Summary

Problem Statement: Our Client  manufacturing centrifugal casting had 70%-80% rejection in large casting due to Porosity issue. Company had deployed multiple avenues to reduce the rejection rate with modest improvement

Solution: We deployed First Cause-and-Effect approach and identified the defect category. Based the defect deployed the Cause-and-Effect Approach to list down all potential causes and further drilled down to using WHY-WHY analysis. Along with this we performed the literature survey to understand the physics of the centrifugal casting.

With this we parametrized the problem and identified 10-12 Factors leading to defect. Scientific evaluation and changing one Factor at a time approach helped us narrow down the root cause to one prime factors:  Heat Rejection through Mold. Tis factor was dependent upon 1: Molten Temperature of Metal 2: Mold Material.  Using Theory of Constraints  and DOE we optimized the Mold design and Molten temperature range to eliminate the issues

Summary

Problems: Our Client was selling MNC companies Software to many clients including defense clients in India. Our client did not have any process and system for lead generation to PO and hence leading to unfullied order, poor lead tracking and follow-up processes.

Estimated loss or lost opportunities due to this was RS. 1Cr per annum.

Solution: SWANHANS designed the custom Lead to Purchase order process for the client using Budget, Need, Authority, Timelines Model. This model and process ensured that only appropriate leads are perused, Process was designed to ensure that appropriate checks and balances are implemented leading to right first-time, quotation, technical demos. We also identified the appropriate roles and responsibilities for various interconnected roles increasing team work. This ensured the better Win Rate; losses were reversed to profits.

Summary

Problem Statement: A medical patholab was having significant operational inefficient leading poor financials, human resources issues, machine downtime.

Solution: Swanhans recommended and implanted ISO15189 framework. As all ISO framework are based on ISO9001 framework, they provide solid business continuity framework. We designed and developed  and implemented custom processes for overall clients’ improvements. This ensured that all employees had access to relevant policies and procedures. We also developed Statistical Process Controls or L-J charts to monitor machine maintenance and estimating future breakdown . This ensured timely maintenance and eliminated the downtimes.

Summary

Problem Statement: Our Client  was using multiple CRM systems to manage leads and Customer Database and follow on Order Management Process. Because multiple systems there was no unified data to understand Lead/opportunity Loss. There was direct cost of subscription due to multiple CRM systems.

Solution: We defined the process of Lead Generation upto Purchase Order for the client customized for them. We analyzed all the CRM system holistically like Alignment with the business process, integration with ERP, utilization of the Lead, Opportunity Data for Manufacturing, Production Planning, Dispatch and Invoicing, etc, Cost Over run, Ease of utilization. And recommended  best CRM solution.

Summary

Problem Statement: A startup engineering services organization had three needs:

• Embed organizations values driven culture across the hierarchy to ensure long term sustainability.
• Create ISO compliant and customized Performance and Competency mapping systems for its employee and their long-term growth plan 
• Reward, promote  and retain eligible employees based on objective evaluation

Solution: Swanhans conducted Voice of Customer  and discussion with various employees across the hierarchy. We captured the opinions, views  and though process across the strata of employee.  With all this information, we developed a Performance Managemnet Process and System. System was developed in MS-Excel for entire organization. System had fine balance of objective and subjective views for employee’s overall growth.  System was optimized using FMEA principal to eliminate identified potential failures. Solutions was outcome of Creative  and Innovative approach

Summary

Problem Statement:

FMEA is a critical tool for any product development and process  improvement for engineering companies. The FMEA is a tool which helps in identifying potential failure modes and cause so that organizations can take proactive improvement. The FMEA is done using excel tool, however it is not intuitive tool leading poor utilization of the concept. Thus, organizations can have severe impact due to lost opportunity to eliminate the problem

Solution:

Provided Consultancy to Industry4.0 Product company to develop an intuitive FMEA Tool, which has simple, probing interface. Using the concepts of mind map, circular representations and meaningful, guided question, entire FMEA exercise is converted into creative thinking exercise.

The tool has all elements as per AIAG FMEA and AIAG VDA FMEA format and required report s as per required standard are possible with single click

Summary

Problem Statement:

Chartered Accountancy Firms cater to multiple clients with various services  as apart of statutory and advisory in nature. Typically, CA and senior Partners manage multiple employees . They need appropriate end-end monitoring system

Solution:

Developed a Robust Erp called CA-MITRA for managing Customer, Employee, Work Module with integrated Task Management and repeat allocation.

Incorporated Systems Thinking Approach to consider er Voices of Employees, Senior Partners, Customers, Technology, Statutory Rules and conditions.

Incorporated Design Thinking principle to have simple and easy to use interface for all employees

Outcome or Benefits:  Unified Control and Data center, effective monitoring of Employee and work load management. Always on time delivery, Intuitive Dashboard  and drill downs for Senior Partners to help Business expansion.

Summary

Problem Statement: A large MNC firm identified that employees Reward and Recognition was having poor feedback and needed improvement.

Solution: Swanhans conducted the sample-based survey and discussions with 100 + employees and captured the baseline score, pain points. Based on the inputs, pain point, new reward and recognition process was designed, piloted.  The new process was made employee centric and open to all employees with simple rules to filter non-eligible. Since the process owns transparent employees embraced the process leading to success. We also delegated the approval process and reduced the approval flow to ensure efficient and timely recognition. Since entire process was rule based and transparent  employee satisfaction score improved from 4.5 to 8

Summary

Problem Statement: Our Client  manufactures 1000+ mechanical components and caters to 100+ customers in India and International Markets. Their current approach was today-to-day manage the orders.  This approach led to delayed order supply.

Solution: For large customer base we need to have Robust Operations Planning process and System. We followed First principal-based Approach to develop an Excel based system. We modelled for each part cycle time for all critical process like MFG, Logistics, Quality, packaging. We measured and identified cycle time and units in a shift.  With this base, we integrated the MKT and Sales team Order book with the PPC Team. We have also mapped the Resources( Human and Machine) and their calendar to ensure availability map.  OPC team needs to spend1-hour to collect the data from MKT, Sales, MFG, Quality, Logistics to enter current process and our scheduler provides the estimated delivery date.

OPC can prioritize the schedule to ensure business strategy and our system provides optimum solution to achieve it.