Reduced Workplace Accidents by 70% and Improved Productivity by 25% through Lean-Based Safety and Space Management Transformation
Client Overview
- Company: RBD Engineers
- Industry: Engineering & Casting Manufacturing
- Location: India
- Established: 1981
- Employees: 400+
- Products/Services: Ready-to-Assemble cast iron, ductile iron, Hi-chrome, steel, copper, bronze, and aluminium castings
- Market Presence: A reputed manufacturer known for precision-engineered casting components for heavy machinery and industrial applications
Challenges (Before Greendot)
RBD Engineers faced dual challenges affecting both safety performance and production efficiency:
- Work Safety Issues:
- No structured safety training or awareness programs
- Inadequate PPE availability and poor compliance with safety norms
- Inconsistent incident tracking and a lack of root cause analysis
- Space Management Issues:
- Congested and disorganized work areas hamper workflow
- Inefficient material movement and storage systems
- Poor layout design is causing production delays and higher waste
Our Approach
Greendot designed a Lean Manufacturing Implementation Program combining safety, layout optimisation, and visual management for measurable results:
- Assessment & Analysis: Conducted safety audits, space utilisation studies, and Gemba observations.
- Action Plan Design: Created two strategic roadmaps, one for Safety Transformation and one for Space Optimization.
- Implementation & Training: Rolled out PPE protocols, 5S, visual management, and Lean layout design through phased execution.
Continuous Monitoring: Safety committee and KPI dashboard established to track compliance, near misses, and space efficiency.
Solutions Implemented
| Area | Solution |
| Work Safety | Company-wide safety training, PPE upgrades, and compliance audits |
| Workplace Organization | 5S implementation with clear labeling, storage racks, and floor markings |
| Layout Optimization | Redesigned production floor for smoother material flow and congestion reduction |
| Visual Management | Introduced signage, color-coded zones, and hazard markings |
| Employee Involvement | Formed safety committees and Kaizen teams to identify hazards and suggest improvements |
| Monitoring | Regular audits, feedback loops, and compliance tracking dashboards |
Results Achieved
- 70% Reduction in Workplace Accidents: A Safer environment reduced injuries and downtime dramatically.
- 90% Safety Compliance: Regular inspections ensured adherence to PPE and statutory norms.
- 25% Increase in Productivity: Optimized layout improved workflow and lead times.
- 15% Reduction in Material Waste: Organized handling reduced damage and search time.
- ₹30 Lakh+ Annual Savings: Achieved through lower accident costs, better space utilization, and reduced waste.
- Enhanced Morale & Reputation: Improved workplace safety culture boosted employee confidence and brand credibility.
ROI: The Lean Safety & Layout initiative achieved ROI within 5 months, generating over ₹30 lakh annualized savings and establishing RBD Engineers as a benchmark for safety-driven productivity.
Why It Worked (Greendot Edge)
- Integrated Lean-Safety Approach: Safety and productivity improved simultaneously.
- Employee-Centric Execution: Involved all departments through Kaizen and safety teams.
- Visual Controls: Real-time safety communication through visual management.
- Sustainable Culture: Continuous monitoring ensured long-term compliance and ownership.
Tools Used
- 5S
- Kaizen
- Visual Management
- Layout Optimization
- Root Cause Analysis (Safety)
- KPI Dashboard
- Safety Audit System
