IMPLEMENTATION OF LEAN

CONCEPT IN NOVATEX LIMITED

PROJECT SUPERVISOR : DR.ZAHOOR UL HUSSAIN
AWAN

PRESENTED BY: ROOSHAN AHMED

ROLL # CH-113
PRESENTATION FLOW
• Project Brief
1
• Research Methodology
2
• Lean on People
3
• Lean on Industry
4
• Recommendations
5
• Time Line
6
PROJECT BRIEF
Project Scope
Objective:
To provide a framework for the implementation of
Lean management principles and the relevant tools in
Novatex limited.
To outline and analyze the procedures and practices
currently being carried out at the organization and
compare these with what is happening in the industry
Problem Statement:
To eliminate waste and wasteful activities.
RESEARCH METHODOLOGY
RESEARCH DESIGN
Secondary Research:
Secondary research includes material from academia
and lean practiced books/ Journals
Primary Research:
 Primary research involves interviews, survey
questionnaires and lean Scorecards
RESEARCH METHODOLOGY
Analysis of Tools & Techniques
Application of tools and techniques consist of two
phases: Lean on People and Lean on Industry
In the lean on People, interviews are conducted to
identify waste areas which are resolved by newly
created PSI Technique.
In the Lean on Industry, Kaizen, work standardization,
VSM (value stream mapping), KPI and root cause
analysis method and other newly introduced methods
are used to solve the identified problems
Lean Implementation is intended for two divisions

Lean

Industr
People
y
1 – Lean On People

Lean

Industr
People
y
Lean On People – PSI Technique

Implemen
Prioritize t

P S
Set in Order
I
Rundown of PSI Technique
PRIORITZE:
Select the foremost prioritize task from the list of
Activities, priority task should have the most impact if
not selected first. Label it “P”

SET IN ORDER:
Select the activity, that is interconnected to “P”. If two
or more activities are interconnected, then select the
one which has the shortest completion time. Label the
series from S1 and so on
IMPLEMENT:
Align P1 and S- Series in order, calculate the time,
compare with the existing series of activities and
implement.
CASE A : Electrical Engineer

Before PSI vs After PSI

CASE B : Process Engineer

Before PSI vs After PSI

CASE C : DCS Engineer
(Operations)
Before PSI vs After PSI
1 – Lean On Industry

Lean

People Industr
y
Survey
face to face interview sessions and data is collected
through surveys to figure out nonvalue adding areas
which bagged waste in the form of time and energy.

Total 7 sections including 28 questions were created.

Link for survey:
https://docs.google.com/forms/d/e/1FAIpQLSfNtehj-3i5GHC3FFNRe
DLjOeW1qQWvCghgQiiBJknDJzfAMg/viewform

After critical analysis a remedy was proposed to

eliminate this non-value addition items by using
techniques in different and unique manner
No. Category Maximum No. of Questions Perfect Responses Score

1 PERSONNEL & LEAN TRAINING 100 4 2 50

2 ORDER FULFILLMENT 100 4 4 100
3 PLANT LAYOUT & SCHEDULING 100 4 3 75
4 PROCESSES & OPERATIONS 100 4 4 100
5 SAFETY IMPLEMENTATION 100 4 1 25
6 Quality 100 4 3 75
7 Downtime & Preventive Maintenance 100 4 4 100

1
100
80
7 60 2

40
20
0 Score %
6 3

5 4
Value Stream Mapping for
VSM is used by the managers and field engineers to
understand the flow of operations and then identify the
Muda in between
It is important to understand the current practices by
mapping the current state and the way the current state
influences the present state of processes.
After analyzing the current state processes, a well-
structured approach is used to get the improved, refine
and in efficacious future state of the processes.
Work Standardization
Visualized/ Pictorial SOP’s for workers, operators and
trainee engineers in order to facilitate staff for process
operations by giving lean training to employees

Effective and weekly training (based on videos and

interactive activities) on lean implementation/
principle and for the creation of lean culture/ mindset
with the organization in turn create overall value for
the whole organization.
Work Standardization
Total 70 number of pictorial SOP’s were formulated.
Sample pictorial SOP is attached below for
understanding
Pictorial SOP
Kaizen
Kaizen is small incremental changes made for
improving productivity and minimizing waste.

VSM audit will help generate kaizen for Novatex

Limited

Implementation with timeline is suggested

Root Cause Analysis
Focus on root cause fixing

No shortcuts

Tools: 5 Y’s and 6 M’s (Man, Machine, Material,

Method, Measurement, Mother Nature)
Novatex Example for 5 Y’s
Conveying Air Filter Chocked?

Why? Filter was not clean as per monthly schedule

Why? Discharge valve was passing
Why? Broken because of mishandling of operator/Use
of F-key
Why? Because he was not properly trained
Why? No training schedule for newly appointed
operator
Recommendations and Financial
Implications
Solutions are recommended which would enhance
reduction of waste efficiency
Recommendations are given to improve the most
relevant KPIs
 Financial implications of the recommendations is
provided to understand quantitative benefits
Roadmap for implementation of recommendations:
tasks, duties, responsibilities, cost & timelines is
shared
References
 Buehlmann and Christian F. Fricke (2016) Benefits of Lean transformation
efforts in small- and medium sized enterprises
 Wilfred H. Knol, Jannes Slomp (2018) The relative importance of
improvement routines for implementing lean practices
Saumyaranjan Sahoo (2019). Assessing lean implementation and benefits
within Indian automotive component manufacturing SMEs.
Wilfred H. Knol, Jannes Slomp. (2018). The relative importance of
improvement routines for implementing lean practices
Juan Carlos Hernandez-Matias (2019) Lean manufacturing and operational
performance Interrelationships between human-related lean practices.
Avinash Panwar. (2016). Understanding the linkages between lean practices
and performance improvements in Indian process industries.
Vinod Yadav (2017) An appraisal on barriers to implement lean in SMEs