Make to Order type plant. Catering to high specialized products made for different customers. Optical measurement systems are designed as per customer requirements. Plant never maintained any standard approach for codification. This lead to major issue in managing the spare parts and stoke management etc.

We designed a complete store system for the Optical Quality Testing Machine Manufacturing unit in Hyderabad. It is made to order type system and their clients are ISRO and Top pharma companies in India.

We studied the procurement process to understand their stores and store management. These products are highly customized as per the requirements of different clients. Part of our study, we documented the entire product development process, procurement process and assembly process.We streamlined the entire store store system through coding the components and created the foundation for IT systems.

Completing TS16949 certification for entire engine plant is really challenging. Designing offshore working model to reduce the cost of the project is big challenge.

We handled the TS16949 complete documentation work for the engine plant of a leading earth moving equipment manufacturing company. We completed almost all of the 6000 assembly operations of the 1.8 KM engine assembly line with control plans in less than 18 month time.

This work includes, as is study, control plan preparations and correcting the time standards for the operations, line balancing etc. To execute this project, we used an offshore and onsite model to reduce the cost of certification. We were able to complete the project in record time and most cost effectively. Client was satisfied with the work and was able to get TS16949 certification in record time.

The client wanted to reduce paper work related to engineering change management and make an error proof system in the engine assembly line. Also the sequence of the operations in assembly operations were not followed and leading to defect products in the assembly line.

To improve the productivity of assembly operators and improve line efficiency, the paperless factory concept was introduced. The assembly operations related to the particular station are to appear just before the engine reaches the station, with details such as parts, part numbers and subassemblies etc. To make workers understand the sequence easily, the animated color graphics appear on the station screen to show complete assembly operation.

We conduct energy audits for SMEs to understand the energy consumption patterns. Our technical team visits the client factory location to understand the feasibility of rooftop solar and studies local weather conditions and estimates rooftop solar capacity. Prepares technical feasibility report with economic viability and presents to top management of the company.

IPQC with support of Solar panel manufacturers, best options such as Net metering, solar park and mix of solar options presented to the client and presents the final project plan to the Management team and makes necessary changes in the project. Cost benefit analysis presented to the decision making body with all available options.

Our team studied the demand pattern across different regions in the country for rice harvesters. Part of our work was to study the demand patterns across the country and across different seasons and come up with better demand forecasting models for different regions. Use the appropriate demand forecasting model to reduce the variation in actual demand and forecasted numbers.

We build a model to improve the accuracy of the demand forecasting model. Also we studied their network of plants, central warehouses and regional warehouses etc.