RMCPL

This is a dramatic case study where quick results were brought about in a very large cement plant. Reliability improved almost overnight. Productivity went up by additional 10% and maintenance cost came down by 50%. Failures virtually vanished. All employees could leave the plant on time and they forgot as to when it was the last time they were called in at the dead of the night to attend to failures. This plant is now an international benchmark in maintenance in the cement industry and they held onto the honour for the last 9 years without fail. Check the results for yourself.....

You may have multiple problems or issues with a system (doesn't matter what). But you need not tackle all these problems individually. By understanding the System (any) as a whole and the interactions between different parts of the system you can find out the inherent 'imperfections' that causes underperformance and failures. These can then be negated through viable micro design innovations. It not only eliminates all problems in one go but also gives you ongoing benefits for years. Click here to see the case study

This is an interesting story that highlights as to how an innovative approach can solve a long standing quality problem for good. The client was suffering on many fronts. Loss of brand image was the first. This was followed by poor sales and product recall which was eating into the profitability of the operation. Read how superior insights can be obtained and intelligent response can come up d through 'observations'. Read the full story here... 

This is a very unusual case study on how a sick company in India threatened by foreign competitors from Thailand and China reversed their fortunes by redesigning their maintenance strategies, planning, policies and work processes. This enabled them to increase productivity by 129% from their previous levels, improve quality from 3 sigma to 6 sigma, drop their product prices by 30% to squarely beat the strong competition and save the company from going broke. It is unusual because most top managers are unaware that maintenance and design can play a pivotal role in their survival. Go through their audited results to appreciate their achievements ...click here