In FY14 & 15, continuous improvement initiatives were
greeted with commendable success. The focus was on
People - providing a comfortable and safe work environment
to the employees, Machine - improving Overall Equipment
Effectiveness (OEE), and Material – curtailing wastes. |
| People Productivity |
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| People are the true engines of any organisation. Enhancing their efficiency automatically leads to improved organisational productivity. During the reporting period, we carried out a systematic ergonomics study under the MOST (Maynard Operation Sequence Technique) programme across manufacturing facilities. |
| The resulting interventions ranged from creating strategic jigs and fixtures to refining process flows and man-to-equipment mapping. Besides enhancing the safety of workplace, we reaped benefits by reducing manpower costs and cycle times, in turn resulting in overall reduction of manufacturing costs. MOST is a 'pre-determined motion time system' to calculate 'standard time' consumed to perform a task. |
| Each task is broken down to a basic body motion and time to perform that task is measured. Optimum manpower required for a particular unit operation is estimated by identifying opportunities for combining / eliminating / reducing redundant motions and improving ergonomics.
A core team is formed from the plant / unit where MOST projects are launched. This team is trained on industrial engineering concepts and MOST techniques. |
| At Formulations Hyderabad Plant 2 packing line, earlier a total of seven people were employed per shift which on MOST study implementations were reduced to three persons/shift. This was attainable due to the minimisation of non-value added activities.
The recommendation from MOST study included: automation, mechanisation, process simplification, increasing the employee engagement level by rationalising work and redeployment of employees. Given below is an illustration. |
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