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OPERATIONAL IMPROVEMENT

AND INNOVATION WITH


JR VICTOR
USING LEAN & INNOVATION, HELPING
CLIENTS MAXIMIZE OPERATIONAL
POTENTIAL
• Maximizing Profitability
• Innovation & Design Thinking
• Continual Growth &
Operational Improvement
• Growing the People
• Creating a Lean Culture

Providing capabilities to take operational


teams to next level of performance
JR VICTOR’S SERVICE PHILOSOPHY

Identifying and
providing
Real Value
in a
changing world
CONSULTING

LEAN & INNOVATION


TRANSFORMATION

TRAINING COACHING

LEAN & LEAN& INNOVATION


INNOVATION IMPLEMENTATION
SKILLS

ABOUT JR VICTOR…
J. Ramesh Victor
(Lean Master & Certified Innovation Practitioner)

• 25 Years experience in Manufacturing Operations and certified Lean


Master (USA & Japan)
• Engaged in Lean transformation for Fortune 500 and small
companies all over Asia since 1999

• Certified Lean Master


• Certified Innovation Practitioner (USA)
• Former Supplier Lean Head for Asia at Seagate Technologies
• Helped clients save Millions of Dollars within a short period of
time
• Have diagnosed, trained and implemented Lean for clients such as:
Seagate, GE, 3M,Carsem, Snap On, NSK, Minebea and many more
• Uses hands-on and pragmatic approach to consulting and earned
nick name as “The Constraint Buster”
• Columnist in Periodicals including SME Connect (Malaysia) on Lean
Transformation in manufacturing
• Award winning & charismatic Public Speaker
SERVICES
Solutions using Lean Manufacturing
Solutions based on Lean Manufacturing provides a holistic transformation of an operation using the tested
secrets of Toyota Production System and other leading Lean implementers
These principles are learnt by us direct from Japan and from Toyota “Old-Boys” who were part of the
development of this system

Solutions Provided:
• Lean manufacturing Consulting & Training
• Toyota Kata- Creating a Kaizen Habit and also
Breakthrough Improvements
• Hoshin Kanri – Policy Deployment and strategic planning
• Toyota Kaizen methodology – Eliminating MUDA (Waste);
MURA (Unevenness); MURI (Overburden)
• Seven Principles of Toyota Production System – The DNA
for sustainable operational improvement culture
• Genchi Gembutsu Practices- Shop-floor systems for
operational excellence
Imparting knowledge and coaching
improvement-teams right at the shop-floor on above methodology
500 persons certified as Lean Masters since 2002. Many have been
elevated to top positions such as MD or GM
Solutions using Training Within Industry (TWI)

• TWI is a proven methodology of


enabling supervisors to be in control
of shop-floor through Instruction, Job
Method Improvement and employee
relationship

• If you want your leadership with the


right Lean job skills: thinking about
and improving safety, quality, cost,
delivery and productivity of your
products or services in the
workplace, than TWI is one part of
the answer.
Skills Enhancement in Lean Tools

Lean Manufacturing Tools:


• Value Stream mapping
• 5S+Safety & Visual Systems
• Standardized Work
• Pokayoke/Error Proofing
• Quick Changeover/SMED
• Inventory management & Kanbans
• Layout Optimization
Providing Skills for Operators
• Equipment Performance
right up to Operations Directors
Improvement in:
• One piece flow Lean Manufacturing
Theory of Constraints
• Cellular Manufacturing
Operational Leadership
• Practical IE skills for Lean and more…
• Lean Diagnostics and much more…
Design Thinking & Leading Breakthrough Innovation

To thrive you need to INNOVATE.


We provide skills to leap ahead. Problem Solving & Kaizen skills alone is not sufficient to grow to the next
level. Breakthrough innovations create big advances and can catapult a company, process, product or
service well ahead of competitors.

