We implemented single piece flow in almost 8 different areas in our company. Productivity increased from 50 to 100% on different product lines. This has helped us achieve higher turnover without adding any machinery or manpower. Importantly, we were able to eliminate WIP in most places. Copper being a major part of RM, it is a major saving for the organization. To add, AB Associates have been extremely professional and meticulous throughout the cluster program. Their efforts are instrumental in ensuring good results are delivered to all the member units.

Although we had a good rapport with our operating people, when it came to improvements we faced a lot ofresistance to change. After the Lean Cluster Program, we got benefits not only in establishing the best practices but also in creating a team that works hand in hand for improvements along with the top management. AB Associates’ meticulous and professional approach improved the competency of our team along with attitude.

At the time of joining the cluster, we used to make around 5 -10 thousand pieces a month for each variety. AB Associates consultants highlighted huge WIP inventories and poor internal OTDs. To all this, they advised single piece flow. We never thought we were a company that could implement something like SPF.
Today, we have added 2 new product varieties and are supplying more than 60 thousand a month comfortably. At the same time, we believe that we have additional capacity to make more than 50 thousand parts in the existing setup. Most importantly, the team is now geared for improvements,it runs on auto mode. Implementation of the business scorecard has helped greatly in our team realizing their own +’s and -’s.