Virat Services Cast Study : Strengthening QMS Implementation For A Brass Components Manufacturer

Client Overview:

A leading manufacture of engineering brass components specializing in custom parts based on engineering drawings was struggling with effective QMS implementation despite being ISO certified. The company's systems and SOP's were well-documented but lacked practical execution on the shop floor, creating a disconnect between policies and operations.

The client faced pressure from high-end national and international customers, who insisted on robust QMS Implementation as a condition for future purchase order.

Challenges Identifies:

1. QMS Implementation Gap:
• SOPs are processes existed only on paper and were not reflected in daily operations.
2. Workforce Limitations:
• The team consisted of semi-skilled workers and rigid, illiterate foremen who resisted adopting new processes due to their decades-old work habits.
3. Customer Expectations:
• High-end clients demanded strict adherence to QMS, threatening to stop orders if the company failed to comply

Virat Services' Approach:

Virat Services provided a two-month consultation with a strategic focus on:

1. Gap Analysis and System Refinements:
• Conducted a detailed audit comparing SOPs with actual practices to identify discrepancies.
• Revised and simplified procedures to ensure practically and ease of execution by semi-skilled staff.
2. Training and Empowerment:
• Delivered training to workers and foremen on key aspects of QMS, including daily and periodic maintenance, quality checks, and production best practices.
• Created multilingual work instructions (English, Hindi, Gujarati) for accessibility.
3. Building Accountability and Engagement:
• Encouraged active participation from foremen and workers through feedback loops and tailored guidance.
• Motivated young workers to adopt new systems and maintain them consistently.
4. Standardizing Processes and Workflow:
• Developed detailed process flow diagram (PFDs) for core functions such as production, Purchase, QC, HR, Sales, and New Product Development.
• Ensured all processes were supported by step-by-step procedures and work instructions.
5. Monitoring and Sustaining Improvements:
• Introduced daily and periodic maintenance formats, with implementation timelines and tracking mechanisms.

Key Improvements Implemented:

The following steps were executed during the consultation, as noted in the session documents:

• Daily Maintenance Checklists: Simplified checklists for machine maintenance to ensure regularity and accountability.
• Preventive Maintenance Schedules: Introduced monthly, half-yearly, and yearly schedules for preventive machine maintenance.
• Work Instructions: Created detailed instructions for operating machines safely and efficiently, displayed prominently on the shop floor.
• Enhanced Quality Control: Reinforced final QC procedures, including verification with calibrated digital tools before use.
• Visual Management: Displayed the quality policy, organizational chart, and process flow diagrams at key locations to reinforce QMS practices.

Results Achieved:

1. Thorough QMS Implementation:
• Successfully closed the gap between documented procedures and actual operations, ensuring compliance with ISO and customer standards.
2. Workforce Transformation:
• Overcame resistance from foremen and engaged young workers to adopt and sustain new practices.
3. Improved Customer Relations:
• Met the stringent QMS requirements of international customers, securing orders and enhancing trust.
4. Owner Satisfaction:
• Delivered a well-implemented, sustainable QMS within two months, exceeding the client’s expectations.

Conclusion:

This case demonstrates how tailored QMS implementation can transform operations in traditional manufacturing setups. Virat Services successfully addressed workforce challenges, standardized processes, and met international customer demands within a short timeframe.

For businesses facing similar challenges, Virat Services offers the expertise to bridge gaps and ensure long-term operational excellence.