Increased Machine Productivity by 15% and Reduced Rejection Rate by 20% through Lean Manufacturing and Kaizen Initiatives
Client Overview
- Company: Powerful Industries
- Industry: Heavy Engineering & Machinery Manufacturing
- Location: CTM, Ahmedabad, Gujarat
- Established: 1981
- Employees: 300+
- Products/Services: Cement plant machinery, heavy bending machines, hydro turbine parts, vertical machining centers, and custom engineering equipment
- Market Presence: A trusted manufacturer with 40+ years of expertise in precision engineering solutions
Challenges (Before Greendot)
Despite decades of experience, Powerful Industries was facing production inefficiencies that limited growth and profitability:
- Low Machine Productivity: Underutilized machinery and frequent downtime reduced output.
- Inefficient Space Utilization: Poor layout caused material flow disruptions and delays.
- Rising Operational Costs: Rework and idle time increased energy and maintenance expenses.
- High Rejection Rate: Poor process control led to excessive defects and resource waste.
Cultural Resistance: Employees were hesitant to adopt change or take ownership of improvement initiatives.
Our Approach
Greendot implemented a structured Lean Manufacturing Transformation Program focused on people, process, and performance:
- Diagnostic Study: Conducted Gemba walks, time–motion analysis, and OEE baseline assessment.
- Kaizen Culture Building: Formed cross-functional Kaizen teams to identify and eliminate bottlenecks.
- Root Cause Analysis: Applied “5 Whys†and cause–effect diagrams to target core problems.
- Pilot Testing & Standardization: Tested improvements on selected machines before plant-wide rollout.
- Continuous Monitoring: Deployed visual management boards and OEE dashboards for real-time progress tracking
Solutions Implemented
| Area | Solution |
| Machine Efficiency | Introduced OEE tracking system and preventive maintenance schedules |
| Waste Reduction | Implemented Kaizen events focusing on defect elimination and process stabilization |
| Workplace Organization | 5S methodology improved space utilization and material accessibility |
| Transparency | Visual dashboards enhanced production visibility and accountability |
| Employee Involvement | Cross-functional Kaizen teams drove continuous improvement |
| Quality Control | Root cause analysis and SOPs standardized quality assurance practices |
Results Achieved
- 15% Increase in Machine Productivity: Optimized performance and reduced downtime enhanced throughput.
- 20% Reduction in Rejection Rate: Standardized work practices improved product quality and consistency.
- 10% Increase in Overall Production Output: Streamlined flow improved delivery efficiency.
- 20% Reduction in Maintenance Costs: Preventive maintenance and better utilization extended machine life.
- Higher Employee Engagement: Participation in Kaizen workshops increased motivation and ownership.
- Enhanced Transparency: Visual dashboards and OEE reports enabled data-driven decision-making.
ROI: The Lean program delivered an estimated annual cost benefit of ₹30–35 lakh, with ROI achieved in just 4 months through productivity gains and reduced rework.
Why It Worked (Greendot Edge)
- People-Driven Change: Engaged every employee through Kaizen ownership.
- Data-Based Decision-Making: Used OEE and real-time dashboards to measure progress.
- Process Standardization: Clear SOPs ensured the sustainability of improvements.
- Culture Transformation: Built a mindset of continuous improvement and collaboration.
Tools Used
- 5S
- Kaizen
- OEE (Overall Equipment Effectiveness)
- Visual Management
- 5 Whys Analysis
- SOP Development
- KPI Dashboard
