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MechMinds: Leading OpEx, Lean, TPM, EH&S, and ZED Consulting Expertise

MechMinds: Your trusted partner for OpEx, Lean, TPM, EH&S, and ZED consulting solutions. Unlock operational excellence with our expertise. Visit: https://mechminds.co.in/

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MechMinds: Leading OpEx, Lean, TPM, EH&S, and ZED Consulting Expertise

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  1. About Us.. For MSMEs and with MSMEs since 2006 • Strong team of 8 Consultants with varied experience • Experience of working with various industry segments in MSMEs. • Product engineering, Operation excellence (OpEx) and management consulting to MSMEs. • Some of our projects include consultancy in key areas like production planning, manufacturing, new product development and many more • 300+ happy customers • Private & Confidential Use By MechMinds Consultant Only

  2. Our Philosophy.. Vision Statement Vision Statement • Our aim to become best consultancy firm across competition. We want to set highest level of integrity and accountability towards our stake holders. • We want To establish best practices in manufacturing industries across nation as well as abroad. • Mission Statement Mission Statement • Our purpose to educate manufacturing industries to adopt systematic approach and run facility with optimize resource. • Our core task to convert owner base organization to the system base organization and transfer their experience legacy in to product and system. • Private & Confidential Use By MechMinds Consultant Only

  3. Industries we work with.. Heavy Fabrication Industries Capital Equipment Manufacturer Engineering Industries Mass production Assembly Lines Automobile Ancillaries manufacturer Private & Confidential Use By MechMinds Consultant Only

  4. Why MechMinds..  Over 15 years of reach experience to deal with different manufacturing process and implementation of project management, new product development, Lean manufacturing tools, HR practices across different manufacturing industries.  Deep understanding of manufacturing domain and its pain and to overcome this we are applying collaborative approach from Top to Bottom line.  Well connect with different vendors to make task easy and speedy  Practical approach towards any problem and hardcore implementer of key deliverables.  We quote ourselves as “Change Agent” for all our cliental.  One point contact for any manufacturing industries for their system development and implementation. Private & Confidential Use By MechMinds Consultant Only

  5. Our Core Services Product Design and Development Management Consulting 5S & Visual Management Operation Excellence Strategic Business Consulting ISO Consulting Lean Manufacturing Trainings Private & Confidential Use By MechMinds Consultant Only

  6. 01. Product Design & Development  In Product Design and Development we are offering below services  Preparation of business and commercial case for any new product development  3D modeling of concept and 2D drawings  Manufacturing drawings and all process drawings for product  Prototype preparation and validation of design  Software base model analysis and calculation base analysis of design  Roadmap preparation and implementation for mass production facility of new product  Design and testing support according to ASME, API, ASTM, NFPA, ASSE, ANSI, ISO 8124:2022 standards  Process how Product Design and Development works Process how Product Design and Development works Private & Confidential Use By MechMinds Consultant Only

  7. 02. Operation Excellence  Well Operation excellence is continuous journey, it is systematic step by step approach towards building robust culture in organization about key stake holders. We are provide services in Opex area  Just In Time implementation projects  Inventory management and optimization  Vendor management through P,Q,S,D  Plant operating cost analysis and optimization  Energy Audit and actions closing  Trainings on Lean concept and 5S  Poke yoke planning and implementation  Shingo Model implementation  4M resource optimization  Enterprise alignment  Detailed value stream mapping and improvements  Kaizen theme implementation and effectiveness  Department formation and making JD and task list  New manufacturing plant set up support  Process how Operation Excellence implementation works Process how Operation Excellence implementation works Gap Scope Define Deliverables Define Action plan Review deliverables Hand over project On site Visit Implementation Identification identification Private & Confidential Use By MechMinds Consultant Only

  8. 03. Lean Manufacturing  In Lean Manufacturing projects are well define and just to do implementation type. It is more depend on data collection. In Lean Manufacturing we are providing below services  SMED projects for changeover  Implementation of QC tools  Losses Analysis and Improvement implementation  KANBAN implementation in continuous assembly line for inventory reduction  Productivity improvements projects  OEE Improvement projects  Waste reduction in process  Throughput time optimization  Andon Implementation  Lean facility layout design  TOC analysis and implement  Kaizen theme implementation and effectiveness  Process how Lean Manufacturing Implementation works Process how Lean Manufacturing Implementation works Gap Scope Define Deliverables Define Action plan Review deliverables Hand over project On site Visit Implementation Identification identification Private & Confidential Use By MechMinds Consultant Only

