Services
Two decades of Lean and TPM implementation experience. From single-day awareness workshops to 12-month transformation partnerships — the scope is matched to what the organisation actually needs.
Core Principle
Your operators and engineers are the domain experts. The shop floor observation is how their knowledge surfaces and becomes actionable.
Zero investment first. Method changes before capital proposals.
Team ownership of the solution. What the team builds, the team sustains.
Measurement left behind. A live system — not a report.
Engagement Structure
Every engagement begins with understanding the specific situation. The structure below is a guide — the actual scope is defined together with the client.
Awareness
1 to 3 Days · On-site or Off-site
For organisations looking to introduce or strengthen specific Lean and TPM concepts across their team. Practical, tool-specific, with shop floor application.
Implementation
3 to 12 Months · On-site
Full implementation alongside your team. Material and information flow both addressed. Internal capability built. Measurement system established and running before the engagement closes.
Diagnostic
2 to 5 Days · On-site
For organisations that want to understand where they are before committing to a full engagement. A clear picture of the current state and a prioritised roadmap.
5-Day Sprint · Zero Investment
5 Days · On-site · 10–15% Output Gain · ₹0 Capital
Your team finds the gap. Your team fixes the gap. The shop floor operator is the domain expert — not the consultant. We provide the Job Method Study framework and then step back. By Day 5 your team owns the improvement completely, with the skill to repeat it on the next bottleneck independently.
See Full Programme Details →Service Areas
34 years of hands-on experience across these specific disciplines — not general management consulting.
Waste elimination, flow improvement, pull systems and line balancing. Value Stream Mapping of both material and information flow. Single Piece Flow implementation where applicable.
7 pillar TPM implementation, 16 major loss reduction, OEE measurement and improvement, Autonomous Maintenance step-by-step deployment. JIPM award preparation experience.
Manual and robotic liquid paint shop — defect reduction, yield improvement, process standardisation. ABB robot programming. Dust VRT methodology. FTT improvement. India's largest plastic paint shop installed and proved out.
ECRS-based method improvement for manual and robotic operations. Time study and work measurement. Ergonomics improvement. Deskilling and standard work documentation using TWI methodology.
End-to-end support for ISO 9001, 14001, 45001 and EnMS 50001 — documentation, gap analysis, implementation, internal audit and certification audit preparation. ZED implementation — Tamil Nadu's first certification in small components sector achieved.
First Time Through improvement, Poka Yoke design, Why-Why analysis, FMEA facilitation. Defect feedback loop redesign — connecting inspection result to producing station faster. Paint defect reduction — petrol tanks, automotive components.
Workshop Topics
Each workshop is adapted to the organisation's industry and current level of Lean maturity.
W01
Principles, implementation sequence, red-tag events, audit systems and sustaining 5S without external pressure.
1 DayW02
Current state and future state mapping. Material flow and information flow symbols. VAR calculation and improvement prioritisation.
1–2 DaysW03
Theory and shop floor walk — identifying all 8 wastes including the often-missed information flow wastes. Waste Pareto for prioritisation.
1 DayW04
All 7 TPM pillars explained with industry examples. OEE calculation and 16 major losses. Autonomous Maintenance step introduction.
1 DayW05
Internal vs external work. Video analysis methodology. ECRS application to changeover steps. Single-digit setup target setting.
1–2 DaysW06
Detection vs prevention. Poka Yoke device types. Zero Quality Control principles. Applied design session for participant's own process.
1 DayW07
Takt time calculation. Cycle time measurement. Operator balance chart. U-cell vs linear layout. Manpower optimisation.
1–2 DaysW08
Why-Why Analysis structured methodology. FMEA introduction and facilitation. Fishbone diagram. 8D problem solving format.
1 DayIndustries
34 years of direct manufacturing experience across these sectors — which means we know the right questions to ask when we listen to your team.
Paint shops · Assembly lines · Body panels · Interior trim · Sub-assembly · Robotic operations
SMT lines · Through-hole assembly · BLDC controllers · EV electronics · PCB assembly · Testing
Fabrication · Wheelchair manufacturing · Medical equipment assembly · Surface treatment · QMS
Washing machine assembly · Consumer electronics · FMCG assembly · Packing lines · Testing
Tannery operations · Shoe manufacturing · Wallet assembly · Leather goods production
Shipyards · Welding operations · Sheet metal fabrication · Structural assembly · Large-scale projects
Tell us the specific problem you are trying to solve. We will respond within 24 hours with an honest assessment of whether and how we can help.
Contact Us → Call: 70103 78025