• Slowdown in improvement of key parameters
• No structured approach to problem solving
• Consumption of raw materials, resource utilisation, reliability and availability of lines were concern areas

ECS Approach:

• Six Sigma was used as a top-down initiative to drive breakthrough improvements in key value drivers
• Principles of Asset Management using TPM were imparted to over 900 employees in manufacturing
• All employees involved in the initiative to achieve visible results

Results:

• USD 0.5 million of benefit accrued within 6 months
• Overall annualised potential benefit at the end of the engagement pegged at USD 1.6 million
• 11 Six Sigma projects successfully completed within 6 months at 2 plants
• Zinc consumption reduced by 2-6 grams per sq. metre in different galvanising lines
• Power consumption reduced by 3.8-5.8 KWH/MT in 3 cold rolling lines
• Prime yield improved by 1-4% in 4 months
• Inventory holding reduced from 57 days of consumption to 44 day