Industrial Engineering Services (IES)
URS has developed a proven mechanism for productivity improvement through Industrial Engineering Techniques. Techniques supported are - Methods and Value Engineering , Lean , Business Process Management ,Operations Research and TPM/TQM.
The Need:
Cost of Production - COP is a key parameter that impacts the operating Profit of and manufacturing organization. This COP is important for the organization to be competitive and to have sustainable business growth. Shop floor productivity is the focal point for improving the COP and the key to improving productivity is in ELIMINATION OF WASTE. The real job of eliminating the waste lies in identifying the waste.
Objective of The Service:
To improve productivity and reduce cost in the operation management
Structured frame work for productivity improvement, implementation and monitoring
Focus on systematic identification of waste
Provide tools for improvement
Provide tools for monitoring performance
Methodology
Productivity - Diagnosis:
Diagnostic study and Establish Baseline
Productivity Improvement Framework
Project Selection Criteria
Productivity - Record:
Flow Process Sheets
Work Measurement
Productivity - Analysis:
Definition and classification of wastes
Identification of wastes based on - Method Study / MUDA / TPM-7 / TPM-16
Assessment of Impact of waste
Identify Gaps
Productivity - Redesign for Improvement:
Tools for Improvement
Principles of Work redesign
Performance Management
Objective of The Service:
Work Design Documentation
Monitoring Plan
Monitoring Parameters
Productivity Monitoring Reporting
The Need:
For and organization to have sustainable growth, the value addition by the company has consistent with employee cost. In other the value addition by the employee has to be progressive. A sound performance management system is the key here, to ensure that composite contribution of all the employees is will aligned with the organization goals.
Objective of The Service:
To improve overall organization growth
To Improve performance efficiency of departments and Individuals
To improve value addition per Employee
Methodology
Performance Planning(P):
Top management deriver for organizational goals
Alignment of Organization Policy with Vision of the organization
Departmental goals and objective aligned with organizational goals
Alignment of Objectives with policy
Establish Performance Measures
Alignment of performance measures with Objectives
Departmental KPIS covering QCD
Performance – Execution (D):
Review and run departmental processes
Control Inputs
Control Processes
Control Outputs
Set Targets for KPIs
Performance Review (C):
Measure KPIs
Measure Progress against action plan
Performance Improvement:
Departmental initiatives and Action Plan
Individual initiatives and Action Plan
The Need:
Organizations that are in known low efficiency level , need radical tools transform into higher efficiency levels. Lean Manufacturing or Lean Services , is an operation management philosophy which shortens the time line between the customer order and the product shipment by eliminating waste or Non Value Added operations in a production line(NVAs).Organizations that are in known low efficiency level , need radical tools transform into higher efficiency levels. Lean Manufacturing or Lean Services , is an operation management philosophy which shortens the time line between the customer order and the product shipment by eliminating waste or Non Value Added operations in a production line(NVAs).
Objective of The Service:
Increase Productivity by 50%
Increase capacity / throughput - Can possibly reduce lead time by more than 50 %
Higher inventory turns - Reduce inventory by more than by 50%
Align production plan with customer schedule
More available floor space - Reduce floor space by 25%
Improved workplace organization
Improved quality: reduced scrap / re-work by more than 20%
Reduced inventories: Raw, WIP, Finished Goods - Reduce WIP more than 50%
Reduce Set Ups
Reduced lead times
Greater gross margin
Improved participation & morale
Methodology
Standardized Factory
5-S
Balanced Work Flow through cell Manufacturing
TAKT Control: ( Production Rate based on customer)
Value Stream Mapping
Value Analysis - Value Added Operation / Non Value added Operations
Continuous Improvement - Kaizen
Quick Chang Over ( QCE)
Visual factory
Error - Proofing ( POKA - YOKE)
Manufacturing Process Analysis
Line Balancing Analysis
Multi Skilling Analysis
Cell Design - Process Sheet
Material Flow Design For Cell
Organization structure Cell
Information System Design for Cell
Training and Empowerment of Team
The Need:
Effectiveness of Business Processes is key for competitiveness for organizations both in manufacturing and service industry. With automation tools available aplenty, automation of wring processes is going to put organizations far behind. Improving the processes to reach the customers faster, at a lower cost, keeping up the good quality is the key for the sustainable growth of the organization. Organizational process focus and continuous improvement of the processes has to be practiced organization wide. This is to be enabled through tools like business excellence assessment. This will give the cutting edge for the organization, in terms of sound processes, competitiveness and sustainability.
Objective of The Service:
Business Process Management, will aim to make organizational processes more effective in terms of quality, cost, response time , flexibility.
Improve Performance Efficiency
Improve Compliance
Improve Quality
Improve responsiveness to customers and markets
Integration with IT and Operations
Integration with suppliers and customers
Methodology
Process Mapping:
Process understanding
Process Architecture
Process Mapping
BPR PLANNING - PRP:
Strategic Planning
Organizational Change Management
BPR-Team Building
Current Business Status
Identity Process
Develop Action Plan
Process Analysis:
Qualitative Analysis - Value Added Analysis / Waste Analysis / Root Cause Analysis
Quantitative Analysis - Process Metrics - Time ,Cost ,delivery / Flow Analysis / Process Simulation
Process Redesign:
Approach For Redesign
Transformational Redesign - Business Process Reengineering /TRIZ
Transactional Redesign -
Transformational Redesign - Optimize Process Elements / Process Flow elements / Optimize overall process /TRIZ
Process automation
Process Implementation Monitoring:
Process Documentation
Monitoring Plan
Big data
Process Monitoring and controlling
The Need:
Organizations, which are in growth phase, have to look beyond the efficiency of the processes in to the effectiveness of the processes and business excellence. TPM and TQM are powerful Strategic operation management tools that focus on long-term sustainable business growth with wider perspectives such as market share and customer satisfaction.
Objective of The Service:
To provide long term hand holding support to organizations to implement TPM / TQM concepts to ensure organization wide sustainable productivity drive looking at total productivity aspect such as P-Q-C-D-S-M Productivity, Quality, Cost, Delivery, Safety and Motivation, to be evidenced in the following.
Reduction of Customer Complaints
Reduction in Cost of Quality
Reduction in Cost of Product
Improved Market Share
Improved Productivity
Total Employee Involvement
Up gradation of ISO Systems
Methodology
Strategy Development - Vision, Mission
Business Plan
TPM / TQM Goals and Objective
Establishing TPM / TQM Pillars
Formation of TPM /TQM teams and integrating with functional teams
Waste Identification Training and Implementation
Kobestu Kaizen Training and Implementation
Quality Maintenance training and Implementation
Establish and Monitor the right Productivity Metrics
Employee Engagement Activities
Hand Holding for Daily Routine Managements
Productivity and Quality Improvement Projects ( Kaizen)
