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Lean manufacturing or lean production, often simply "lean", is a systematic method for minimization of 8 wastes ("Muda") within a manufacturing system without sacrificing productivity.

8 classical wastes of a manufacturing unit are

1. Transportation

2. Inventory

3. Movement

4. Waiting

5. Over Production

6. Over Processing

7. Defects &

8. Skill

Lean also takes into account waste created through overburden ("Muri") and waste created through unevenness in workloads ("Mura")

Business Analyst Group is the  empanelled Lean Manufacturing Consultant ( LMC) of Quality Council of India (QCI). QCI is the national apex body for accreditation under the ministry of industries and the National Monitoring and implementation unit of MSME for Lean Manufacturing. BAG has been working with manufacturing units of different industry sectors since the year 2007

Lean manufacturing is a management philosophy derived mostly from the Toyota Production System (TPS). Lean manufacturing or lean production, often simply "lean", is a systematic method for the elimination of waste ("Muda") within a manufacturing process. Lean also takes into account waste created through overburden ("Muri") and waste created through unevenness in workloads ("Mura"). Working from the perspective of the client who consumes a product or service, "value" is any action or process that a customer would be willing to pay for. Essentially, lean is centered on making obvious what adds value by reducing everything else. Lean manufacturing is renowned for its focus on reduction of the seven wastes to improve overall customer value.

The Micro, Small and Medium Enterprises (MSMEs) are a vital part of the Indian economy contributing to over 45% of industrial production and around 40% of the total exports. There are more than 13 million MSMEs in India employing about 31 million people, easily the single largest contributor in terms of employment generation in the manufacturing sector.

Under the Lean Manufacturing Scheme, MSMEs will be assisted in reducing their manufacturing costs, through proper personnel management, better space utilization, scientific inventory management, improved process flows, reduced engineering time and so on with application of LM techniques.

Despite constituting more than 80% of the total number of industrial enterprises and supporting industrial development, many MSMEs in India have problems such as

·      Sub-optimal scale of operation

·      Technological obsolescence

·      Supply chain inefficiencies

·      Increasing domestic and global competition

·      Fund shortage

·      Change in manufacturing strategies

·      Turbulent and uncertain market scenario

Lean manufacturing is aimed at the elimination of waste in every area of production including

·         customer relations

·         product design

·         supplier networks and

·         factory management

The goal of Lean Manufacturing is to incorporate

·         less human effort

·         less inventory

·         less time to develop products, and

·         less space

 

to become highly responsive to customer demand, while at the same time producing top quality products in the most efficient and economical manner.

 

What is 5S

5S is the starting point of any quality initiative in a factory.

5S represents Japanese words that describe the steps of a workplace organization process.

English equivalent words are also shown below

1. Seiri (Sort)

2. Seiton (Set in order)

3. Seiso (Shine)

4. Seiketsu (Standardize)

5. Shitsuke (Sustain)

In simple terms, the five S methodology helps a workplace remove items that are no longer needed (sort), organize the items to optimize efficiency and flow (set in order), clean the area in order to more easily identify problems (shine), implement colour coding and labels to stay consistent with other areas (standardize) and develop behaviours that keep the workplace organized over the long term (sustain).

5S is a team run process and should be conducted by the people who work within the area in which the principles of 5S are being applied, it is not a tool that can be applied by an outsider onto an area without the knowledge and cooperation of the people within it.

What is Kaizen

Kaizen is a lean manufacturing tool that improves quality, productivity, safety, and workplace culture. Kaizen focuses on applying small, daily changes that result in major improvements over time.

Kaizen first surfaced during the effort to rebuild Japan after World War II. At the time, several U.S. business consultants collaborated with Japanese companies to improve manufacturing. The collaboration resulted in the development of several new management techniques, one of which was Kaizen. Kaizen comes from two Japanese words Kai (improvement) and Zen (good). Over time, it became widely known as "continuous improvement."

Unlike many business practices, Kaizen's strength comes from requiring all workers-from the CEO to the shop floor assistant-to participate by making suggestions to improve the business

Total Quality Management (TQM) is a management framework based on the belief that an organization can build long-term success by having all its members, from low-level workers to its highest ranking executives, focus on quality improvement and, thus, delivering customer satisfaction.

Quality Circle (QC)

It is a work group of employees who meet regularly to discuss their quality problems, investigate causes, recommend solutions, and take corrective actions. Generally, QC is a small group of employees belonging to the same / similar work area.

This is so because the employees doing the similar type of work are well familiar to problems faced by them. The size of the QC should not be too big so as to prevent some members from participating meaningfully in its meetings. Generally, six to eight members are considered the ideal size of the QC.

