Operations Research and Quantitative Optimization Techniques for Productivity - Success Stories in India

2010 - 2011

Decision Support System for Optimization of Material Procurement at SAIL
http://bvicam.ac.in/bijit/downloads/pdf/issue7/05.pdf

SAIL - Productivity and Industrial Engineering Initiatives and Achievements

2013 - 14
State-run Steel Authority of India's (SAIL)  production grew to 3.2 million tonnes, the highest ever in the first quarter, clocking a six per cent rise over the same period last year.


Production efficiency also got a boost with energy consumption  lower by one per cent and blast furnace productivity improving by two per cent.


With several projects on the anvil, the annual production capacity of hot metal of the company is expected to grow to 19 million tonnes by next fiscal from the current level of 14 million tonnes.
http://www.thehindu.com/business/Industry/sail-notches-up-best-ever-q1-production-at-32-mt/article4873684.ece

2010 - 2011
Decision Support System for Optimization of Material Procurement at SAIL
http://bvicam.ac.in/bijit/downloads/pdf/issue7/05.pdf 

2002 - 2003

A cost cutting target of Rs 500 crore was also being chased by SAIL, which effected a sizeable decrease in its losses in the first half of 2002-03.
http://www.thehindubusinessline.com/2002/11/14/stories/2002111402170200.htm

Time Study, Work Measurement and MOST STudies - Success Stories India

Consultants

Baroda Productivity Council
http://www.bpcindia.org/Services.aspx?Service=3


Dassault Systemes
3D Manufacturing Time-Motion Study
http://www.3ds.com/products-services/3dexperience/on-premise/manufacturing-planning-on-premise/manufacturing-time-motion-study/


SNIC, India
http://www.snic.co.in/services.php

Production Methods Efficiency Engineering - Success Stories in India

Improvement of Productivity through Line Balancing - Case Study
IIIE Journal, October 2013
http://www.vcs.co.in/news-room/publications/3237-article-3.html


Consultants

Vrunda Consultancy Services

VCS is a IE & management consulting company, with more than 120 Clients in Asia Pacific region. Combining unparalleled experience, comprehensive capabilities across all industries and business functions, and extensive research on the most successful companies, we collaborates with clients to help them become high-performance businesses. Our "high performance business strategy" builds on our expertise in IE & Management consulting, to help clients perform at the highest levels so they can create sustainable value for their customers and stakeholders.
http://www.vcs.co.in/consulting/3233-vcs-company-profile.html

Value Engineering Success Stories - India

A global leader in the elevator and escalator industry achieves  reduction of cost by drawing on Pricol Technologies’ Value Analysis and Value Engineering expertise.

Reduction in weight of the component and costs were the key objectives of the client. Pricol Technologies deployed its team of experts to perform a preliminary analysis to understand the strength of the components and fatigue requirements. 3D CAD models were developed from the existing mechanical components. Value Analysis/ Value Engineering teams sought to redesign the components, preserve the functional value and reduce the cost of manufacturing. The reliability and robustness of the existing model was maintained while redesigning the structure. The approach followed by Pricol Technologies helped the client in accomplishing their objectives.

Benefits

Reduction in the weight of the component by almost 70%

Reduction in cost of the component by 40%

Reduced process time of manufacturing

Optimised inventory and maintenance levels

Complexity of operations reduced significantly

http://www.pricoltech.com/success-stories

Consultants

Leveraging on its integrated eco system and the frugal engineering methodologies, Pricol Technologies brings in its palette a spectrum of services to help your businesses in each stage of your Product Life Cycle (PLC). March ahead by synthesizing innovation with engineering.

New Product Development

Mechanical Design

Embedded Systems

Visualization and Technical Publication

Value Analysis / Value Engineering

Manufacturing Engineering

Product Realization

Low Volume-High Mix Manufacturing

http://www.pricoltech.com/offerings

Pricol Technologies

Corporate Headquaters

II Floor, Srivari Srimath,

1045, Avinashi Road,

Tamil Nadu, India.

Email: sales@pricoltech.com

Coal India Limited - Productivity and Industrial Engineering Initiatives

Coal India Vision 2020 - One Billion Tonnes Production

February 2015

Shri Bhattacharya, CMD of CIL said that the strategies for future include Technology Upgradation in Opencast Mines with high capacity equipment , Operator independent Truck Dispatch System, Vehicle tracking system using GPS/GPRS, Coal Handling Plants (CHPs) and SILOS for Faster Loading and monitoring using Laser Scanners. As far as productivity improvement in Underground mines is concerned, Shri Bhattacharya said that the steps taken by CIL will include introduction of Continuous Miner Technology in large scale, Long-wall Technology at selected places, Man Riding system in major mines and Use of Tele monitoring Techniques.

