Case Study : Transforming Productivity In A Machine Manufacturing Company Through QMS Implementation

Client Overview:

In May 2024, a mid sized machine manufacturing company partnered with Virat Services to address inefficiencies in their production process. the company produces an average of 72 machines per year, with significant deliver delays - 3 months for standard models and 4-6 months for custom machines. The operations were running at a primitive level, lacking formalized systems for standardized process.

Challenges Identified:

1. Low Output: Production averaged only 72 machines annually, far below potential capacity.
2. Long Delivery Times: Delivery timelines were inconsistent and delayed, causing dissatisfaction among customers.
3. Unstructured Processes: Lack of Quality Management System (QMS) led to inefficiencies errors, and wastage.
4. Employee Engagement: Workers and staff lacked training in modern production methods and the "continuous improvement" mindset.

Virat Services' Approach:

Virat Services tailored a customized QMS solution for the client, focusing on:

• Process Standardization: Developing and implementing standardized systems to streamline production.
• Employee Training: Conducting workshops for workers, fitters, and staff on QMS practices and instilling a culture of continuous improvement and teamwork.
• Performance Monitoring: Introducing real-time tracking of machine dispatches against monthly and yearly targets.
• Target Settings: Setting ambitious yet achievable goals to progressively increase production capacity.

Implementation & Progress:

1. Initial Goal Setting:
• Aimed to increase production from 72 to 101 machines per year by creating an effective QMS framework.
• Establish a system to monitor monthly dispatch performance.
2. First-Quarter Success:
• Within the first 3 months, the company exceeded the target by dispatching two additional machines.
3. Raising The Bar:
• Encouraged the company to adopt a new target of 125 machines annually, ensuring scalability and sustainability without hiring additional staff or incurring major expenses.
4. Mindset Shifts:
• Fostered a culture of continuous improvement by empowering employees with tools, techniques, and motivation to collaborate effectively.

Results Achieved:

• Increased Output: The company is on track to achieve 200% productivity growth by scaling up production to 125 machines and eventually beyond.
• Reduced Delivery Times: Streamlined processes have significantly decreased machine delivery timelines, improving customer satisfaction.
• Cost-effectiveness: All improvements were made without hiring additional staff or incurring significant overhead costs.

Conclusion:

By implementing a structured and customized QMS, Virat Services transformed a traditional, inefficient production setup into a streamlined, high-performing operation. This case highlights the power of process standardization, employee engagement, and continuous improvement in unlocking hidden potential within organizations.

Today, the company is well on its way to becoming a leader in its industry, demonstrating that operational excellence is achievable with the right systems and mindset in place.