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