Objective of Techno-Economic Feasibility Report (TEFR) and Detailed ProjectReport(DPR) is to determine the technical feasibility and financial viability of the project, assess the risks associated with the project and enumerate imminent actions that are required to be taken.

TEFR & DPR covers the followings

• Exploratory Research on the product

• Market Study for Market Assessment

• Infrastructure & site selection

• Raw Materials

• Broad Market Assessment

• Infrastructure and Site Selection

• Manufacturing Process and Technical Concept

• Electrical, Instrumentation and Control System

• Civil Engineering Considerations

• Manpower Requirement and Training

• Environmental Aspect

• Project Implementation Schedule

• Assessment of Capital Cost

• Cost of Production and Profitability

• Investment and Financial Analysis

We render consultancy, impart training and provide handholdingsupport to implement ISO 9001-2015 (QMS), ISO 14001-2015 (EMS), OHSAS 18000
What is Quality Management System (QMS)A system by which an organization aims to reduce and eventually eliminate nonconformance tospecifications, standards and customer expectations in the most cost effective and efficientmanner.ISO 9001-2015 is the upgraded version of ISO 9001-2008 issued in September 2015. All ISO9001-2008 certificates will be cancelled on September 2018 and within this period the oldcertifications are to be upgraded.
What are the benefits of ISO 9001-2015 (QMS)ISO 9001 helps organizations ensure their customers consistently receive high quality productsand services, which in turn brings many benefits, including satisfied customers, management,and employees.Because ISO 9001 specifies the requirements for an effective quality management system,organizations find that using the standard helps them Organize a QMS Create satisfied customers, management, and employees Continually improveISO 9001 also provides financial benefits, such as cost savings.
What is Environment Management System (EMS)ISO 14001-2015 is the international standard that specifies requirements for an effectiveEnvironmental Management System (EMS)
Call 9831177399for Certification of QMS (9001-2015) EMS (14001-2015) OHSAS 18001 and/or SA 8000
What are the benefits of ISO 14001-2015 (EMS)It helps to Assure that the environmental impact is being taken care off Meet legal obligations Improve overall environmental impact Reduce waste Drive down costsWhat is Occupational Health and Safety Assessment Series, (OHSAS)This is an internationally appliedBritish Standard for occupational health andsafetymanagement systems. It exists to help all kinds of organizations put in placedemonstrably sound occupational health and safety performance. The standard is known asOHSAS 18001What are the benefits of OHSAS 18001 (OHSAS)The benefits are Ensures legislative awareness and compliance Ensures health and wellbeing of employees, sob contractors and public Reduces accident and incident rates by reducing or elimination workplace hazards Increases employee motivation through the provision of a safer workplace andparticipation process Minimizes the liability of employers through adoption of proactive controlWhat is Social Accountability Certification (SA)SA or SA8000 is the leading social certification standard for factories and organizationsacross the globe. TheStandard has evolved into an overall framework that helps certifiedorganizations demonstrate their dedication to the fair treatment of workers. The Standardmeasures social performance in eight areas important to social accountability in workplaces,complemented by the management system element that emphasizes worker involvementand drives continuous improvement in all areas of the Standard.

Reciprocating to the concept of "Make in India" of our Hon'ble Prime Minister to improve the competitiveness of MSME, Quality Council of India (QCI) has developed the ZED Maturity Assessment Model. Through ZED model the MSMEs will be assessed through 50 parameters in5-point rating. In these parameters 20 parameters are mandatory for all industries and minimum other 10 parameters are optional.ZED certification systemEach company will be assessed in 30 parameters by 5-point rating. There are 5 levels of certificates. The Rating is an weight age average of the marks obtained on each parameter.The level of certificate will be ascertained on the basis of final rating which are Below 2.2 No certificate
For Certification of Integrated Management System (IMS)that is
certification of QMS, EMS &OHSAS together
Business Analyst Group renders consultancy and prepares MSME for Zed certification.
2.2 - 2.5 Bronze level certificate2.5 - 3.0 Silver level certificate3.0 - 3.5 Gold level certificate3.5 - 4.0 Diamond level certificate4.0 to 5.0 Platinum level certificate ZED model requires Compliance of QMS, EMS, OHSAS certification Implementation of sustainable development Implementation of Lean Manufacturing Implementation of Six Sigma Constant growth Involvement of all and Continuous Improvement
On behalf of QCI, BAG in association with different trade associations is organizing awareness programme on ZED Maturity Assessment Model and rendering consultancy on ZED model.