Reduced Production Lead Time from 29 Days to 9 Days and Increased Sales by 30% through Lean Manufacturing and Kaizen Culture
Client Overview
- Company: DG Industries
- Industry: Material Handling Equipment & Industrial Warehouse Products
- Location: India
- Established: 2009
- Employees: 200+
- Products/Services: Industrial Trolleys, Conveyors, Racks, Lifting Solutions, and Customized Handling Equipment
- Market Presence: Leading manufacturer and trusted supplier across Indian and overseas markets
Challenges (Before Greendot)
Despite a strong market reputation, DG Industries faced process inefficiencies that limited scalability and responsiveness:
- Long Production Lead Time (29 days): Inefficient planning and bottlenecks delayed order fulfillment.
- Inventory Mismanagement: Difficulty tracking stock quantities led to frequent stockouts and lost production time.
- Sales Visibility Gap: Lack of data on lead generation and conversion hindered decision-making.
- No Root Cause Tracking: Absence of sales rejection data prevented improvement in conversion rate.
Weak Organizational Culture: Low employee engagement, teamwork gaps, and resistance to change slowed innovation.
Our Approach
Greendot designed a multi-layered Lean Transformation strategy built around process, people, and culture:
- Diagnostic Study: Assessed lead time contributors, sales–operations linkage, and workflow inefficiencies.
- Strategy Design: Combined Kaizen, 5S, and Value Stream Mapping (VSM) to eliminate waste and optimize flow.
- Implementation: Trained all teams on problem-solving, data analysis, and continuous improvement.
- Review Mechanism: Monthly Lean audit dashboards and KPI tracking ensured accountability and sustainability.
Solutions Implemented
| Area | Solution |
| Process Optimization | 5S implementation across all departments; workplace organization improved efficiency by 25% |
| Inventory Control | Visual management and designated storage reduced search time and stockouts |
| Production Flow | Value Stream Mapping identified bottlenecks and reduced non-value-added steps |
| Employee Involvement | Kaizen methodology empowered employees to identify and solve inefficiencies |
| Training | Custom training modules on Kaizen, teamwork, and data-driven problem solving |
| Culture | Leadership workshops and team-building sessions to reduce resistance to change |
Results Achieved
- Lead Time Reduced from 29 Days to 9 Days: A 78% improvement in turnaround time and delivery performance.
- Sales increased by 30%: Faster production enabled higher throughput and improved customer responsiveness.
- Improved Inventory Control: Reduced stockouts and optimized raw material availability.
- Enhanced Workplace Organization: 5S implementation fostered orderliness and efficiency.
- Employee Engagement: Over 150 employees trained; 90% participation in Kaizen and 5S activities.
- Cultural Shift: Teams developed a proactive, data-driven, and ownership-oriented work mindset.
ROI: The Lean transformation generated an estimated ₹40 lakh annual impact through faster deliveries, lower waste, and increased order volume.
Why It Worked (Greendot Edge)
- Holistic Approach: Focused equally on process improvement and culture change.
- Customized Training: Tailored programs aligned with real DG shopfloor challenges.
- Data-Backed Execution: Decisions driven by measurable performance metrics.
- Sustained Results: Continuous monitoring and visual dashboards ensured long-term gains.
Tools Used
- 5S
- Kaizen
- Value Stream Mapping (VSM)
- Visual Management
- KPI Dashboard
- Lean Leadership Training
