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/

2. Private & Confidential Use By MechMindsConsultant Only
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

3. •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.
Our Philosophy..
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4. Industrieswe work with..
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Automobile
Ancillaries
manufacturer
Mass
production
Assembly Lines
Engineering
Industries
Capital
Equipment
Manufacturer
Heavy
Fabrication
Industries

5. Why MechMinds..
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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.

6. Our Core Services
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Product Design and
Development
Operation
Excellence
Lean
Manufacturing
5S &
Visual Management
ISO
Consulting
Trainings
Management
Consulting
Strategic Business
Consulting

7. 01. Product Design & Development
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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

8. 02. Operation Excellence
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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
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
Process how Operation Excellence implementation works
On site Visit
Gap
Identification
Scope
identification
Define
Deliverables
Define Action
plan
Implementation
Review
deliverables
Hand over
project

9. 03. Lean Manufacturing
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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
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
Process how Lean Manufacturing Implementation works
On site Visit
Gap
Identification
Scope
identification
Define
Deliverables
Define Action
plan
Implementation
Review
deliverables
Hand over
project

10. 04. 5S & Visual Factories
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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
In 5S and Visual factories we are provide below services
Process how 5S & Visual Factories works
Workplace
organization
Visual
Display
Visual
Measures
Visual
Management

11. 05. ISO Consulting
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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
In ISO we offered Assessment and Implementation support for various standards
Process how ISO Consulting works

12. 06. Trainings
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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
Trainings are backbone of any industries. Talent development and
Process how Training Model works
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
Training
Imparted
Effectiveness
Assessment
Implementation
Assessment

13. 07. Management Consulting
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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
In Management consulting we are providing below services
um
Process how Management Consulting Works

14. 08. Strategic Business Consulting
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In Business Consulting model we are following 12 Types framework in it.
1.PEST Analysis
i.Political
ii.Economic
iii.Social
iv.Technological
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.Corporation
ii.Competition
iii.Customer
4. SWOT Matrix
i.Strength
ii.Weakness
iii.Opportunities
iv.Threats
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
7. McKinsey 7S
i.Structure
ii.Strategy
iii.Skill
iv.System.
v.Shared value
vi.Style
vii.Staff
8. Benchmarking
i.Production Cost
ii.Revenue
iii.Employee turnover
iv.Process cycle time
9. The 4 P’s
i.Product
ii.Price
iii.Promotion
iv.Placement
10. External v/s Internal
i.External
ii.Internal
11. Cost v/s Benefit
i.Cost
ii.Benefit
12. Quantitative versus qualitative
i.Quantitative
ii.Qualitative

15. Case Studies
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5S IMPLEMENTATION SMED PROJECT

16. Case Studies
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Visual Factory & Balance Score card
Lean Facility Layout
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:
o 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:
o 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:
o 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.
o At reception area and in plant we have displayed overall plant layout with safety measures
and safe evacuation marking.
o 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.
o 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.
o Implemented Andon system in assembly line to capture real time data for material shortage,
Machine breakdown, Quality problems.
Abstract
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:
o 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:
o 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:
o We have implemented concept of process layout and product layout.
o Start to understand information flow, Material flow, Process flow to design layout in optimize
level.
o We always made multiple option to evaluate best layout.
o Single piece flow or batch production layout will decide before start block diagram in AutoCAD.

17. Case Studies
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New Product Development Value stream mapping
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:
o 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.

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

 About Company:
o 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:
o 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

 Approach and Method:
o We have started to plot current state map with data available.
o 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.
o We divided actions in two main phase 1
st
is eliminate or reduce Non value adding activity and
2
nd
is convert reduce piled inventory and made single piece flow.
o After that we plot future state map and made compression of current state v/s future state.
o Main indicator in VSM is to improve through put, reduce NVA and save hidden cost involved in
systems.
Apply level load
Pull system
Kaizens
Standardize work
Kanban for WIP and Inventory
TPM
5S
Production Lead Time :
11.25 days
Total VA time : <1 Day
Current
state
Future
state
Opportunity
Identified and
Implement
Value stream mapping for Automotive component Assembly Line
Production Lead Time :
55 days
Total VA time : <1 Day

18. Founder Profile
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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

19. Feed back and Q&A?
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Feed Back and Comment :