Innovation tools and programs


• Design Thinking
• Innovation Assessment
• Critical Tools and methods of Innovation
• Innovation workshops
• Facilitation of Innovation in an organization

Learn how to:


Lead the Innovation process to achieve breakthrough improvements
for your organization/self
Build value and sustainable competitive advantage Innovation is the imperative
Create ideas for new products, services, strategies, processes etc. of today’s time. It allows your
Survive and grow in an ever-changing world organization to become
Complement and obtain better results in Lean, Six Sigma and other “faster than anyone better,
improvement methodologies better than anyone faster”
Lean Consulting
Operational
Improvement
LEAN practitioner and
SPECIALIST specialist at your
site, working
hands-on with
your staff to start
transforming it
within weeks!
Arrow Process
Typical Operational
Why use
Improvement graphics from
Consulting PowerPointing.com?
Activities

Leave an impact in the plant


Diagnose to understand operational Use Quick and Effective problem
• Plan for sustaining and
focus area and plan improvement solving methods and tools
maintaining the culture
• Hands-On Diagnostics takes place • Identify problem and use prolem
while team is given the skills to do so solving tools to immediately
• Identify operational constraints address it
• Activity planning and target results • Act on implementation
immediately

UNDERSTAND EXPLOIT THE PLAN & MONITOR AND ACHIEVE


THE PROBLEM CONSTRAINT IMPLEMENT AFFIRM TARGETED
IMPROVEMENT IMPROVEMENT RESULTS

HANDS-ON
ALL THE
DAYS
Monitor implementation
Deep Diving into operations: and make changes if
• Immediate actions to stop necessary
operational problems/constraint
• Constraint management activity • Measure results, assess
done and team learn skills to do so and rectify risks and plan
for full implementation
START SEING RESULTS WITHIN
TWO TO THREE WEEKS
Training In A Pragmatic Manner

HANDS-ON RIGHT AT THE SHOP FLOOR

Amateurs work until


they get it right.
Professionals work
until they can't get it
wrong.
SUMMARY OF CLIENTS
ACHIEVEMENTS

• Reduced Inventory by 50%


• Reduced Downtime by 30%
• Reduced Excess Headcount by more than 50%
• Reduced cycle time by 50%
• Reduced Scraps & Rework by 15%
• Increased On Time Delivery from 70% to more than 95%
• Reduced space utilization by 40%
• Employee engagement and skill enhancement
• Leadership succession and growth achieved
• Developed organizational change agents

IN TOTAL, KNOWN FINANCIAL SAVINGS FOR CLIENTS THROUGH LEAN PROJECTS


COACHED BY US EXCEED RM390,000,000
SELECTED SUCCESS CASE STUDIES
COMPANY THE CHALLENGE INVOLVEMENT OUTCOME
(Type & Location)
MNC in Data Storage •Cannot meet time to volume Six months engagement at • Increased Throughput by
Industry, Singapore •Inventory Control Problems clients shop-floor identifying 21%
•High Machine Downtime improvement opportunities • Reduced Downtime by 40%
•Lose of business due to above and coaching improvement • Financial savings:
factors teams through hands-on RM72,000,000
activities
SME manufacturer in KL, •Very High Lead time from order Two weeks Training and • Reduced Machine Setup by
Malaysia processing to shipment (about 20 projects mentoring at shop- 50%
days) floor • Increased machine OEE
•High Raw Material Inventory • Financial savings
RM177,000
Large Equipment • Long Lead time to complete Engaged in shop-floor for • Reduced assembly Lead
manufacturer, Penang each machine assembly diagnostics and established time by 45%
• Paying high late delivery penalty assembly Standard Work. • Eliminated late Deliveries
payment to Giant MNC Total Time at plant 3 weeks
Manufacturer

