Reduced Assembly Time from 3 Days to 1 Day and Boosted Production Efficiency by 50% through Lean Implementation
Client Overview
- Company: FCG Hi-Tech Pvt. Ltd.
- Industry: Electrical Equipment Manufacturing
- Location: India
- Employees: 400+
- Products/Services: Explosion-proof electrical equipment, switchgears, control panels, and industrial electrical components.
Market Presence: A reputed Indian brand with decades of expertise in manufacturing and supplying high-precision electrical products to global markets.
Challenges (Before Greendot)
FCG Hi-Tech struggled with operational inefficiencies that affected customer commitments and profitability:
- Casting Inefficiencies: High scrap rate and rework due to inconsistent processes.
- Delayed Deliveries: Extended production cycles and poor coordination led to missed deadlines.
- Underutilized Machine Shop: Despite frequent overtime, production lagged behind targets, inflating costs.
- Lack of Process Visibility: No real-time system for monitoring shopfloor performance.
Employee Resistance: Initial hesitation to adopt Lean practices due to lack of awarenessture: Low employee engagement, teamwork gaps, and resistance to change slowed innovation.
Our Approach
Greendot developed a phased Lean Manufacturing roadmap designed to increase throughput and minimize waste:
- Assessment: Conducted time–motion studies, workflow mapping, and downtime analysis to identify bottlenecks.
- Training: Delivered Lean & Kaizen training sessions across departments, building awareness and engagement.
- Cross-Functional Teams: Formed improvement cells combining production, maintenance, and planning teams.
- Pilot Projects: Tested Lean tools in selected product lines before full-scale rollout.
Monitoring: Established Kamishibai dashboards for real-time KPI tracking and continuous feedback.
Solutions Implemented
| Area | Solution |
| Workplace Organization | 5S implementation across all units improved order, safety, and space utilization |
| Productivity | Value Stream Mapping (VSM) identified non-value-added steps and optimized production flow |
| Quality & Efficiency | Line balancing eliminated bottlenecks and reduced assembly time |
| Culture | Kaizen events empowered employees to suggest and execute process improvements |
| Visibility | Kamishibai visual dashboards provided real-time shopfloor performance data |
Results Achieved
- 30% Reduction in Assembly Time: Assembly duration reduced from 3 days to just 1 day.
- 50% Increase in Production Efficiency: Overall throughput and process synchronization improved significantly.
- 20% Rise in Casting Output: Scrap reduction and improved casting quality increased yield.
- 2 Weeks Faster Delivery Time: On-time delivery performance improved dramatically.
- ₹80,000 Overtime Cost Saved per Month: Optimized scheduling reduced unnecessary overtime in the machine shop.
- Employee Empowerment: Enhanced morale and ownership due to visible participation in Kaizen and Lean initiatives.
ROI: Project delivered an estimated ₹40 lakh annual cost benefit, with complete ROI achieved in less than 4 months through improved efficiency and reduced rework.
Why It Worked (Greendot Edge)
- Holistic Lean Deployment: From 5S to Kamishibai dashboards, every process was aligned for flow efficiency.
- Employee Buy-In: Hands-on engagement ensured quick adoption and sustainable improvement.
- Real-Time Visibility: Transparent performance dashboards improved accountability.
- Standardized Practices: SOP-based consistency reduced variation and rework.
Tools Used
- 5S
- Kaizen
- Value Stream Mapping (VSM)
- Line Balancing
- Kamishibai Dashboard
- KPI Monitoring
