Achieved 75% Improvement in Operational Efficiency and Boosted Daily Production from 15 to 27 Tons by Implementing Data-Driven Lean Systems

Client Overview

· Industry: Copper Extrusion & Conductivity Products

· Location: Gujarat, India

· Employees: 250+

· Products/Services: High-Conductivity Electrolytic Copper Rods, Wires & Customized Copper Components

· Certifications: ISO 9001, ISO 14001, ISO 45001, Zero Liquid Discharge

Challenges (Before Greendot)

Low productivity and frequent machine downtime are causing delivery delays.

· Lack of standardized data collection and analysis for OEE tracking.

· Frequent die failures leading to high maintenance costs and idle hours.

· Absence of proactive maintenance and poor cross-functional coordination.

· Long changeover times limiting flexibility and output.

· Minimal operator involvement and inadequate Lean awareness.

Our Approach

1. Diagnostic Study: Greendot conducted a full process diagnosis across the extrusion line – studying downtime data, machine logs, maintenance patterns, and operator practices.

2. Strategy Design: Designed a data-driven OEE Improvement Strategy, integrating Lean tools (5S, SMED, Kaizen) and capacity mapping.

3. Implementation: Executed plant-wide transformation through daily monitoring, maintenance optimization, and structured training programs.

4. Review Mechanism: Introduced Weekly Review Dashboards, cross-departmental brainstorming sessions, and on-ground audits to sustain results.

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

Overall OEE improved by 75%, driven by data-backed process monitoring.

· Availability: Up from 50% → 65%

· Performance: Up from 73% → 85%

· Quality: Up from 73% → 88%

· Daily Production: Increased from 15-16 tons to 25-27 tons (+60% Growth).

· Changeover Time Reduced by 40% (Saved 11 minutes per setup).

· Die Failure Frequency Reduced by 30%, improving reliability and uptime.

· 50+ Kaizens implemented, reducing waste and enhancing product quality.

· Cross-Functional Team Engagement: Operators and maintenance teams led improvement drives.

· Cultural Transformation: Developed “ownership mindset” and built a continuous improvement culture.

· Estimated ROI: Over ₹70 lakh annual savings through waste reduction, downtime control, and efficiency gain.

Why It Worked (Greendot Edge)

• Practical Implementation: Focused on on-ground, real-world improvements.

• Expert Handholding: Continuous shop-floor mentoring by Lean experts.

• Sustainable Systems: Daily review, dashboards, and ownership culture ensured results stayed consistent.

Tools Used

• 5S System

• Kaizen & Visual Management

• SMED (Single-Minute Exchange of Dies)

• Value Stream Mapping (VSM)

• OEE Analysis

• 4M & Root Cause Analysis

• “My Machine” Ownership Concept

• KPI Dashboard