To bring about a change in companies that are not performing well, we bring Total Employee Involvement in action. Our firm has tried different tools specially the Japanese Management Tools and have observed that when implemented in a purposeful and focussed manner will solve the problems of the company. The major tools that we employ include the following:

• Balanced Scorecard
• 5-S
• Total Productive Maintenance
• Key Focus Areas
• Six Sigma

In this service we strive to achieve individual and workplace excellence through 5-S. We implement this 5-S at three levels like physical level, information level and system level.

• Provide Training:

5-S Awareness Training at all levels including Top Management Training the Trainers who would in turn impart training to their fellow Associates Audit Training to the selected team of Associates who would carry out Self - Audit, External Audit and Steering Committee Audit Training 5-S Champions who would be able to propagate 5-S across the organisation independently so that all employees carry out 5-S on an on- going basis

• Facilitate Planning and Implementation:

* Enable organisation to identify Champions, Co-Champions and Members form Zones and Steering Committee who would drive the movement from the front and ensure this exercise become a daily routine
* Implementation of 5-S at three major levels - Physical, Systems and Information

• Benefits of 5S:

* Creates serene work environment
* Ensures safety in workplace
* Improves quality of products and services
* Eliminates waste
* Minimises inventory
* Reduces Non value Adding / Low value Adding assets
* Reduces / eliminates non-value adding activities
* Facilitates and reinforces ISO 9000 and ISO 14000 activities
* Reduces stress, strain and work pressures
* Encourages Total Employee Involvement
* Enhances quality of work life
* Helps in Kaizen, TPM and TQM Processes

We offer Total Productivity Maintenance for handling of several managerial tasks. We provide training in:

* TPM Awareness Training
* Pillars of TPM & Steps to achieve TPM
* Implementation Training including Training in Scientific Tools Facilitate

Planning and Implementation:

* Selection of TPM Champion and formation of cross-functional teams
* Formulation of Organization-wide TPM Implementation Structure
* Selection of Model / Pilot Machines
* Formulation of Company-wide TPM Policy and Pledge
* Derive a structured Master Plan for the entire Unit Benefits of TPM in terms of: Productivity Improvement:
* OEE( Overall equipment effectiveness)/ OPP (Overall plant effectiveness) = Efficiency x Quality x Availability
* Mean Time between Failures (MTBF)
* Mean Time to Repair (MTTR) Quality - Zero Defects

Process Capability Improvement (Cp & Cpk) Cost - Minimize Life Cycle Cost, Reduce Lead Times, WIP,and Inventory and Spare Parts Management Delivery - Timely delivery to the customers - both internal and external Safety - Zero accidents both major and minor including near misses Depreciation - Eliminate or at least minimise depreciation of plant and equipment Morale - Suggestion Schemes, better Knowledge and Skills Enhance relations between various levels of Associates working together Create a Win - Win Situation for all

Addressing Key Result Areas Through A 12-Step Scientific Approach :

• Provide Training In :
  • 12 Steps to Key Result Areas implementation
  • Structured & Guided Brainstorming
  • Design Review (DR)
  • Failure Mode & Effect Analysis (FMEA)
  • 7 QC & 7 Management Tools
• Facilitate Planning and Implementation :
  • Choose the Key Focus Areas, Coordinators and members working on each KRA
  • Derive solutions for the problems identified by each team
  • Continue with improvements using PDCA Cycle
• Benefits of KRA Approach :
  • Greater task clarity/ Understanding the problem with greater clarity and working towards arriving at a lasting and permanent solution, without losing focus on immediate and urgent needs
  Multiple level solutions - immediate, intermediate and long-term
  • Development of a Holistic approach through involvement of all concerned individuals/ functions
  • Enhances sense of ownership and responsibility
  • Promotes teamwork
  • Solution is derived based on scientific approach and analysis, using well accepted and tested tools/ techniques, which is beneficial to the organisation on a long-term basis

TQM concept implementation by us is an all encompassing quality focussed approach covering all aspect of operation of an organisation. The key to improving quality is to improve processes that define, produce and support products and services. While Total Quality Management has proven to be an effective process for improving organisational functioning, its value can only be assured through a comprehensive and integrated implementation process. We cover the following tools and technologies in Total Quality Management:

* Variation, SPC, Control Charts, Sample Size, 7 QC Tools / 7 Management Tools
* Taguchi Methods (DOE-Design of Experiments)
* Quality Function Deployment
* Daily Management
* Team Management & Systems Thinking through KRA Approach
* Basic Quality Tools
* Management and Planning Tools
* Theory of Constraints
* Deming's PDCA Cycle
* Business Excellence Models using Malcolm Balridge, Edwards Deming, European FQM, CII (Confederation of Indian Industry) approaches; and ISO Standards
* 5S & Visual Controls
* TPM - Total Quality in Physical Assets Management

