K. Girdharlal International Ltd., India a DTCs Sightholder and a leading diamond
Company is transforming itself by adopting lean manufacturing, the Japanese
technique for improving the efficiency and effectiveness of manufacturing
practices and operation. The group employs more than 2000 people at its
factory in Surat, India. Over the period of last 2 decades, the group has been
consistently innovating processes to manufacture high quality diamonds. As part
of that, the Group has initiated to develop the culture of continual
improvement across the organization through implementation of lean tools
commensurate with TPS (Toyota Production System) philosophy. This has been
pursued through participation in Government of India (GOI) sponsored scheme
under the guidance of RSM Astute Consulting (Astute) being an empanelled Lean
Manufacturing Consultant as per the scheme.
Project started with definition of milestones to
derive tangible results in terms of productivity improvement, reduction in
production cycle time, increase in process wise throughput through elimination
of 7 types of wastes namely Transportation, Motion, Waiting, Overproduction,
Inventory, Defects and Unused Creativity of People. During the first phase
of the project, considerable benefits have been derived in terms of
reduction in process cycle time, increase in productivity of machine/ people,
increase in throughput of process/department, better workplace management and
effective communication across the production shop floor. This has been pursued
with the help of lean tools viz. 5S, Visual Controls, Kaizen, Value Stream
Mapping, Standardized Work Practices and Mistake Proofing. The process of lean
implementation also encompasses culture of continuous improvement, awareness
amongst the people to seek for the root cause of the problem areas with the
help of problem solving tools and improved motivation and morale amongst team.
The journey of lean transformation is still being pursued through active
involvement.
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