  9. 04. 5S & Visual Factories  In 5S and Visual factories we are provide below services  5S Implementation and assessment  Visuals for 5S  Shop floor performance report display  All shop floor related standard visuals implementation  Implementation of standard operating procedures  Marking on shop floor for identifying things  DWM (Daily work Management) implementation and display as benchmark practice  Process how 5S & Visual Factories works Process how 5S & Visual Factories works Workplace organization Visual Display Visual Measures Visual Management Private & Confidential Use By MechMinds Consultant Only

  10. 05. ISO Consulting  In ISO we offered Assessment and Implementation support for various standards  ISO 45001:2018 Occupational Health and safety management system  ISO 9001:2015 Quality Management System  ISO 14001 Environment Management System  IATF 16494 Automotive Standard  ISO 22000 Food safety management system  ISO 50001 Energy Management System  ISO 13485 QMS for Medical devices  ISO 27001 IT Management System  Process how ISO Consulting works Process how ISO Consulting works Private & Confidential Use By MechMinds Consultant Only

  11. 06. Trainings  Trainings are backbone of any industries. Talent development and  Process how Training Model works Process how Training Model works  Work place Management  5S Implementation  7 QC Tools  Daily Work Management  Five Core Tools IATF 16494(PFMEA,PPAP,MSA,SPC,APQP)  Lean Manufacturing  TPM  Kanban Implementation  SMED Implementation  Effective Production Planning  Visual Management  People Management  Servant Leadership development  CEO Mentorship and Coaching  Business Strategies Implementation  Project Management basic  Skill Matrix Implementation  Manufacturing Leadership Gap Identification Implementation Assessment Training Module Design Effectiveness Assessment Training Imparted Private & Confidential Use By MechMinds Consultant Only

  12. 07. Management Consulting  In Management consulting we are providing below services um  Human Resource Management system Implementation  Leadership & Development Model implementation  Individuals development plan  Organization growth strategy road map define and implementation  Sales or Revenue improvement  Profitability Improvement  Organization level policies and procedure support and implementation  Process how Management Consulting Works Process how Management Consulting Works Private & Confidential Use By MechMinds Consultant Only

  13. 08. Strategic Business Consulting In Business Consulting model we are following 12 Types framework in it.  2. Porter’s Five Forces i. Threat to new entrance ii. Competitive advantage iii. Supplier Power iv. Buyer Power v. Threat of substitute 3. The 3 C’s i. ii. iii. 1. PEST Analysis i. Political ii. Economic iii. Social iv. Technological Corporation Competition Customer 5. BCG-Growth share Matrix i. Dogs ii. Cash cows iii. Stars iv. Question mark 6. Balance Scorecard i. Financial Data ii. Business Process iii. Customer perspective iv. Learning & Growth 4. SWOT Matrix i. ii. iii. iv. Strength Weakness Opportunities Threats 7. McKinsey 7S i. ii. iii. iv. v. vi. vii. 9. The 4 P’s i. ii. iii. iv. 8. Benchmarking i. Production Cost ii. Revenue iii. Employee turnover iv. Process cycle time Structure Strategy Skill System. Shared value Style Staff Product Price Promotion Placement 12. Quantitative versus qualitative 10. External v/s Internal i. External ii. Internal 11. Cost v/s Benefit i. Cost ii. Benefit i. ii. Quantitative Qualitative Private & Confidential Use By MechMinds Consultant Only

  14. Case Studies SMED PROJECT 5S IMPLEMENTATION Private & Confidential Use By MechMinds Consultant Only

  15. Case Studies Lean Facility Layout Visual Factory & Balance Score card Abstract Abstract For Lean and 5S visual management is more important. We have implemented HPT (High performance Team) display and training centre display. Balance scorecard shows entire plant KPI and performance at a glance to showcase customer as well visitors and one point display to understand plant health in terms of parameters. Lean facility layout is very core subject and required task when we perform or start to making new manufacturing set up. It is most important task to implement Lean layout at the starting of development process when plan is under construction. Based on detailed process flow this layout has been made. About Company: oClient is global automotive supplier tier 1 and serve major OEM like Ford India, Tata Motors, Suzuki Motor Gujarat. They are in to manufacturing of automotive interiors parts and seating assembly and seating chassis Analysis: oAlmost we have studied 15 plants data across global like Japan, Korea plants. As per global guidelines we have to perform. We have implement team and start working on it. Approach and Method: oWe have listed down all process for manufacturing and assemblies and start making SOP in local language and in English as per global benchmark format. oAt reception area and in plant we have displayed overall plant layout with safety measures and safe evacuation marking. oFor balancer score card we have made plant KPI with target and actual. After that we have started to print full scale KPI sheet for display at shop floor. oWe have created space for daily morning meeting called DWM (daily work management) based on P, Q, D, S and 4M resources for measure daily targets and actuals and missed KPI. oImplemented Andon system in assembly line to capture real time data for material shortage, Machine breakdown, Quality problems. About Company: oClient is global engineering OEM company and serve in Oil & Gas, Chemical sector, Pharma sector. They have global technology tie up and manufacturing facility available in Vadodara (Gujarat) They are in to manufacturing of pumps, valves, compressors, mixing machines. Analysis: oWe have studied detail process flow of each product line and start marking on shop floor. Based on demand and supply method we have calculated takt time and based on this we started to plot layout in AutoCAD. Approach and Method: oWe have implemented concept of process layout and product layout. oStart to understand information flow, Material flow, Process flow to design layout in optimize level. oWe always made multiple option to evaluate best layout. oSingle piece flow or batch production layout will decide before start block diagram in AutoCAD. Private & Confidential Use By MechMinds Consultant Only

