Owners, directors and plant heads describe what changed when their teams applied Lean, 5S, Kaizen and structured problem solving. Quotes are as they wrote them; results are as each client reported them.
More output from the same machine shop and foundry
Context
A manufacturer of clutch plates and auto components with a machine shop and a foundry.
What the team did
5S, value stream mapping, problem solving, layout finalisation, capacity mapping and planning, and video study.
Period
About six months
Results, as reported by the client
4,000 → 5,000
pieces a day from the machine shop
8 → 12
foundry heats per shift
Fettling
turned from a bottleneck into a fast output area
“We are working with them in many more projects and they have added value to our organization.”
Textiles, export house · Bhiwandi, Maharashtra
Faster flow and more output in the first six months
Context
A Government of India recognised export house with a manufacturing unit in Bhiwandi.
What the team did
A Lean Kaizen roadmap using the VEIZEN® methodology: 5S, process flow activity mapping, value stream mapping, Moonshine techniques, Lean layouts, waste elimination and work standardisation.
Period
First six months of the programme (letter dated October 2018)
Results, as reported by the client
−25%
space used
−30%
throughput time
+35%
productivity
Everyone
involved in 5S and Kaizen initiatives
“Their strengths lie in their HANDS-ON approach at the work place & empathizing with people to hand hold and lift them towards excellence.”
More client journeys
Filter by the method the client used.
Electronics, AS 9100 · Chennai
A 30-month transformation, planned around a major expansion
Reported result: “Notable improvements across all KPIs”, with a culture of proactive problem-solving.
“Under Dr. Murali's guidance and Mr. Mohan Kumar's weekly reviews, our team has consistently improved processes and efficiency.”
Lean
5S
Kaizen
Machine building · Bangalore
Four years of Lean and 5S across day-to-day operations
Reported result: “Notable improvements in quality, lead time reduction, and employee engagement.”
“Through initiatives such as BKWs and the implementation of PFAM (Process Flow Activity Mapping) and ECRS (Eliminate, Combine, Rearrange, Simplify), we have successfully streamlined processes and eliminated waste in our day-to-day operations.”
Lean
5S
Manufacturing · Sriperumbudur
From an online session to a Lean implementation
Reported result: “Significant enhancements in efficiency, quality, and customer satisfaction.”
“Value Enablers Academy demonstrated a profound understanding of Lean principles, focusing not just on practices but on cultural transformation.”
Lean
Synthetics and textiles · Mumbai
A Kaizen journey that involved the whole organisation
Reported result: Milestones in 5S, visual management, production and quality culture, and inventory reduction in under a year.
“The bridge between theory and practice is far larger and deeper than what most people think it is.”
Kaizen
5S
No longer stories for this method yet. See the quotes below.
What clients say about working with us
“The Key aspect of your approach is “involving the entire team towards a common goal”.”
ShivakumaraManaging Director, Ayurwin Pharma Lean training and implementation, 2016
“With Kaizen Enablers help, we have been seeing sustainable cultural and operational improvements. The Lean journey we have been taking with them is taking us forward and helping us to be more competitive.”
“The journey so far has been training the team across all levels and the implementation of every element learnt by the team.”
Robbert AllennHead – Human Resources, Bostik India Lean management, 2017
“He was a Consultant, Coach, Teacher, Mentor, Motivator all tied together into a single package.”
B.V.S. MaruthiSenior General Manager, Eveready Industries (PowerCell) Operational excellence, 2017
“5-S though simple, but was effective enough to bring around the cultural changes in the working environment by changing the mindset and enabling team building.”
Harpal S KalraSenior General Manager – Works, Eveready Industries, Haridwar 5S and Kaizen, 2018
“…the team is very motivated to follow it on a daily basis and sustaining all the good practices implemented during the workshop.”