Company names have not been disclosed due to professional confidentiality code of the consulting profession
SELECTED SUCCESS CASE STUDIES
COMPANY THE CHALLENGE INVOLVEMENT OUTCOME
(Type & Location)
Large Steel Manufacturer, • No continuous improvement Conducted training on Lean • Total savings from four
Malaysia culture in factory skills. projects is
• Badly maintained equipment Hand-holding and coaching of • Spare part holding reduced
• Very High spare part stock four projects for 6 months at by 30%
holding shop-floor. • RM3,900,000
MNC Fibre Optic module • High Inventory Holding Conducted training on Lean for • Total projects savings
manufacturer, Malaysia • Long Machine Setup Time 1 year (several groups in RM17,000,000
• Necessity to establish skills for stages. • Won several NPC awards at
key operational staff on Lean Coaching at shop-floor for Regional & National Level
project teams. through Lean projects
Established a Lean system for
the organization
Steel Manufacturer in • No Problem formal problem Engaged in 6 months training, • Reduced down Time 20%
Malaysia solving skills in place consulting and coaching on • Reduced Spare Part holding
• High Waste and Downtime Lean methodologies and hand Cost
held four pilot project teams • Improved Yield by 2%
RM3,000,000

Company names have not been disclosed due to professional confidentiality code of the consulting profession
SELECTED SUCCESS CASE STUDIES
COMPANY THE CHALLENGE INVOLVEMENT OUTCOME
(Type & Location)
Medium Size MNC Filter • Long Lead Time Conducted Value Stream • Order processing Lead
manufacturer • High Machine downtime mapping and diagnostics. Time reduced from average
• Bad work place organization (5S) Coaching and mentoring on 14 days to average 2 days
projects at shop-floor for 12 • Equipment setup time
months reduced by 50%

Fortune 500 MNC • Long supply chain Lead Time Transformation using Lean • 114% Inventory Turn
• Necessity to improve time to methodologies and Innovation improvement
market throughout the supply chain • 500% productivity
• High inventory throughout improvement (prod. per
supply chain headcount)
• 20% increase in market
share
Hospital, Malaysia • Mistakes in hospital processes Skills transfer on Kaizen and • Reduced audit failures to
and audit failures Error Proofing techniques zero
• Customer complaints due to • Reduced customer
mistakes at various department complaints by 50%

Company names have not been disclosed due to professional confidentiality code of the consulting profession
“ ...Ramesh Victor has demonstrated the ability of going into problem factories, and quickly
turn around their manufacturing operations. Approximately 7 people in the whole of
Seagate 45,000 possessed this skill set ”
Richard C. Craven B.Eng, MSc, MBA, CEng, MIMechE
Seagate Supplier Lean Head for Europe & Asia

“Utterly fantastic...without lean implementation at...we would not have met the Barracuda ATA- IV schedules”
Matt Johnen. VP Asia Materials (Seagate)
“ Lean Manufacturing in general opinion is too BIG and difficult to be achieved. But with Ramesh Victor as our trainer/consultant
Lean has become easily understood by Belton candidates of all levels. Lean has become applicable in Belton”
Pongyut, Director of Engineering
Belton Industrial, Thailand

“….result is...very ordinary people here ( Production Supervisors, Engineers), moving on very ordinary projects ( Poka--yoke, UPH
improvement, Kanban system, etc) for some VERY extra-ordinary results. I am very pleased that so much dollars and cents has
been saved with a lot of simple, sensible and stellar projects.
Keep up the good work and I am so proud with all of you.”
Comment of Managing Director of Finisar to
AMC Lean Master Candidates
“we find your training and coaching sessions informative, practical and professionally
delivered. The choice to go wide to give the big picture before drilling down to select areas
delivering highest business impact, is a strategy that serves us well…Besides an average of
30 to 40 percent improvement in set up time…, cycle time improvement from 6.5 to 4.2
days…we are also pleased to see a reduction in critical defects...
SW Woo, COO
Carsem M Sdn Bhd.
“ Lean Manufacturing came at the right time to save millions of dollars for us in capital avoidance…”
Michael, Lean/Engineering Manager
MSP, Ipoh (NSK Group)

