Achieved 20% Higher Production, 30% Lower Maintenance Cost, and 15% Inventory Reduction through Lean Manufacturing
Client Overview
- Company: Ashwin Auto Cast Pvt. Ltd.
- Industry: Automotive Casting Manufacturing
- Location: India
- Employees: 300+
- Products/Services: High-quality Cast Iron & SG Iron Castings including Pressure Plates, Clutch Covers, Gear Housings, and Brackets.
- Founded: 1998
- Certifications: ISO-compliant as per Indian & International standards
Challenges (Before Greendot)
Ashwin Auto Cast faced recurring production inefficiencies that affected cost and delivery performance:
- Unclear Production Flow: Frequent bottlenecks slowed production and caused uneven workloads.
- Delayed Deliveries: Inconsistent production rates impacted customer reliability.
- High Assembly Time: Lack of standardized processes extended total assembly hours.
- Excessive Waste: Over-handling and unnecessary material movement increased cost and rejection.
- Low Visibility: Absence of real-time data made it difficult to monitor and improve performance
Our Approach
Greendot designed a structured Lean roadmap tailored for automotive component manufacturing:
- Diagnostic Study: Collected data on cycle times, downtime, and movement inefficiencies.
- Strategy Design: Integrated 5S, Kanban, Kaizen, and JIT for maximum operational control.
- Implementation: Phased rollout of Lean tools across casting and assembly sections.
- Review Mechanism: Weekly review dashboards, Kaizen workshops, and team feedback sessions
Solutions Implemented
| Area | Solution |
| Workplace Organization | 5S methodology to eliminate clutter, standardize flow, and sustain order |
| Production Flow | Kanban system for pull-based production and reduced overstocking |
| Maintenance | Visual management dashboards to track equipment uptime and maintenance trends |
| Continuous Improvement | Regular Kaizen events for problem-solving and bottleneck removal |
| Inventory Management | Just-in-Time (JIT) system for synchronized supplier delivery |
| Employee Development | Operator skill-building and Lean mindset training |
Results Achieved
- 20% Improvement in Production Rate: Streamlined production flow increased daily output.
- 6-7% Reduction in Rejection Rate: Standardized work reduced quality variation and rework.
- 30% Reduction in Maintenance Cost: Preventive and optimized scheduling reduced wear and downtime.
- 15% Decrease in Inventory Levels: JIT system cut unnecessary stock and improved cash flow.
- Higher Employee Morale: Lean implementation fostered ownership, transparency, and teamwork.
- Improved Communication: Visual dashboards enhanced cross-department coordination.
ROI: The project achieved an estimated payback within 4 months, with annualized savings exceeding ₹25 lakh through productivity gains, waste reduction, and lower maintenance expenses..
Why It Worked (Greendot Edge)
- Data-Driven Problem Solving: Improvements backed by accurate metrics and shopfloor observations.
- Hands-on Implementation: Direct engagement with operators ensured adoption.
- Transparency Tools: Real-time dashboards kept teams aligned and accountable.
- Sustainable Systems: Kaizen and 5S audits ensured long-term results beyond the project
Tools Used
- 5S
- Kaizen
- Kanban
- Visual Management
- Just-in-Time (JIT)
- TPM
- KPI Dashboard
