Reduced Delivery Lead Time by 81% and Cut Rejections by 50% through Lean Manufacturing and Continuous Improvement Culture

Client Overview

• Company: R.S. Automation
• Industry: Industrial Automation & Control Systems
• Location: Ahmedabad, Gujarat, India
• Established: 1999
• Employees: 250+
• Products/Services: PLCs, HMIs, Servo Drives, Motion Controllers, Synchronization & Power Panels, Heating Control Panels, and Automation Systems
• Market Presence: One of India’s largest suppliers of advanced automation and electrical control systems serving industrial clients nationwide

Challenges (Before Greendot)

Despite its technical expertise and strong customer base, R.S. Automation faced significant operational inefficiencies:

• Production Bottlenecks: Unclear production flow created bottlenecks and delays.
• Long Delivery Lead Time: Missed deadlines due to slow production cycles.
• Inventory Overload: Unorganized inventory led to excess stock, higher storage costs, and occasional product obsolescence.
• Unorganized Workplace: Cluttered shopfloor increased search time and reduced productivity.
• Cultural Resistance: Employees were accustomed to traditional methods and hesitant to adopt Lean system

Our Approach

Greendot developed a customized Lean Manufacturing Implementation Plan focused on productivity improvement, waste reduction, and cultural transformation:

• Diagnostic Study: Mapped current workflow using Value Stream Mapping (VSM) to identify non-value-added steps.
• Training & Awareness: Conducted Lean and Kaizen workshops for all production teams.
• Pilot Project: Tested Lean tools in one assembly line to refine approach before company-wide rollout.
• Continuous Monitoring: Established performance metrics for lead time, inventory, and product quality.
• Employee Empowerment: Encouraged employee-led Kaizen events to instill a culture of ownership and improvement.

Solutions Implemented

Results Achieved

• 81% Reduction in Delivery Lead Time: Timely production ensured faster customer deliveries.
• 50% Reduction in Product Rejections: Improved process control reduced defect rate from 1.5% to 0.7%.
• Optimized Inventory Management: JIT system reduced stock levels and storage costs significantly.
• 30 Kaizen Events Executed: Continuous improvements identified and implemented by cross-functional teams.
• Improved Workflow Efficiency: Material movement and production flow were streamlined, improving overall throughput.
• Enhanced Customer Satisfaction: Consistent, on-time delivery boosted client confidence and repeat business.

ROI: The Lean transformation delivered a ₹28–30 lakh annual cost benefit, achieving ROI in under 5 months through efficiency gains, reduced waste, and faster deliveries

Why It Worked (Greendot Edge)

• Employee-Driven Transformation: Lean principles were embraced at every level.
• Data-Backed Decisions: Real-time metrics guided every improvement initiative.
• Scalable Implementation: Pilot-first approach ensured flawless company-wide rollout.
• Continuous Learning: Regular Kaizen events embedded a culture of ongoing improvement.

Tools Used

• 5S
• Kaizen
• Value Stream Mapping (VSM)
• Kanban System (JIT)
• Root Cause Analysis
• KPI Dashboard