“ Lean Manufacturing is an effective tool to reduce wastage, optimize capacities & reduce costs….AMC’s course led by
Ramesh Victor taught us the effectiveness of various Lean Tools….The course is very interactive and the simulation games
are very interesting. The course instructors use their extensive industrial experience to elaborate important points and
make participants understand the key points”
Roger Goh, Vice President
Beyonics Precision, Johore Bahru
“Very good projects and excellent savings, nothing should stop us from standardizing these actions across the floor
immediately ..”
Innovex Thailand, VP of Quality
and Operations
One or more of services has been rendered to:

Malaysia Malaysia Malaysia


➢ General Electric, JB ➢ Perak Community Specialist ➢ Mapa
➢ Komag, Pen, JB, Sarawak Hospital ➢ Rosa Pasadena (Hotel)
➢ Eng Teknologi, Penang ➢ Schaefer Kalk ➢ Carsem Semiconductor
➢ MMI Johore Bahru ➢ Imerys ➢ PSC Casting
➢ Beyonics Precision JB ➢ Siegwerk ➢ HCM-Hygenic Corporation
➢ Wong Engineering, Kulim ➢ Pantai Hospital ➢ MEMC (silicon wafer)
➢ NSK, Malaysia ➢ Hartalega ➢ Unisem
➢ MSP, Ipoh ➢ K1 ➢ Sun Edison
➢ ZF Steering ➢ Belton Springs ➢ First Solar
➢ Balda Thong Fook, Ipoh ➢ Micromechanics ➢ Kenanga Investment Bank
➢ Finisar Ipoh ➢ Mondi Ipoh ➢ Dynacraft
➢ Hovid Pharmaceuticals, Ipoh ➢ Infrastructure University KL (IUKL) ➢ Frontken
➢ Ryco Hydraulics, Kulim ➢ Dexon Engineering ➢ United Uli Goodlight
➢ Crest Ultrasonic, Perai ➢ Renesas Semiconductor ➢ Ann Joo Steel
➢ Camfil Farr, Batu Gajah ➢ Smart Modular, Perai ➢ Bard
➢ Poly Plus, Perai ➢ Knowles ➢ Osram
➢ Rhombus, Perai ➢ Altum, JB ➢ Hauni
➢ H & P, Perai ➢ Juason Plastic, Perai ➢ SAM Engineering & Equipment
➢ Automotive Lighting, Penang ➢ Balda (Mold Tool Room)
➢ Trane (Aircon)
One or more of services has been rendered to:

Taiwan Thailand
➢ Ambit ➢ Minebea (NMB)
➢ Nanotech ➢ Innovex
➢ Belton
China ➢ Beyonics
➢ Seksun, Suzhou ➢ Compart
➢ MMI, Wuxi ➢ Fabrinet
➢ Belton, Shenzhen ➢ Agere
➢ Belton, Wuxi ➢ Magnecomp
➢ Compart Singapore
➢ Magnecomp ➢ Seksun Corp
➢ Optimal ➢ Philips (Alliance with Gemba USA)
➢ Snap On
➢ Broadway Shanghai India
Indonesia ➢ Public seminars for various clients
➢ Philips (Alliance with Gemba USA) ➢ Royal Enfield
➢ Titan (Tata Group)
Others / global ➢ Trident
➢ Seagate Technologies
Japan
➢ Furukawa
HAVE SUCCESSFULLY HELPED COMPANIES IN THEIR JOURNEY OF OPERATIONAL EXCELLENCE
SINCE 1999
WE HAVE THE EXPERTISE: CLIENTS PAST SAVINGS EXCEED USD 390,000,000
FOCUS ON RESULTS & TRANSFORMATION: HAVE DONE IT BEFORE…!
Have helped clients achieve savings of more than USD 390,000,000. Can help you achieve your
Goals towards establishing a culture of operational excellence…
www.innovare-sol.com