34 Years · 6 Industries · Hands-On Implementation
Lean and TPM consulting grounded in 34 years of direct manufacturing experience — from shop floor operations to business leadership. Implementation that sustains because it is built with your team, not handed to them.
Career Impact — Selected Highlights
₹60L saving (2006)
75% output increase — Batch to Single Piece Flow
100% productivity improvement — Medical fabrication
22 → 3 dust defects per bumper · Automotive paint shop
JIPM TPM Excellence Award — Japan Institute audited
India's largest plastic paint shop — installed and proved out
Where We Add Value
01
When the line is running but the numbers are not meeting plan — and the root cause is not visible from production reports alone. Material flow and information flow assessed together to locate exactly where the time is going.
02
When machines are running and people are working yet orders ship late. The delay is often upstream of the production floor — in scheduling, material release, or design change communication — not where it appears to be.
03
When the same defect reappears after every corrective action. The question is how fast a rejection at the inspection point reaches the producing station — and whether the correction happens within the same shift or the next day.
04
When machines appear available but output is still short of target. OEE disaggregated into availability, performance and quality losses to identify whether the real constraint is equipment, method or information.
05
When a previous improvement showed results for 2–3 months and then reverted to the original state. Sustaining an improvement requires the team to own it — standard work, measurement and internal capability are what determine whether it holds.
06
When the business does not know its Value-Added Ratio — the proportion of total lead time where actual work is happening. In most manufacturing operations this number is below 10%. Knowing it changes where improvement effort is directed.
Our Approach
Your operators and engineers are the domain experts. The person who has stood at that station for five years knows things no outside consultant ever will. The engagement works because we listen first — and give that knowledge a framework to become visible, measurable and improvable. 34 years across tool room, maintenance, industrial engineering, paint shop and business leadership means we know the right questions to ask.
Experience Span — Every Function Covered
Track Record
Numbers without context are not evidence. Each result below includes the situation and the method used.
Vitalcore Industrials · Chennai
Ceiling fan controller output from 8,500 to 11,500 units/day through Value Stream Engineering and line rebalancing. Customer demand fully met.
VSE + CT Study + Line Balance
Phoenix Medical Systems · Pondicherry
Fabrication productivity doubled. All outsourced operations brought in-house in 3 months. Loss-making product converted to profitable.
Business Head — Full P&L accountability
MATE — Maruti & Ford · Tapukara
Dust defects per bumper reduced from 22 to 3. India's largest plastic paint shop installed and proved out on schedule.
Dust VRT + 4M Standardisation
The Supreme Industries · Pondicherry
Cushion assembly from 530 to 950 units/day through batch-to-Single-Piece-Flow conversion. TPM Excellence Award — JIPM audited.
SPF Conversion + Robotic Paint Shop
Whirlpool of India · Pondicherry
Saved per year through assembly line consolidation in 2006 — equivalent to over ₹2 Crore at today's value. Changeover: 90 → 18 minutes.
SMED + Line Consolidation · 2006
Bright Brothers · Pondicherry
Paint shop capacity from 280 to 460 parts/shift. First Time Through improved from 45% to 70% within one year.
Layout Redesign + Equipment Upgrade
Featured Programme
10–15% output increase. Zero capital investment. Your team implements the improvement on your floor — with their own hands. The result is theirs to keep.
"The shop floor operator is the domain expert. The consultant provides the framework. When both work together — the solution lasts."
Featured Programme · Zero Investment
Your team finds the gap. Your team fixes the gap. The shop floor operator is the domain expert — not the consultant. 10–15% output increase. Zero capital investment. The improvement belongs to your team — permanently.
Engagement Types
Every engagement begins with understanding the specific situation. The scope is defined by what the organisation needs — not a fixed package.
Comprehensive
Full Lean and TPM implementation alongside your team. Both production flow and information flow addressed. Internal capability built. Measurement system established and running before the engagement closes.
3 – 12 Months · On-siteDiagnostic
Value Stream Map of current state with Value-Added Ratio calculated. Both material and information flow assessed. Prioritised improvement roadmap delivered — zero-investment opportunities identified first.
2 – 5 Days · On-siteFocused
Targeted at one defined and measurable problem — output shortfall, recurring defects, paint shop yield, OEE gap, changeover time. Scoped to the specific area with results measurable within the engagement period.
2 – 8 Weeks · On-siteServices
Implementation — Larger Time Frame
3 to 12 months | Comprehensive engagement
Awareness — Shorter Time Frame
1 to 3 days | Focused sessions
Organisations we have worked with · Automotive · Electronics · Medical · Consumer Goods · Fabrication
Enquire
We work with manufacturing organisations where the MD, Plant Head or VP Operations has a defined performance gap and wants an engagement that delivers measurable results — not just a report.