Tetrahedron Manufacturing Service Corporate Deck

Ⓒ Tetrahedron Manufacturing Services Pvt Ltd, 2019
Tetrahedron Manufacturing Services Pvt Ltd

End-To-End Solutions for Manufacturing Industry
Manufacturing Excellence Training & Skill Development Automation & Industry 4.0 Strategic Sourcing & IPO
Sustainable Tangible Result
Automation
Industry 4.0 & Low
Automation
Training & Skill
Manufacturing
Development
& Industry 4.0

Excellence
Low Cost
Cost
We believe that every company We Offer 300+ Training and Skill Innovative zero cost & low cost
has a unique culture and unique Development Modules targeted at and sustainable automation helps
set of problems, and the business managers. Each of the companies to reduce cost,
manufacturing excellence model session is customized by conducting improve quality-safety-morale
we customize brings sure-shot state of the art pre and post with unique combination of low
time-bound tangible result for assessment techniques and gap cost systems like Gravity, Heat,
your company analysis. Sound, Light, Friction & Magnets
108+ Customers
We Are DIPP Recognised Start Up For Manufacturing Solutions
We are First One in India to Develop AGV Under INR 1,00,000
Ⓒ Tetrahedron Manufacturing Services Pvt Ltd
Centre Of Manufacturing Excellence
Achieving World Class Manufacturing System & Sustenance

V 1.1_2019 01
Lean Layout QMS Green SCM MIS Time S SDP BPR Audit Costing NPD
1 Lean Manufacturing
Manufacturing Excellence
2 Layout Development
3 QMS and Safety Management
4 Green Manufacturing
Center of
5 SCM, Logistics & Inventory Mgmt

12
6 Data Analysis & MIS
7 Time Study & Motion Study
8 Supplier Development & Up-Gradation
9 Business Process Re-Engineering
10 System and Process Audit
11 Costing & Budgeting
12 NPD, Engineering Design & Analysis

1 - Lean Manufacturing
• Waste Identification ( TIMWOOD)

• 5S and Work Place Improvement
• Productivity Improvement ( VAPE or Unit Work / Employee)
• Line Balancing & Flexible Manufacturing
• One Piece Flow / Single Piece Flow
• Formation Ratio for Leveled Work Allocation
• Heijunka (Lean Production Planning)
• Lead Time Optimization
2 – Flow Focused Layout Development
• Layout Design for Green Field Projects
• Layout Improvement for Existing Facility ( 30% Space

Creation)
• Flow Simulation in Layout for Lean Management
• Structural Analysis for Plant Layout
3 – Quality Management and System
• Implement ISO / IMS System

• COPQ Reduction
• Incoming Supplier Quality Improvement
• Statistical Quality Control and Improvement
• Quality Oriented Process Design
• Quality Process Documentation and Training
• Quality Abnormality Identification & Elimination
4 – Green Manufacturing
• Energy Cost Reduction and Carbon Foot Print Reduction
• Water Sustainability
• Process Innovation Focus Reduce Material Consumption
5 – SCM, Inventory and Logistics
• Supply Chain Design and Cost Optimization

• Network Analysis & Routing Standardisation
• Inventory Analysis & Optimization
• Lean Logistics System
• Logistics Cost Reduction
• Multimodal Transport Analysis
• Transporter Negotiation
• FTL / PTL Analysis
6 – Data Analysis & MIS
• Identify Strategic Parameter for MIS

• Develop Interactive MIS Dash Board
• Reporting System – Periodic, On Demand, Exception & Deep Drill
• IT Enabled MIS System (Remote Accessibility)
• Decision Making Support to Management by MIS
• Manufacturing / Inventory / HR Data Analytics
7 – Time Study & Motion Study

• Time Study
– Actual Work
– Observation / Inspection Time
– Idle Time
– Transportation Time
– Movement Time
• Motion Study
– Movement Analysis
– POU ( Point of Use)
– Ergonomics Report
• MOST – Maynard Operation Sequence Technique
• MSM – Method Standard Measurement

8 – Supplier Development & Up-Gradation

• New Supplier Identifcation & On-boarding
• Supplier Manufacturing Capability Audit
• Supplier Quality Audit
• Documentation Audit
• Support Supplier Cluster for Better Supplier Performance
• Supplier Manufacturing System Integration with Customer
9 – Business Process Re-Engineering

• Business Process Mapping
• Business Process Improvement – 3D Approach

– Delay in process
– Deviation in Standard Process
– Duplication of Process
• New / Modified Process Simulation
10 – System and Process Audit

• Manufacturing Process Audit
• Procution Planning System Audit
• Process Efficiency Improvement Scope Analysis
• Product and Part Traceability Audit
• Manufacturing System Up-Gradation
• Bench-marking Comparison Analysis
• GAP – Analysis and Upgradation Plan for Financial Impact
11 – Costing and Budgeting

• Product and Part Costing
• Process Costing
• New Product Development Costing
• Manpower Investment Planning
Lean Layout QMS Green SCM MIS Time S SDP BPR Audit Costing NPD`
12 – NPD, Engineering Design and Analysis

• New Product Development
• NPD Process Design and Validation
• Market research for New Product Introduction
• NPD Investment Planning
• Engineering Design (2D + 3D)
• Product Assembly Simulation
• Structural, Thermal, Coupled Analysis
Automation & Industry 4.0

