Lean manufacturing is a diamond in the rough for one mineral company

K. Girdharlal International, a diamond company that employs more than 2,000 people at its factory in India, has identified Lean manufacturing practices as being pivotal in the business' efforts to improve operational efficiency and effectiveness. Up until recently, K. Girdharlal had been using more traditional top-down management techniques. However, the organization is now looking to continuously innovate on established practices and reduce wasteful processes and procedures.

Crucial to the implementation of Lean manufacturing processes was a significant shift in cultural development. Employees and management alike became more familiar with Lean tools associated with the Toyota Production System (TPS) philosophy, and they have been trained to use these practices to achieve the maximum benefits. By understanding that Lean is as much a cultural change as it is a shift in practices, the transformation has helped to improve morale throughout the workplace.

To aid the integration of Lean practices, K. Girdharlal started by setting milestones with timetables to achieve specific results, such as improved productivity, reduced cycle time, process consolidation through waste elimination. In particular, the company took a look at how the seven core wastes could be applied to its operations, such as overproduction and misuse of creative talent.

“It's our privilege to be on path of transforming organization to lean for sustainable growth and strengthen the bottom line. We are keen to take the process forward as part of continual improvement,” said Yogesh Shah, the director at K. Girdharlal.

As K. Girdharlal moves forward, the company hopes to take steps such as increasing the productivity of machines and people, improving workplace management and leadership and creating an effective means of communication across the production floor.

Making Lean integration a company-wide effort

Lean integration is a beneficial transformation for any business, but it's pivotal that businesses devote themselves to the commitment. Like any radical shift in culture and operations, Lean manufacturing requires time for everyone involved to adjust.

Dozens of companies throughout the world have shown that Kaizen mindsets and practices can bring tremendous value to any industry. However, companies need to be able to stick with these new practices in order to reap the greatest rewards.