Lean @ Work

A successful Lean implementation case study

Client overview

The client is one of the largest energy retailer in gas and electricity in Australia. Wipro’s team of over
50+ engineers have been engaged with this customer for more than 5 years for development and
support of applications like MDM, BizTalk, Intellect, HDS.

Project challenge & goal

The Microsoft BizTalk team was involved in implementation of 22 new interfaces during which they
faced multiple challenges like ineffective reviews, recurring defects post fix, lengthy manual deployment
cycle time, high number of system test defects. The team ran a risk of effort and schedule overrun,
defect slippage to subsequent system integration test phase. The BizTalk team decided to adopt a Lean
approach to overcome these challenges and took target to reduce deployment cycle time by 10-15%
and overall effort overrun by 10%.

Solutions implemented – Lean levers

VSM on deployment process

• Before: Process efficiency was 81.3% (NVA time: 50 minutes, value added time: 216 minutes,
cycle time: 266 minutes)

• After: Through automation, the deployment cycle time reduced to 107 minutes and process
efficiency improved to 87% (NVA time:14 minutes, value added time: 93 minutes)

• Defects in deployment process was reduced to zero defects from earlier 15 defects

Standardization

Before:

➢ Code/review checklist was not comprehensive

➢ Code version control tool had many redundant files. No proper structure was in place.

➢ High defects slippage to SIT and subsequent phases

After:

➢ Created new deployment document - team trained to follow it which lead to zero deployment
issues

➢ Detailed code review checklist was used by team to do self and the formal review sessions.
Helped to cover all interdependencies with relevant stake holders.
 ➢ Created onboarding training plan for all new comers

➢ Cleaned Code version system to remove all reductant files thereby eliminating possibility of
invalid defects.

➢ Defect discovery rate improved from 4.67 to 5.87 defects / person day – i.e. less defects
slipped to SIT and subsequent phases.

Automation

➢ Before: Manual deployment of interfaces had more NVA-time and post deployment defects

➢ After: Automation was adopted using Microsoft BTDF Framework Scripts. This helped in creating
partial and full deployment scripts. Automation reduced deployment time from 3.5 hrs. to 1.5
hrs. Post deployment defects were NIL.

Benefits

Customer benefits:

➢ Turnaround time for deployment reduced by 57% and reductions in defects from 15 (in Phase 1)
to 0 (in Phase 5)

➢ Improved quality of deliverables - Only 4.1% of the total defects discovered by the customer
were attributable to work done by Wipro team as compare to other development vendors

Wipro benefits:

➢ Customer appreciations for quality work delivered by Wipro. Received PCSAT rating of 7/7

➢ Effort optimization and POC saving – 10.5 person-month EQOMM – 17K USD

➢ Improved review, build deployment & new hire onboarding processes.

➢ Improved phase containment of defects.

Customer appreciations

On successful NSW/ACT Biz Talk release

❖ “Thanks. Another milestone passed. Great news, well done to the team!!” – Anne Weatherston
(EA CIO)

❖ “Thank you Surendra and everyone involved. Great work!”- Jorg Ottensmeyer (EA NSW/ACT
PROGRAM MANAGER
The team

Lean Facilitator - Suman Mishra

Lean Practitioner - Minal S
Lean Champions - Surendra Agrawal & Umesh Ravindran
Lean Leader - Vishal Shah
Team - Aman Jain, Manish Kumar, Sarthak Goel,
Pritesh Lad, Vishnu Tamrakar, Suyasha Umrikar, Ankita Devaniya, Sanika Kawthalkar, Sangay Sherpa,
Humera Khan

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