Driving Operational Excellence in Diversified Grinding Wheel Manufacturing Company

February 1, 2024

Driving Operational Excellence in Diversified Grinding Wheel Manufacturing Company


mbawankar |

This comprehensive case study sheds light on the remarkable journey of a pioneering company that introduced grinding wheel manufacturing to India back in 1941. The company has since diversified its portfolio to include Abrasives, Ceramic Materials (Silicon Carbide and Performance Ceramics & Refractories), Performance Plastics, and ADFORS. The study delves into the company's strategic initiatives, encompassing work content measurement through time study, capacity calculation, cycle time determination, manpower assessment, and efficient work distribution. By meticulously analyzing these aspects, the case study illustrates how the company achieved operational excellence, improved resource utilization, and enhanced productivity across its diverse business segments.

Key Points

  • Work content Measurement using time study.
  • Capacity calculation.
  • Cycle time standardization.
  • Manpower Optimization.
  • Evenly work distribution.

Client's Challenge

  • Work standard development and validation.
  • Capacity calculation for plant.
  • Cycle time calculation by cyclic/non-cyclic activities.
  • Manpower Calculation.
  • Work Distribution.

PMI's Approach

The study was organized in a 3-stage process:

  1. Data Collection - Video shooting of all activities on the line.
  2. Estimation & Data Analysis – Preparation of Process Flow & Schematic Layout , Elemental detail preparation using Time Study technique, Work content estimation ,Work distribution with Man machine chart , Analysis & Manpower calculation.
  3. Making client time familiar with PMTS study technique for easy understanding.
  4. Validation of observed processes data, elemental details, analysis from Client representatives .
  5. Results and Conclusion – Sheets for work content estimation, fatigue reduction, improved productivity, improved manpower utilization, identification of NVA work content.

Involvement of Associates

  • PMI – 1 Project Manager, 2 Engineers.
  • Client – 2 Project Co-ordinators.

Data Collection:

  • Visit to client site and understanding the plant before starting data collection.
  • Shooting of videos using high tech cameras for better capturing of data collection.
  • Interaction with client to understand process from videos.

Data Analysis:

  • Preparation of sheets of Time study using appropriate technique and validation by client.
  • Analysis (Optimum manpower utilization & identifying cycle times and capacity of plant).
  • Work content sheet preparation for cycle time as per demand.
  • Improvement & suggestions for fatigue reduction & making existing system better.

Results & Conclusion

After doing analysis and evaluation following results were obtained –

  1. Based on 50 machines data, average efficiency of the plant is 59.63%
  2. As per existing plant average i.e. 59.63% (24 machines are below average & 26 machines are above average.)
  3. For proposed plant average i.e. 75% (23 machines would be below average & 27 would be above average)
  4. Existing unit per man per shift is 8 (16 Inch) & proposed unit per man per shift is – 11 (16 Inch), thus productivity improvement would be 37.5%

Existing Plant Scenario

Existing vs Proposed Plant Scenario

Graphical Representation

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