CIL is also introducing a number of systems improvements that would help the company in realizing its challenging target. Use of ICT, remote sensing geophysical technologies and proper monitoring and evaluation methodologies will be the key features, Shri Bhattacharya added.

http://pib.nic.in/newsite/erelease.aspx?relid=115313

Six Sigma Success Stories in India

TQMI Consultancy Six Sigma Success Stories

Some Success Stories of Six Sigma

Industry Sector -  ROI - Annualized Savings


Data Storage and Photo-Voltaic
50:1
Rs. 25 crores in 2006-07 and Rs. 40 crores in 2007-08  and Rs. 50 crores each for 2008-09 and 2009-10 (Total USD 37 million)

Life Insurance
10:1
Rs. 100 cores  (USD 20 million) in 2008-2010

Tractors and Farm Equipment
4:1
Rs. 4 cores in one year in 2009-10 (USD  90K)

Pharma
15:01
Rs. 20 crores in 2008-10 (USD 4.5 million)

Chemicals/ Petro-Chemicals
9:1
Rs. 2.5 Crores in each in three waves (total USD 1.6 million)

Petroleum refinery
40:1
> Rs. 40 Crores in 2005-06 (>USD 20 million)

Leather and Leather Products
10:1
Rs. 2.5 Crores in 2003-04 (USD 500K)

Telecom Carrier
8:1
Rs. 5-6 Crores in each of four waves completed in 2004-07 (Total  USD 5 million)

Telecom
8:1
Rs. 27 Crores in 2010 (USD 6 million)

Home Appliances
14:1
Rs. 12 Crores and Rs. 22.5 Crores in 2002 & 2003 respectively (Total USD 8 million)

Banking
10:1
Rs. 3.5 Crores in 2003 (USD 775K)

Total savings to Indian Industry: ~ Rs. 1500 Crores

TQMI Sigma Implementation - Full Case Study Presentation of  an Engineering Company that won the Deming Prize from JUSE for effective implementation of TQM

Reported annualized savings of USD 3 million. ROI  15:1
Plan for 2007: Savings of USD 5million


WIPRO Case Study
Download from IIT Kharagpur Website
WIPRO is the first to implement six sigma effectively in India
It is now offering consultancy services also in Six Sigma
It achieved benefit of Rs. 120 crore due to six sigma projects in 2005-06 (reported in the case)

More case studies from TQMI
http://www.tqmi.com/case-studies.page.84.html

BPCL - Productivity and Industrial Engineering Initiatives and Achievements

BHARAT PETROLEUM CORPORATION LIMITED: FINANCIAL AND LABOR PRODUCTIVITY BENCHMARKS

Are workers at Bharat Petroleum Corporation Limited productive? There is no absolute answer to this economic question. The second study considers how labor deployment and productivity indicators for Bharat Petroleum Corporation Limited differ from the global benchmarks. It looks at the amount of labor required to operate Bharat Petroleum Corporation Limited and the resulting return on human investment. What is the ratio of short-term and long-term assets to employee? What are comparative capital-labor ratios? What are the average sales and net profits per employee in Bharat Petroleum Corporation Limited compared to benchmarks in the same economic sector?

Reports for over 54 Petroleum Refining companies are available now, including the following:


Amerada Hess Corpn
Ashland Inc.
BP Amoco PLC(BP AMOCO)
Chevron Corporation
Conoco Inc.
Cosmo Oil Co., Ltd.
Fortum Oyj
Imperial Oil Limited
Japan Energy Corporation
Lyondell Chemical Company
Nippon Oil Company, Limited
Petro-Canada
Phillips Petroleum Co.
Repsol-YPF SA
Royal Dutch Petroleum Company
RWE-DEA Aktiengesellschaft fuer Mineraloel und Chemie
Showa Shell Sekiyu Kabushiki Kaisha
Societe Elf Aquitaine S.A.
Technip Societe Anonyme
The Shell Transport and Trading Company, p.l.c.
Tosco Corporation
Total Fina Elf SA
Unocal Corporation
USX-Marathon Group

http://www.icongrouponline.com/pr/Bharat_Petroleum_Corporation_Limited_IN/PR.html



According to BPCL's own numbers, the bottle filling plant's productivity has seen a 34 percent increase since the beginning of the Facility Service Agreement;
http://www.kosancrisplant.com/en/home/cases/case-bpcl-india/

Tata Motors Ltd. - Productivity and Industrial Engineering Initiatives and Achievements

2013-14

INFORMATION TECHNOLOGY INITIATIVES

The Company''s business strategies are well supported by IT proactively
building the capabilities. The Company''s IT leverages strong
partnerships with productand services companies to support business
growth and innovation. This has enabled us to strengthen our core
technology capabilities.

