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

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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

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Our Philosophy..

• 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
• 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.

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Industries we work with..
Heavy Fabrication Industries
Capital Equipment Manufacturer
Engineering Industries
Mass production Assembly Lines Automobile
Ancillaries manufacturer
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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.

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Our Core Services
Product Design and Development
Management Consulting
5S Visual Management
Operation Excellence
Strategic Business Consulting
ISO Consulting
Lean Manufacturing
Trainings
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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 81242022
  standards
• Process how Product Design and Development works

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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

Gap Identification
Scope identification
Define Deliverables
Define Action plan
Review deliverables
Hand over project
On site Visit
Implementation
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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

Gap Identification
Scope identification
Define Deliverables
Define Action plan
Review deliverables
Hand over project
On site Visit
Implementation
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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

Workplace organization
Visual Display
Visual Measures
Visual Management
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05. ISO Consulting

• In ISO we offered Assessment and Implementation
  support for various standards
• ISO 450012018 Occupational Health and safety
  management system
• ISO 90012015 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

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06. Trainings

• Process how Training Model works

• Trainings are backbone of any industries. Talent
  development and

• 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
Training Module Design
Implementation Assessment
Training Imparted
Effectiveness Assessment
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07. Management Consulting

• In Management consulting we are providing below
  services
• 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

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08. Strategic Business Consulting

• In Business Consulting model we are following 12
  Types framework in it.

PEST Analysis Political Economic Social Technological Porters Five Forces Threat to new entrance Competitive advantage Supplier Power Buyer Power Threat of substitute The 3 Cs Corporation Competition Customer
SWOT Matrix Strength Weakness Opportunities Threats BCG-Growth share Matrix Dogs Cash cows Stars Question mark Balance Scorecard Financial Data Business Process Customer perspective Learning Growth
McKinsey 7S Structure Strategy Skill System. Shared value Style Staff Benchmarking Production Cost Revenue Employee turnover Process cycle time The 4 Ps Product Price Promotion Placement
External v/s Internal External Internal Cost v/s Benefit Cost Benefit Quantitative versus qualitat Quantitative Qualitative
ive
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Case Studies
SMED PROJECT
5S IMPLEMENTATION
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Case Studies
Lean Facility Layout Abstract

• Visual Factory Balance Score card
• 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.
• About Company
• Client 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
• Almost 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
• We have listed down all process for manufacturing
  and assemblies and start making SOP in local
  language and in English as per global benchmark
  format.
• At reception area and in plant we have displayed
  overall plant layout with safety measures and
  safe evacuation marking.
• For 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.
• We 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.
• Implemented Andon system in assembly line to
  capture real time data for material shortage,
  Machine breakdown, Quality problems.

• 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
• Client 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
• We 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
• We have implemented concept of process layout and
  product layout.
• Start to understand information flow, Material
  flow, Process flow to design layout in optimize
  level.
• We always made multiple option to evaluate best
  layout.
• Single piece flow or batch production layout will
  decide before start block diagram in AutoCAD.

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Case Studies
Value stream mapping Abstract

• New Product Development
• Abstract
• 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
• Client 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.

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

• About Company
• Client 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
• Processes 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

• Analysis
• We 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
• We have applied reveres engineering concept in
  this project.
• We ordered power chuck from market to study
  benchmarking practices
• We have started to make 2D drawings and based on
  this we have developed 3D models of chucks.
• We have started analysis part after design
  complete like calculation of clamping force,
  operating range, Max RPM, Max gripping force.
• Pilot lot production start and inhouse we check
  QC and tested ok with all measurement
• parameters and performance parameters.

• Approach and Method
• We have started to plot current state map with
  data available.
• After 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.
• We 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.
• After that we plot future state map and made
  compression of current state v/s future state.
• Main 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 Value stream mapping for Automotive component Assembly Line Value stream mapping for Automotive component Assembly Line Value stream mapping for Automotive component Assembly Line Value stream mapping for Automotive component Assembly Line Value stream mapping for Automotive component Assembly Line
Current state Production Lead Time 55 days Opportunity Identified and Implement Apply level load Future state Production Lead Time 11.25 days
Current state Production Lead Time 55 days Opportunity Identified and Implement Pull system Future state Production Lead Time 11.25 days
Current state Production Lead Time 55 days Opportunity Identified and Implement Kaizens Future state Production Lead Time 11.25 days
Current state Total VA time lt1 Day Opportunity Identified and Implement Standardize work Future state Total VA time lt1 Day
Current state Total VA time lt1 Day Opportunity Identified and Implement Kanban for WIP and Invento Future state Total VA time lt1 Day
Current state Total VA time lt1 Day Opportunity Identified and Implement TPM Future state Total VA time lt1 Day
Current state Opportunity Identified and Implement 5S Future state
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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

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