Lean Manufacturing Case Study for Components Company

Technologies:

Forging, casting, machining

Lean & Lean/Six Sigma Endorsements

PPG, Patancheru, India - We would like to thank Omnex for their expert assistance provided to our joint venture partner in Patancheru, India. The Omnex people were very knowledgeable and flexible in providing support to the improvement team and in tailoring materials to align the effort with the PPG model for Lean deployment. The first workshop was an immense success! The filling operation was the beneficiary of the first workshop targeting a filling process that traditionally took 3 shifts to fill one 4 kiloliter batch. The process and even the equipment was reengineered in just one week by a very dedicated cross-functional team lead by PPG and Omnex. The confirmation run on the last day confirmed it was now possible to fill that same batch in just 1½ hours with two operators. In addition to the speed gains in quality and safety were also realized by enclosing the entire filtration process. The workshop was so successful that the team in Patancheru continued to apply the methodology to another 6 problems in just 7 weeks. With outstanding results.

D. A. Lalain
Global Quality Director
PPG OEM Coatings

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