Process MAP of Initial Study shows that the average time between orders receiving to inspector

checking before given transportation division takes average 187 minutes (3.11 hours) whereas
Transportation division takes 3 to 5 days to deliver orders.

One potential improvement is to have customers place orders electronically, directly to the
picking area. This will cut down delays and number of lost orders. Further needs to improve
delivery time, which takes 3 to 5 days even one week for some customers.

It is clear that the order-filling process is hampered by unnecessary delays including long
delivery time & orders Lost.

Minimizing waste and overall cost

cooling the mixture and validate heating and cooling reactor which will save 6- 7 hours in total
manufacturing cycle time. The company is operating under a strategy that aims to minimize the
overall cost of operation in production process company need to change the process of measuring
acid value and viscosity after

Once we reduce production process time than XYZ company utilize second shift to start second
batch in order to meet market demand.

We need reduce manufacturing cycle time to one shift with some extended over time instead of
two complete shifts.

As quality problem observed and company providing only on Job training to their staff. We need
to focus and implement the following training on quality.

Six sigma
A business process for improving quality, reducing costs, and increasing customer satisfaction.

Total quality management (TQM)

A philosophy that involves everyone in an organization in a continual effort to improve quality
and achieve customer satisfaction.

Supplier quality.
. It will save lot of money, thereby reducing or eliminating defect. We also propose to produce
additive in-house expected saving is around USD 1.4 million. Company also need to avail
quantity discount approximately 720 k. All above savings will enable to company reduce the cost
and enable to invest some marketing activities to enhance company market share.
Suppliers must be included in quality assurance and quality improvement efforts so that their
processes are capable of delivering quality parts and materials in a timely manner