The major highlights of IT initiatives at the Company are:

The Company commemorated 10 years of its path breaking CRM solution,
one of the largest in automotive industry with 4,000  channel partners
and more than 50,000  users.

The Company played a key role in setting up AutoDX, a SIAM ACMA
initiative for electronic data interchange (EDI).

The Company is implementing cloud based employee collaboration tools
which will bring a diverse and multi locational workforce closer,
enabling the OneTeamOne Vision initiative.

The Company is extending its enterprise applications to mobiles through
mobile apps. First five applications have been piloted for Telematics,
Rural Marketing, Dealer Sales Force (CV and PV) and Quality
Inspections.

The Company won the ''CSI Award for the Excellence in IT'' for executing
the large and complex migration of entire Manufacturing Execution
System (MES) platform in car plant.

JLR global expansion to China is being competently supported by IT
capabilities.

All Tata Motors group companies continue to work together on IT
synergies and sharing the expertise.

DIGITAL PRODUCT DEVELOPMENT SYSTEMS INITIATIVES

Product development processes continue to grow on best of the breed
tools and technology solutions, for enhancing product development
capabilities, addressing guality and speed.  Capabilities were
developed for realistic product visualization in digital platform for
product style. Bid response mechanisms for specific customers were
developed. Processes relating to early manufacturing feedback in
engineering functions were evolved with state of the art toolsets.

PLM processes continue to mature strengthening the product development
processes across the extended organization.

In-house Knowledge Based Engineering (KNEXT) applications spread
enhanced by deploying 20 new applications in various product design
functions.

Virtual validation as a strategic initiative introduced in the product
development process providing better turnaround time and understanding
of product in the field.

Tools for collaboration of engineering information across multiple work
locations, multiple geographies were developed as part of DRiVE
initiative.

Systems were developed to handle WCQ LI and other guality initiatives.

30 new applications were conceived and developed on in- house pFirst
framework to handle various cross functiona work stream delivery.

Digital Manufacturing Planning (DMP) capabilities enhanced to use
various process documents (PFD, PFMEA, CP, etc) in Pune manufacturing
location.

TECHNOLOGY AND ENVIRONMENT FRIENDLY INITIATIVES

The Tata Motors Group continues to innovate, with a view to enhance the
market share and aims at products which cater to the changing needs of
the customer for both fleet owners and individua customers. Besides new
product developments covered above, some of the key initiatives on
Environment friendly technologies include:

Fuel efficiency improvement through development of advanced driveline
oil formulation in line with previous development of engine oil only

Continuation of fuel efficiency improvement initiatives on commercial
vehicle engines through software features in engine management system
and vehicle level parameter optimization.

Downsizing of gasoline engines using pressure charging technology
(turbochargers) for Co2 reduction on passenger cars.

Designed and developed electric vehicles based on Tata Magic and Tata
Iris, which were demonstrated in Autoexpo 2014.  A fleet of small
number of demonstrator vehicles is being developed.

Start of a collaborative initiative to investigate sustainable
synthetic fuels for India and developing nations.

Designed, developed and demonstrated Hydrogen fuelled zero emission
fuel cell bus for urban transportation. Further testing is in progress.

Use of bio CNG in internal combustion engines for vehicles is under
testing.

Unveiling the latest milestone of its advanced aluminium which would be
high-strength, lightweight and the Jaguar Land Rover''s most aluminium
intensive structure to date bringing considerable benefits in terms of
dynamics, safety and efficiency.

Jaguar Land Rover introduced world''s first hybrid electric vehicle with
a diesel engine by bringing down fuel consumption to 6.41/100 km. which
only few years ago, seemed to be totally unachievable in a vehicle size
of Range Rover.

Introduction of InControl Apps in the Cars manufactured by Jaguar Land
Rover to minimize driver distractions.

Collaborative innovation through Investment in a new UK advanced
research facility, the National Automotive Innovation Centre providing
dedicated facilities for an expanded Jaguar Land Rover Advanced
Research Team.

Total Factor Productivity in Indian Companies including Tata Companies - Summary of the report