Innovation@

Innovation

Innovators
Photo

Prashant Shah

Innovators
Photo

Amol Lahoti

Poonam Bhalla

My way of Life.

Niraj Kumar

Challenge : Reduction in Carbon foot print & conservation of resources in Supply

Chain Management
Benefit : Increase in effectiveness & streamline the Supply Chain led to reduction in
GHG generation by 85 MT/Year of CO2 & reduction of Rs. 20 million worth Inventory
Why this Challenge :
High transportation cost & wastages of resources
To reduce unwanted flow of material
Reduction in Inventories
Customer dissatisfaction due to longer response time
To reduce manufacturing cost

Innovation@

Innovation

Successful implementation of this project led to reduction in GHG emission of 85 MT

of CO2 & saving of Rs. 3 million in resources

Total Ideas Generated : 32

SL
No

Solid Ideas

My way of Life.

Solid Ideas implemented : 4

Target
Date

Target
Date

Proto

Final

Benefit Nov14

Cumulative
Benefit Mar15
INR Mil

May14

Reduction in CO2
generation by 57
MT

Reduction in CO2
generation by
125 MT

Reduction of 28
Rs. 20 Million in
Inventory

Reduction of Rs.
25 Million in
Inventory

Streamlining the material movements among

plants by shifting manufacturing line near to
Customer

More value addition at Suppliers end to supply

ready to use parts

Oct13

Oct14

Supplier consolidation to reduce complexity in

Supply Chain Management

June13

Mar14

Educating & implementing lean tool to reduce

non value added activities at suppliers end VSME

April13

Nov14

Dec13

Cumulative

386 Nos.

308 Nos.

56 Nos.

Innovation@

Innovation

Solid Idea 1 - Streamlining the material movements among plants by shifting

manufacturing line near to Customer

My way of Life.

After

01-01-2014
Present Condition :

All suppliers used to supply materials to Hosur then

finished product were sent to customers at Gurgaon.

Innovated :

We shifted manufacturing line to location near to

customers at Gurgaon led to reduction of
materials movements by 15000 KM/month

This led to reduction in consumption of 36,000

Liters of Diesel01-06-2014
per annum

We reduced carbon footprint of 97 MT of CO2 per

annum

Impact : Implementation of this idea led to reduction in carbon foot print of 97 MT of CO2 per annum thus we
achieved our vision to protect our mother nature while producing best quality products for our customers.
3

Innovation@

Innovation

Solid Idea 2 - More value addition at Suppliers end to supply ready to use parts

Before
Present Condition :

Due to multiple to & fro movements among plant &

Vendors for parts manufacturing, total distance
travelled till parts get converted to finished good
was very high

Due to high material movement, we consumed more

fossil fuels and thus producing more GHG emission

My way of Life.

After
Innovated :

After developing vendors for multiple job &

streamlining the materials movement total distance
travelled was reduced by 5000 KM/month

This led to reduction in consumption of 12,000

Liters of Diesel per annum

We reduced carbon footprint of 28 MT of CO2 per

annum

Impact : Implementation of this idea led to reduction in carbon foot print of 28 MT of CO2 per annum.
4

Innovation@

Innovation

Solid Idea 2 - More value addition at Suppliers end to supply ready to use parts

Before
Present Condition :

Total Inventory = Inventory at vendors + Inventory at Plant +

transit inventory (Among plants & Vendors)

This led to more shrinkage, pilferage & damage during

material movements

My way of Life.

After
Innovated :

Total Inventory = Inventory at Plant

This led to increase in efficiency in supply chain

Total Inventory reduction = Rs. 2 Crore was achieved after

completing this project

Saving Annualized = Reduction in Rs. 2 Crore of Inventory = Rs. 3 million annual saving for company

Innovation@

Innovation

Solid Idea 3 - Supplier consolidation to reduce complexity in Supply Chain Management

My way of Life.

Before
Present Condition :

It took lot of process activities & time from

converting raw materials to finished good at
different vendors that led to poor response to our
customers & inefficient supply chain management.

After
Innovated :

Aggregation of many process at one vendors that

is near to customer end led to just in time &
highly efficient supply chain management

Empowering vendors to do more value addition activities at their end led to increase in
efficiency & response time to meet customers requirement.
Impact= Reduction in our response time to customers led to more customer satisfaction and
confidence buildup among us and our esteemed customers.
6

Innovation@

Innovation

Solid Idea 4 - Educating & implementing lean tool to reduce non value added activities at
suppliers end - VSME

Before
Present Condition :
There was hardly any collaboration with
Vendors on new ideas
More wastage & defect due to no
awareness about lean tools.

My way of Life.

After
Innovated :
Collaboration with vendors on lean ideas, received
from tier 2 & 3 suppliers
Consumption based delivery schedule to Vendors
5S implementation to all small suppliers
Effective space utilization by improved layout

Impact= It creates the culture of innovation among tier 2 & tier3 suppliers that led to better product
quality & more customer satisfaction
7