• Line stoppages were high leading to throughput drop and hence lost sales
• First pass yield was low contributing to throughput reduction.
• Increasing trends of FG and WIP inventories
• Leadership vision of a lean and visual factory prepared for the future growth

ECS Approach:

• Lean Manufacturing with TPM for basic stability and Six Sigma for radical improvement
• Value stream mapped for different product categories
• 12 Product teams, 26 Operating teams trained and deployed for daily management based on Lean, 5S and TPM principles
• Six Sigma Projects undertaken in the areas of First Pass yield improvement, Inventory reduction.

Results: