Beruflich Dokumente
Kultur Dokumente
Identifying and
providing
Real Value
in a
changing world
CONSULTING
TRAINING COACHING
ABOUT JR VICTOR…
J. Ramesh Victor
(Lean Master & Certified Innovation Practitioner)
Solutions Provided:
• Lean manufacturing Consulting & Training
• Toyota Kata- Creating a Kaizen Habit and also
Breakthrough Improvements
• Hoshin Kanri – Policy Deployment and strategic planning
• Toyota Kaizen methodology – Eliminating MUDA (Waste);
MURA (Unevenness); MURI (Overburden)
• Seven Principles of Toyota Production System – The DNA
for sustainable operational improvement culture
• Genchi Gembutsu Practices- Shop-floor systems for
operational excellence
Imparting knowledge and coaching
improvement-teams right at the shop-floor on above methodology
500 persons certified as Lean Masters since 2002. Many have been
elevated to top positions such as MD or GM
Solutions using Training Within Industry (TWI)
HANDS-ON
ALL THE
DAYS
Monitor implementation
Deep Diving into operations: and make changes if
• Immediate actions to stop necessary
operational problems/constraint
• Constraint management activity • Measure results, assess
done and team learn skills to do so and rectify risks and plan
for full implementation
START SEING RESULTS WITHIN
TWO TO THREE WEEKS
Training In A Pragmatic Manner
Company names have not been disclosed due to professional confidentiality code of the consulting profession
SELECTED SUCCESS CASE STUDIES
COMPANY THE CHALLENGE INVOLVEMENT OUTCOME
(Type & Location)
Large Steel Manufacturer, • No continuous improvement Conducted training on Lean • Total savings from four
Malaysia culture in factory skills. projects is
• Badly maintained equipment Hand-holding and coaching of • Spare part holding reduced
• Very High spare part stock four projects for 6 months at by 30%
holding shop-floor. • RM3,900,000
MNC Fibre Optic module • High Inventory Holding Conducted training on Lean for • Total projects savings
manufacturer, Malaysia • Long Machine Setup Time 1 year (several groups in RM17,000,000
• Necessity to establish skills for stages. • Won several NPC awards at
key operational staff on Lean Coaching at shop-floor for Regional & National Level
project teams. through Lean projects
Established a Lean system for
the organization
Steel Manufacturer in • No Problem formal problem Engaged in 6 months training, • Reduced down Time 20%
Malaysia solving skills in place consulting and coaching on • Reduced Spare Part holding
• High Waste and Downtime Lean methodologies and hand Cost
held four pilot project teams • Improved Yield by 2%
RM3,000,000
Company names have not been disclosed due to professional confidentiality code of the consulting profession
SELECTED SUCCESS CASE STUDIES
COMPANY THE CHALLENGE INVOLVEMENT OUTCOME
(Type & Location)
Medium Size MNC Filter • Long Lead Time Conducted Value Stream • Order processing Lead
manufacturer • High Machine downtime mapping and diagnostics. Time reduced from average
• Bad work place organization (5S) Coaching and mentoring on 14 days to average 2 days
projects at shop-floor for 12 • Equipment setup time
months reduced by 50%
Fortune 500 MNC • Long supply chain Lead Time Transformation using Lean • 114% Inventory Turn
• Necessity to improve time to methodologies and Innovation improvement
market throughout the supply chain • 500% productivity
• High inventory throughout improvement (prod. per
supply chain headcount)
• 20% increase in market
share
Hospital, Malaysia • Mistakes in hospital processes Skills transfer on Kaizen and • Reduced audit failures to
and audit failures Error Proofing techniques zero
• Customer complaints due to • Reduced customer
mistakes at various department complaints by 50%
Company names have not been disclosed due to professional confidentiality code of the consulting profession
“ ...Ramesh Victor has demonstrated the ability of going into problem factories, and quickly
turn around their manufacturing operations. Approximately 7 people in the whole of
Seagate 45,000 possessed this skill set ”
Richard C. Craven B.Eng, MSc, MBA, CEng, MIMechE
Seagate Supplier Lean Head for Europe & Asia
“Utterly fantastic...without lean implementation at...we would not have met the Barracuda ATA- IV schedules”
Matt Johnen. VP Asia Materials (Seagate)
“ Lean Manufacturing in general opinion is too BIG and difficult to be achieved. But with Ramesh Victor as our trainer/consultant
Lean has become easily understood by Belton candidates of all levels. Lean has become applicable in Belton”
Pongyut, Director of Engineering
Belton Industrial, Thailand
“….result is...very ordinary people here ( Production Supervisors, Engineers), moving on very ordinary projects ( Poka--yoke, UPH
improvement, Kanban system, etc) for some VERY extra-ordinary results. I am very pleased that so much dollars and cents has
been saved with a lot of simple, sensible and stellar projects.
Keep up the good work and I am so proud with all of you.”
Comment of Managing Director of Finisar to
AMC Lean Master Candidates
“we find your training and coaching sessions informative, practical and professionally
delivered. The choice to go wide to give the big picture before drilling down to select areas
delivering highest business impact, is a strategy that serves us well…Besides an average of
30 to 40 percent improvement in set up time…, cycle time improvement from 6.5 to 4.2
days…we are also pleased to see a reduction in critical defects...
SW Woo, COO
Carsem M Sdn Bhd.
“ Lean Manufacturing came at the right time to save millions of dollars for us in capital avoidance…”
Michael, Lean/Engineering Manager
MSP, Ipoh (NSK Group)
“ Lean Manufacturing is an effective tool to reduce wastage, optimize capacities & reduce costs….AMC’s course led by
Ramesh Victor taught us the effectiveness of various Lean Tools….The course is very interactive and the simulation games
are very interesting. The course instructors use their extensive industrial experience to elaborate important points and
make participants understand the key points”
Roger Goh, Vice President
Beyonics Precision, Johore Bahru
“Very good projects and excellent savings, nothing should stop us from standardizing these actions across the floor
immediately ..”
Innovex Thailand, VP of Quality
and Operations
One or more of services has been rendered to:
Taiwan Thailand
➢ Ambit ➢ Minebea (NMB)
➢ Nanotech ➢ Innovex
➢ Belton
China ➢ Beyonics
➢ Seksun, Suzhou ➢ Compart
➢ MMI, Wuxi ➢ Fabrinet
➢ Belton, Shenzhen ➢ Agere
➢ Belton, Wuxi ➢ Magnecomp
➢ Compart Singapore
➢ Magnecomp ➢ Seksun Corp
➢ Optimal ➢ Philips (Alliance with Gemba USA)
➢ Snap On
➢ Broadway Shanghai India
Indonesia ➢ Public seminars for various clients
➢ Philips (Alliance with Gemba USA) ➢ Royal Enfield
➢ Titan (Tata Group)
Others / global ➢ Trident
➢ Seagate Technologies
Japan
➢ Furukawa
HAVE SUCCESSFULLY HELPED COMPANIES IN THEIR JOURNEY OF OPERATIONAL EXCELLENCE
SINCE 1999
WE HAVE THE EXPERTISE: CLIENTS PAST SAVINGS EXCEED USD 390,000,000
FOCUS ON RESULTS & TRANSFORMATION: HAVE DONE IT BEFORE…!
Have helped clients achieve savings of more than USD 390,000,000. Can help you achieve your
Goals towards establishing a culture of operational excellence…
www.innovare-sol.com