Manufacturing industry is one of the most looked upon industry in the country. Manpower productivity improvement is mature in this industry and is led by various MNCs around the world. Team Faber Infinite was there to support one of the largest players in this industry and was able to deliver phenomenal productivity results. As a part of the series cherishing the productivity improvement stories, this time we bring you a saga from the air compressor and mining equipment manufacturer.
About the Client
The client is one of the leading manufacturers and sellers of industrial gas and air compressors and mining equipment. They are a leading provider of sustainable productivity solutions all around the globe. They cater to demands in more than 180 countries with products and services that are designated to focus on productivity, energy efficiency, safety and ergonomics.
What were the challenges?
Low productivity was one of the major issues that kept the client on their toes at all the time. The client faced some other major issues in the form of the union of the laborers in the manufacturing plant. Moreover, it was clarified that the issue of the productivity also affected the well-being of operators. At the same time, non-value adding activities also added to the costs of the client without adding any kind of value to the products or the processes.
The assembly lines were not able to meet the increased demands of the market. High labor cost was one the other problems faced by the client.
Team Faber Infinite’s Approach
Team Faber conducted various types of study, implemented various tools and analyzed the results to get to the bottom of the pertaining issues in the manufacturing units. We conducted Time and Motion Study at the client site to define the standard time for work based on the ILO norms for ongoing processes.
We worked on assembly line and performed line balancing at the client site by calculating the TAKT time for the assembly line based on the demands of the customer. Moreover, we assisted the client in redesigning the workstation to eliminate the fatigue from the processes and improve ergonomics to increase the efficiency of the operators.
Non-value adding activities such as search time, material availability, setup change time etc. were eliminated by using tools such as SMED, Kanban, 5S, 2 Bin system, layout designing, incentive scheme and logistics management.
Results? Yes, we delivered them!
The entire project led by Faber Infinite improved the throughput of the manufacturing plant by 50% while the manpower productivity of the unit was improved by more than 33%. The work content of the workplace was reduced by 40% as a result of the implementation of tools by Team Faber. Labor costs also saw a decline of more than 50% after the transformation journey was completed. We helped the client in designing a total of 10 workstation layouts per assembly line as per the ergonomic designs. Half a dozen assembly lines were redesigned to improve the manpower productivity.
Faber Infinite has been one of the very firm supporters of ‘Make in India’ and has always promoted the concept of producing in India, more competitively. During this 21st National Productivity Week, let us all take a pledge to make India more productive and the most sort after country when it comes to quality produce all around the globe.
Written & Compiled By Faber Kishlay & Faber Mayuri