Ceramic industry has now become an integral part of the Indian industry. It has managed to bring a huge difference in the economy of the country. During the last two decades, the Indian ceramic industry has seen a phenomenal growth in product profile, geographical spread and value-added products. India is also the third largest consumer of ceramic tiles in the world.
In this series of bringing out productivity improvement stories, as a part of applauding the National Productivity Week, we are extremely happy to share a tale from ceramic industry in this blog.
About the Client
The client is one of the leading bone china crockery manufacturers in the country and leads the charts in terms of manufacturing ceramic products like bone china crockery. The client has made its own space in the ceramic industry with its perseverance and persistence.
Challenges faced by the client
Ceramic industry is a highly labor-intensive industry where the manpower cost is as high as 40 to 50% from the normal costs. Thus, the biggest challenge in the industry is manpower productivity apart from being energy intensive. The client faced several issues and a lot of inefficiencies corrupted the entire production system. Traditional layout of two floors also posed difficulties and the client faced a tough time in producing despite having a considerable demand for its products.
How Team Faber handled and emulsified the processes for smoother production
Team Faber Infinite analyzed the entire plant and redesigned it by converting it into a single floor production unit by the means of Value Stream Mapping. We also conducted a Time and Motion Study at the client site to assist in their plant expansion program. This was further facilitated and improved by using the LEAN Facility design. Team Faber worked on various other improvement projects like Manpower improvement and Culture Building to remove the blockers from the road that were stopping the client from reaching its target and achieving excellence.
Results delivered, Once again!
The manpower productivity improvement project led by Team Faber helped the client in improving the productivity of the plant by more than 100%. This further helped the client in committing and complying with the incoming orders. Also, the in-depth study and analysis of processes through Time and Motion Study at the client site has helped the organization in sustaining the continual development and the improved productivity.
Moreover, apart from all these, we also helped the organization in improving the layout of the production unit, preparing Standard Timesheet, Line Balancing and Manpower allocation to further improve and enhance the effectiveness of the existing processes and controls in the manufacturing unit.
Team Faber Infinite supports the dream of making India more productive. We believe that India can become the leader of the global market and can achieve through the improved and better productivity. India is the future and at the 21st National Productivity Week, let us vow to make India a more productive nation.
Written & Compiled By Faber Kishlay & Faber Mayuri