Witness firsthand how we collaborated with a leading spare part manufacturer and rewrite the rules of manufacturing management from the ground up. With a focus on Zero Shortages and Maximizing Efficiency we reduced WIP Inventory by 52.5% where the initial target was 30% with the strategic implementation of the KANBAN system and precise batch reduction. Our team of Consultants were able to save 70.8 LPA through productivity improvement and 1.8 LPA through Kanban Implementation. Learn about ToolKit and Pull System through Kanban to improve your company’s operational excellence. Are you ready to unlock your full potential? Contact us today and discover how D&V Business Consulting can revolutionize your operations and take the first step towards operational excellence. Visit our website to know more: https://www.dvconsulting.co.in/

1. Transforming Automobile
Spare Parts Manufacturing
A Lean Transformation Journey in Automobile Spare
Parts Manufacturing with D&V Business Consulting
Services
52.5%
Reduction in
WIP Inventory
44%
Cashflow Savings
through Kanban
10.3%
Productivity
Improvement
through Kaizens
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2. Introduction
In the dynamic landscape of automobile spare
parts manufacturing, companies are constantly
seeking innovative solutions to enhance
efficiency, reduce costs, and streamline
operations. This case study delves into the
transformative journey of a leading spare parts
manufacturer, guided by D&V Business
Consulting Services, in overcoming key
challenges and achieving substantial
improvements.
Zero Shortages,
Maximized Efficiency

3. Maintain 0% child part shortages in
supermarkets
Develop a robust system to eliminate shortages
in supermarkets, ensuring a seamless flow of
spare parts and meeting customer demands
consistently.
Improve productivity up to 20%
Enhance overall productivity through strategic
interventions that focus on efficiency, resource
optimization, and streamlined manufacturing
processes.
Reduce overproduction (Inventory)
up to 30%
Implement strategies to optimize inventory levels
and minimize overproduction, ensuring a lean
and efficient supply chain.
Objectives

4. Vision Mission
Empower our clients with cutting-edge
solutions, foster innovation in manufacturing
processes, and create a sustainable business
model that aligns with global standards.
Through strategic interventions, lean
methodologies, and a commitment to
continuous improvement, we aim to
revolutionize the industry, setting new
standards for operational excellence,
sustainability, and customer satisfaction. Our
vision is to be recognized as pioneers in spare
parts manufacturing, contributing to a future
where efficiency, quality, and innovation drive
every aspect of our operations.
In our vision, we see a transformative
landscape where operational excellence,
sustainability, and innovation converge
seamlessly. We aspire to lead the industry by
implementing cutting-edge solutions,
fostering a culture of continuous
improvement, and setting new benchmarks
for efficiency and quality. Our vision is to be
the vanguard of change, redefining the
standards of spare parts manufacturing
through lean methodologies and strategic
interventions. Through this vision, we aim to
inspire and shape a future where every aspect
of our operations reflects the pinnacle of
excellence in the automotive spare parts
industry.

5. How We Tackle The Challenges
Kanban System
(Inventory Management)
Implement a Kanban system to
optimize inventory levels, ensuring
that production aligns with
demand, thus minimizing
overproduction.
Batch Size Reduction
Based on Demand
Tailor batch sizes according to real-
time demand, preventing
overproduction and reducing
excess inventory.
SMED (Single Minute
Exchange of Dies)
Implement SMED techniques to
significantly reduce changeover
times resulting from batch size
reduction, enhancing overall
production efficiency.

6. Pull System
The transition from a push system to a pull system ensures that production is demand-
driven, reduces waste, and enhances efficiency.
Process Mapping
Analyze and map out the manufacturing processes to identify areas for improvement,
reducing inefficiencies and enhancing workflow.
Bottleneck Analysis
Identify bottlenecks in the production process and implement strategies to eliminate or
alleviate them, ensuring a smooth and continuous flow of production.
Kaizen
Introduce Kaizen principles to encourage continuous improvement, fostering a culture of
innovation and efficiency within the organization.
TPM (One-Point Lesson)
Implement Total Productive Maintenance to ensure equipment reliability and minimize
downtime through targeted training and maintenance programs.
Lean Toolkit

7. Concept: Pull system through Kanban

8. 52.5% Reduction in WIP Inventory
Efficient inventory management through the Kanban system
is projected to reduce work-in-progress inventory by over
half.
50% Reduction in Changeover Time through
SMED
Efficient inventory management through the Kanban system
is projected to reduce work-in-progress inventory by over
half.
44% Cashflow Savings through Kanban
Efficient inventory management through the Kanban system
is projected to reduce work-in-progress inventory by over
half.
10.3% Productivity Improvement through
Kaizens
Efficient inventory management through the Kanban system
is projected to reduce work-in-progress inventory by over
half.
Projected Benefits
The collaborative efforts between the
automobile spare parts manufacturing
company and D&V Business Consulting
Services are poised to usher in a new era of
operational excellence, efficiency, and financial
sustainability. Through the strategic
implementation of lean methodologies and
innovative solutions, the company is well-
positioned to overcome its challenges and
emerge as a leader in the highly competitive
spare parts manufacturing industry.

9. Business Impact of the Project
70.8 LPA Savings through
Productivity Improvement
The projected productivity improvements are estimated to
lead to significant annual savings, strengthening the
company's financial position.
1.5 LPA Savings through Kanban
Implementation
Implementation of the Kanban system is expected to
generate substantial savings in cash flow, contributing to
the company's overall financial health.

10. Get in Touch
sales@dvconsulting.co.in
+91 98240 09829
www.dvconsulting.co.in
626, Iconic Shyamal, Ahmedabad, 380015

11. Thank You
F o r Y o u r A t t e n t i o n
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