Project Report: A case study

Mr Jeff D’souza is the head of a manufacturing plant and

reports to CEO Mr Christiaan John. Mr D’souza joined this
company 3 years back and his prior experience was with an
engineering company which produced medical devices. He
was hired assuming that he will help the company to
transform, however, a very minimal growth was seen since
the time he was hired and given the role of plant head.

Mr John wants Mr D’souza to explore opportunity to reduce

the cost of inventory and processing time so that the factory
remains profitable. Mr John also wants Mr D’souza to explore
further opportunities for increasing capacity
CONTROL/CLOSURE
 Lead Time Trend After Improvements:
Lead Time Trend – Month Wise
35.0
29.8 29.5
30.0
24.9 24.3 23.7
25.0 22.3
21.0
18.8 18.9 19.4 18.4 18.3
18.0
20.0 Target: Avg. 16.0
18 Days
15.0

10.0

5.0

0.0
Month-1 Month-2 Month-3 Month-4 Month-5 Month-6 Month-7 Month-8 Month-9 Month-10 Month-11 Month-12
Jan-20 Feb-20 Mar-20 Apr-20 May-20 Jun-20 Jul-20 Aug-20 Sep-20 Oct-20 Nov-20 Dec-20 Jan-21 Feb-21

Governance Mechanism:
• Discussion With Site head on Monthly Basis for the product having lead time more than 18 days.
• Discussion with team members on Monthly basis about the Bx. Which is having OOS/OOT or any
Validation.
• Daily Tracking for Critical Product Like XYZ and PBT by Main team.

Note: The KAIZEN implemented are Poka-Yoke type.

Thanks!