Uncategorized Archives - Greendot Management Consultancy

TPM vs Lean, Six Sigma, and Other Methodologies: Which Maintenance Strategy Delivers the Highest ROI?

Choosing the Right Path to Operational Excellence In the world of modern manufacturing, one thing is certain: downtime is expensive, and inefficiency is invisible until it hurts. For plant heads, directors, and C-suite leaders, improving reliability, reducing waste, and optimizing performance is no longer optional—it’s essential for survival and scalability. That’s why industry leaders invest in continuous improvement frameworks like Total Productive

TPM in the Age of Sustainability: How Total Productive Maintenance Powers Green Growth

Sustainability Isn’t Just a Buzzword — It’s the Future In today’s world of manufacturing, sustainability isn’t optional anymore — it’s essential. It’s not just about ticking boxes for compliance or corporate social responsibility. It’s about staying competitive, winning trust, and building a resilient business for the long haul. And as CEOs, directors, plant heads, and operations leaders try to balance performance with environmental responsibility, one key question

OEE Isn’t Just for Manufacturing Anymore — Here’s How It’s Powering Smarter Operations Everywhere

OEE Isn’t Just for Manufacturing Anymore: In today’s hyper-competitive, resource-sensitive world, organizations are under pressure to do more with less. Less time. Less energy. Less waste. And while OEE (Overall Equipment Effectiveness) has long been a manufacturing staple, it’s now stepping outside the factory floor — transforming how leaders run facilities, logistics networks, and infrastructure-heavy businesses. Whether you manage forklifts, HVAC systems, diagnostic equipment, or

TPM Myths Busted: What Everyone Gets Wrong About Productive Maintenance

Introduction: TPM Is Not What You Think It Is Talk to any plant manager or operational head about TPM — and you’ll likely hear phrases like: “It’s too technical”, “Just another maintenance schedule”, or worse, “It’s not for us.” We’re here to tell you: That’s a myth. Total Productive Maintenance (TPM) is not a maintenance initiative. It’s a strategic mindset shift that transforms operations, boosts reliability, and builds a high-performance culture. Yet

Why Most OEE Projects Fail—And How You Can Beat the Odds-Copy

Most OEE Projects Fail, The OEE Trap: Powerful Metric, Poor Results If you’re a plant head, operations manager, or CEO, chances are you’ve heard of OEE—Overall Equipment Effectiveness. It’s the golden KPI. The one that tells you how well your machines are performing. But let’s be honest… How many OEE projects have you seen that looked great in Excel, only to fall apart in reality?

The Dark Side of OEE: When Chasing Numbers Damages Real Manufacturing Performance

Dark Side of OEE: The Metric That Helps You Win—or Lose Overall Equipment Effectiveness (OEE) has become a standard benchmark in modern manufacturing. It promises visibility, productivity, and control. It’s powerful. It’s everywhere. But here’s what most operations heads don’t say out loud: OEE can damage plant performance—if you focus on hitting the number rather than fixing what’s behind it. We’ve seen plants celebrating 85% OEE on dashboards—while

How GenAI Is Rewriting the Rules of Factory Maintenance: A Firsthand Case Study

The Future of Factory Maintenance Has Arrived—and It’s Intelligent Ask any plant head or maintenance director what keeps them up at night, and they’ll give you the same answers: Until recently, the go-to strategy was predictive maintenance using condition monitoring, SCADA data, and routine PM schedules. But in 2024, something game-changing entered the factory floor: Generative AI (GenAI)—the most

Secret Sauce: Creative TPM Hacks from World-Class Factories You’ve Never Heard Of

Think You Know TPM hacks? Think Again. Everyone talks about TPM—Total Productive Maintenance—as a gold standard for reliability and uptime. But while most factories follow the playbook, the real game-changers bend the rules, innovate the routines, and extract double-digit ROI with unexpected TPM tweaks. This isn’t about sweeping floors or painting lines. It’s about hyper-optimized workflows, zero-loss strategies,

Manufacturing Sustainability Is No Longer a Future Goal—It’s a Business Imperative

Manufacturing Sustainability, By 2030, over 80% of global manufacturers will be held accountable for their carbon footprint, not only by regulators but also by customers, investors, and OEM clients. Carbon neutrality is no longer a buzzword—it’s a contractual requirement. But here’s what most plants miss: Your machine performance directly affects your emissions. Every breakdown, every defect, every energy spike—it all adds up to waste,

OEE in the Age of Industry 5.0: Is Human‑Centric Manufacturing the Next Big Thing?

Industry 5.0: A Shift Worth Embracing—The Rise of Human-Centric OEE Have you noticed how “efficiency” has been primarily about machines and numbers? In Industry 4.0, OEE (Overall Equipment Effectiveness) meant perfect availability, optimal speed, zero defects. But that’s starting to change. Enter Industry 5.0—where the future factory puts humans back at the center of everything. This isn’t about replacing

Lean Manufacturing in SME: Maximizing Efficiency and Reducing Waste

Introduction to Lean Manufacturing in SME Overview of Lean Principles Lean manufacturing SME is a methodology focused on reducing waste and enhancing efficiency within production processes. It stems from the Toyota Production System (TPS) and centers on five core principles: defining value, mapping the value stream, creating flow, establishing pull, and striving for continuous improvement.

Unlocking the Growth Potential of India’s Small-Scale Industries: The Role of Lean Manufacturing

Small-scale industries (SSIs) play a vital role in Indiaâ€™s economy, contributing around 40% of total industrial production and employing over 117 million people (Ministry of MSME). Yet, despite their contribution, many SSIs face persistent challenges in efficiency, profitability, and growth. Why is this, and how can lean manufacturing address these challenges? Letâ€™s explore. Understanding the

Lean Manufacturing in SME

Lean Manufacturing in SME: Maximizing Efficiency and Reducing Waste Introduction to Lean Manufacturing in SME Overview of Lean Principles Lean manufacturing is a methodology focused on reducing waste and enhancing efficiency within production processes. It stems from the Toyota Production System (TPS) and centers on five core principles: defining value, mapping the value stream, creating

Quality Circle in Total Quality Management (TQM)

Quality Circle is a group of employees within an organization who come together to identify, analyze, and solve work-related problems. The primary goal of Quality Circle is to improve quality and productivity, reduce costs, and enhance the overall work environment. Quality Circle is an essential component of Total Quality Management (TQM), a management philosophy that

Everything you want to know about Quality Circles

What is a Quality Circle? Understanding the Meaning and Importance Quality circles play a significant role in Total Quality Management (TQM) practices. These collaborative groups bring employees together to address and solve work-related problems. In this article, we will explore the concept of quality circles, their benefits, and how they contribute to overall organizational excellence.