  16. Case Studies Value stream mapping New Product Development Abstract Abstract The aim of this article is a practical demonstration of Value Stream Mapping method (VSM) for visualization and rationalization of processes and its use in the context of a real enterprise. Own philosophy of a method lies in a view of the value-chain “from doors to doors” among all important transportation and transformation processes flowing in a company since receiving of raw materials and semi-finished products from suppliers to final delivery of finished products to a customer Design and development are core target area for any growing business. With this we are strongly align with management team regarding product development. We understand requirement and making concept drawings and models to test design. Also, we are strongly believing in concept “Made in Bharat” and “Make in India”. About Company: oClient is reputed CNC component supplier as tier 2 to tier 1. They are in to value chain of major automotive OEM. With this they have their own product like chuck, Jaws. Analysis: oWe have studied detail market requirement and size of business with power chucks. We made entire business case with ROI calculations to start design and development. And parallel we have initiated CAPEX to execute manufacturing process of power chucks. Approach and Method: oWe have applied reveres engineering concept in this project. oWe ordered power chuck from market to study benchmarking practices oWe have started to make 2D drawings and based on this we have developed 3D models of chucks. oWe have started analysis part after design complete like calculation of clamping force, operating range, Max RPM, Max gripping force. oPilot lot production start and inhouse we check QC and tested ok with all measurement parameters and performance parameters. About Company: oClient is global automotive supplier tier 1 and serve major OEM like Ford India, Tata Motors, Suzuki Motor Gujarat. They are in to manufacturing of automotive interiors parts and seating assembly and seating chassis. Analysis: oProcesses within VSM are strictly separated in to the two groups: Value-Adding Processes (VA) and Non-Value-Adding processes (NVA). The outcome of a VSM method is a diagram presenting a value flow in a company. Trough VSM is possible to identify places of piling inventory, calculate a lead time and realize how many percent of a time are Value-Adding and how many are not Approach and Method: oWe have started to plot current state map with data available. oAfter completion of current state map, we have started to plot opportunity for improvement in current state map and made strong action plan to implement opportunity. oWe divided actions in two main phase 1st is eliminate or reduce Non value adding activity and 2nd is convert reduce piled inventory and made single piece flow. oAfter that we plot future state map and made compression of current state v/s future state. oMain indicator in VSM is to improve through put, reduce NVA and save hidden cost involved in systems. Value stream mapping for Automotive component Assembly Line Apply level load Pull system Kaizens Standardize work Kanban for WIP and Inventory TPM 5S Production Lead Time : 55 days Production Lead Time : 11.25 days Opportunity Identified and Implement Current state Future state Total VA time : <1 Day Total VA time : <1 Day Private & Confidential Use By MechMinds Consultant Only

  17. Founder Profile  Over 15 years of cross industrial experience in different manufacturing industries including Automotive and Engineering. Independently handle various departments in manufacturing industries like Process Engineering, Advance Manufacturing Engineering, Production and Operation management, Management representative, Project Management, New Product development, Continuous Improvement manager.  Having various certification like TQM, PFMEA, Lean and Six Sigma Green Belt, Chartered Engineer from Institution of Engineers India (IEI)  Education Details :  B.Tech – Mechatronics Engineering  M.Tech – Manufacturing Management – BITS PILANI RAJASTHAN  Key Projects Deliver :  New facility lean layout implementation  New product development (hydraulic and battery operated safety tool)  Six Sigma project for defect reduction ( Internal PPM reduction project for tapper roller bearing)  PFA coating plug valve product development process and testing parameter standardization Private & Confidential Use By MechMinds Consultant Only

  18. Feed back and Q&A?  Feed Back and Comment : Private & Confidential Use By MechMinds Consultant Only

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