Achieved ₹2.8 Billion Annual Cost Savings and 60% Production Growth by Transforming Low OEE Operations into a Data-Driven Lean System

Client Overview

• Industry: Copper Extrusion & Conductivity Products

• Location: Gujarat, India

• Employees: 250+

• Products/Services: Electrolytic Copper Rods, Wires & Customized Conductivity Products

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

Call to Action

Optimize your operations and cut costs with proven Lean practices. Contact: nirav@mygreendot.co.in | www.mygreendot.co.in