Engineered for Excellence
Tech Expansion
Client
GreenTech Manufacturing
Service
Eco-Industrial Solutions
Date
December 2024
— The Idea
Objective
The main goal of this project was to analyze, improve, and optimize our manufacturing processes to enhance productivity, reduce waste, lower costs, and improve product consistency across all units. We focused on adopting lean manufacturing principles, applying automation where necessary, and streamlining workflows for sustainable operations.
— Powering Production
Process Mapping & Analysis
We conducted a thorough process mapping of the factory using tools such as: Value Stream Mapping (VSM) Time & Motion Studies Root Cause Analysis (RCA) Each step in the production line was mapped from raw material intake to final packaging. Time and motion studies revealed bottlenecks in packaging and assembly lines. Root cause analysis helped uncover that unbalanced workload distribution and frequent equipment downtimes were the main issues affecting throughput.
— Precision in Motion
Lean Implementation
We applied Lean principles to eliminate non-value-adding steps. Key actions included: 5S System Implementation (Sort, Set in order, Shine, Standardize, Sustain) Kaizen Events for continuous improvement Setup Time Reduction through SMED (Single Minute Exchange of Dies) By reorganizing workspaces and reducing time lost during machine setup and changeovers, we achieved a 17% improvement in overall equipment efficiency (OEE). Kaizen events empowered our operators to suggest and implement small changes with big impacts.
— Innovation in Action
Automation & Digital Monitoring
We introduced partial automation in material handling and real-time monitoring tools: Automated Guided Vehicles (AGVs) for internal logistics SCADA Systems for real-time production monitoring Sensor-Based Alerts for machine anomalies AGVs reduced human labor requirements and increased transport speed within the facility. SCADA helped in collecting live data from machines, improving decision-making and maintenance planning. Downtime notifications via sensors minimized unexpected halts.
Voices of Satisfied Clients
Hear from our satisfied clients about our factory’s quality, reliability, and exceptional service standards.