We offer this scorecard and policy deployment balanced service for various organizations. These services are carried out in a systematic manner so that the best can easily be availed by our clients. Our services in this sector includes: - Develop Organizational Balanced Scorecard along the four dimensional perspectives - Finance, Customer, Internal Business Processes and Innovation - Learning & Growth - Quantify & measure the present level of performance. Derive & set up the targets for future performance in each dimension - Inter-link and align individual, departmental/ functional and organisational initiatives - Shift from a uni-dimensional annual financial budget to a four-dimensional one. Finance budget (as in all companies); Customer-related budget, Internal Business Processes related and Learning & Growth focussed budgets - BSC based Annual & Five-Year Plans Policy Deployment is carried out in two Phases

• Phase I: Study the existing systems and policies in line with the Organisational Values, Vision and Mission and study how they enable or disable the budgetary and other targets from being achieved
• Phase II: Implementation of Balanced Scorecard through focused Policy Deployment spanning all departments, sections and levels of the organisation Benefits
• Shifting the focus organization-wide from purely financial measurements, reviews and corrections to the other equally important non financial areas
• Developing an organisation-wide holistic common understanding of the goals and objectives and the route to be adopted for achieving them
• Enhancing managerial capabilities
• Improving operational planning
• Deriving a mechanism to ensure result-orientation of individuals and measurement of their performance
• Introduction and reinforcement of relevant management controls
• Ensure increase in speed of response and shift from a reactive approach to a proactive one

The concept of Poka-Yoke was developed and revolutionized by a Japanese Manufacturing Engineer and Management Expert named Shigieo Shingo. The concept was originally known as 'fool proofing' but was later changed to 'mistake proofing'. The word Poka Yoke means to avoid inadvertent errors. The effective implementation of this concept leads to a business that consumes less energy, time and resources in doing the things in a wrong manner.

This concept aims at eliminating chances of making mistakes. In extreme cases, if there arises a possibility to eliminate the mistake completely, it is to be ensured that it is immediately detected and set right before sending to the client. Undetected service errors may result in serious failure of the product. Any person ranging from a manager to a line supervisor can develop a Poka Yoke to solve minor defects that might lead to inconvenience to clients or major ones leading to safety or environment hazards.

Our company helps the customers in instituting a system for implementing Poka-Yoke. The customer's employees are given intense training in Poka-Yoke concepts as well as the steps to implement them. We enable their teams to understand the entire process that includes knowing the way mistakes happen and measures to prevent them from taking place.

Six Sigma is defined as a measurement tool consistent usage of which transforms each level of an organisation to improve the organisation's overall quality and profitability. Breakthrough Strategy works its way up and down the hierarchies of an organisation. Hence, we help our clients to understand and integrate various processes at every level of the organisation to ensure long-term company wide improvements.

• Business Level - Executives at Business level use Six Sigma to improve :
  • Market Share
  • Increase Profitability
  • Ensure corporation's long-term viability
• Operations Level - Managers at Operations level use Six sigma to :
  • Improve yield
  • Eliminate hidden factories
  • Reduce labour and material costs
• Process Level - Employees utilise Six Sigma to :
  • Reduce defects and variation
  • Improve process capability
  • Align with the business and operational goals
  • Result in improved profitability and customer satisfaction

Our company offers training in lean manufacturing and also offer assistance in its effective implementation. This is a continuous process that involves:

• Identifying the core objectives of the organization.
• Identify what the customer pulls.
• Identify waste in all layers of the organization.
• Identifying value adding and non-value adding activities.
• Insisting on activities, which are valued by the customer.
• Extending lean principles out side the organization.

The lean implementation process is carried out in three stages that involve:

• Analysis
• Implementation
• Post-Implementation

Some of the techniques that we use in Lean implementation include the following:

• Value Stream Mapping
• Supermarket pull system.
• Finished Goods Supermarket
• Continuous Flow Production.
• Small Batch Production.
• Cellular Manufacturing.
• Production mix
• JIT
• KANBAN
• 5S
• TPM
• Poka-Yoke, Etc

Benefits of Lean Manufacturing

• Cut-down Inventory levels
• Reduced Lead time
• Waste elimination
• Improved Quality
• Elimination of Non value adding activities
• On time delivery.
• Reduced Production Cost
• Continuous Improvement
• Smal batch size, etc.

Propounded by Eliahu Godratt, the theory of constraints recognizes that organisations exist to achieve a goal. This concept focusses on an organisation's scarce resources for improving the performance of the real constraint. For managing constraints, a five step process involving ongoing improvement is followed:

• Identify - In order to manage a constraint, it is essential to identify it.
• Exploit - Focus on how to get more value within the existing limitations, by focussing on the weaknesses within the constraint.
• Subordinate - If our goal is to achieve the target, which would be seriously affected by the identified constraint, subordinate all other goals and initiatives to this single goal of overcoming this constraint.
• Eliminate or reduce queuing at the non-constraint resource/s by reducing resources applied there.
• Elevate - If, after fully exploiting this process, it still cannot produce enough value to satisfy the set goal, find other ways to meet it (like increasing capacity).
• Review and go back to Step 1.

• Pocket Book on 5S (Workplace Excellence) - Available in English and Telugu.
• Comprehensive Book on 5S
  
• 5S posters - Available in English, Hindi and Telugu.
  

• A book on Business & Ethics 

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