefits: 72,69,126 Rs. /Year

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    Nirav, has worked with our Cluster for Lean Mfg implementation. He is constantly striving for excellence in his chosen domain and working hard towards his goal to taking Green Dot to the next level. Immense clarity of thought, good methodology for implementation across wide spectrum of Industries, keeping himself abreast with latest theories. He is a good orator and a good influence. I highly recommend Nirav to those who are seeking business solutions for the better.
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