By Tetrahedron Manufacturing Services Pvt Ltd
Technology & Innovation for Cost Reduction and Sustenance

V 1.1_2019 01
Zero Cost and Low Cost Automation
Principles Used Reduce

• Hydraulic 1 Process & Assembly Automation
Manpower
• Pneumatic 2 Machine Automation Cost
• Magnets
• Springs 3 Material Handling Automation
• Gravity
Improve
• Sound 4 Hazardous Process Automation
Productivity
• Light
5 Packaging Automation & Quality
• PLC, DCS, SCADA
6 Dimensioning Automation
Tools and Systems 7 Quality Control Automation Improve

• TRIZ Ergonomics
• WV Innovation
8 Climate Control Automation
Zero Cost Automation & Low Cost Automation
Prelim Analysis Detail Engineering Drawing Implement & Handhold
•3 ~ 4 Day Prelim Visit to •Detail Engineering •Implement by Clinet In-

Observe Drawing House Team
•List Possible & Feasible •Concept Validation by •By 3rd Party Vendor /
ZCA and LCA Expert Manufacturer 30%
Auto load / unload after processing

•Concept and Tentative •Simulation to see the •By tetrahedron Team
Investment actual operation
5%
Machine auto detect defects during

10%
Machine / Equipment auto run

after placement of material
20%
and post processing
(Robotics)
Automatic Transfer of
material to machine
Saving Potential
Using Jigs and Fixture

ZCA • RoI < 3 Months
25%
material in hand
Zero Cost • In-House Developed
Holding the
Automation
LCA • RoI < 18 Month

Low Cost • Easy To Develop
Automation
Level 0 Level 1 Level 2 Level 3 Level 4 Level 5
Industry 4.0 - Smart Factory Systems & Tools
1 Industrial Internet of Things (IIoT)
Industry 4.0 2 Big Data Analysis
2010s – Smart Factory
3 Robotic Process Automation (RPA)
Industry 3.0 4 Additive Manufacturing – 3D Printing

1970s – Automation
5 Augmented Reality & Virtual Reality
Industry 2.0 6 Simulation & Analysis

1940s – Mass Production
7 Cyber Security
Industry 1.0
8 Integration
1800s – Steam Engine
9 Horizontal & Vertical System
Industry 4.0 - Implementation Approach
Smart Factory Business System Organisation &

Blue Print Requirement & Implementation Skill
Development Impact Study & Customisation Development
Smart Factory Needs Post Blue Print Tetrahedron identifies All new system needs
Smart Planning and Development, the best hardware & a skilled and
Tetrahedron, as stage Tetrahedron advise software, coordinate educated workforce.
1, hand-hold and help client on the short with CFT (Cross Tetrahedron develops
companies to listed systems / tools Functional Team), the relevant QPs
understand which of and the target managing the project (Qualification Packs),
the elements are business impact timeline & develops Map Competency &
relevant & required, e.g. Decision Making, interactive & Train for successfully
rather than investing Productivity, Quality, customised MIS / using the New I 4.0
in trivial systems & Cost Reduction Dashboard Systems
Training & Skill Development Workshop

Tetrahedron Manufacturing Services Pvt Ltd
End-2-End Training & Skill Development Solution

V 1.1_2019 01
Strategy & Management Technical Workshops Process Improvement Soft Skill & Behavioral Development Workshops
Training & Skill Development Expertise
E-2-E 300+ 70% VR / AR DOJO

End-to-End Workshops Activity Based Modules Skill Center
From Competency Designed & Developed 70% of Workshop time Technology like Virtual Tetrahedron’s
Definition, Skill & Delivered 300+ is used for Individual Reality and Augmented Manodzukuri expertise
Mapping, Training Need Workshop in Activity, Pair Exercise, Reality based training- help clients to design
Identification, Pre–test, (1)Strategic Modules, Group Exercise along workshop modules help DOJO training relevant
Course Customisation (2)Technical Modules, with Role play and individual to learn and to their manufacturing
as per Pre-Test output, (3)Process Modules, Case studies relevant re-learn the standard process and set up 12
Post-Test, One Project to the subject and modules with out level DOJO Centers
(4)Behavioral Module,
Implementation Support participant experience trainers assistance.
and 3 stage Training
(5)Integrated Modules and expectation. Each These modules helped
Effectiveness for professionals workshop is concluded company with large
Measurement after across the mgmt levels with an action plan for batch recruitment,
session completion implementation structured training plan,
highly critical process
Training & Skill Development Expertise
E-2-E 300+ 5 70% DOJO

End-to-End Workshops Category Activity Based Skill Center
Designed &
From Competency Developed & Segmented in 5 70% of Workshop Tetrahedron’s
Definition, Skill Delivered 300+ High Category to address time is used for group Manodzukuri
Mapping, Training Impact Workshop All Levels of and individual expertise help clients
Need Identification, Modules Segmented Management, exercise, role play to design DOJO
Pre–test, Course in 5 Category Officers, Supervisor and case studies training relevant to
specifically designed
Customisation, Post- and Operators by relevant to the subject their manufacturing
for professionals
test and Project across the industry Strategic Workshop, and participant process and set up
handholding and across the Technical Workshop, experience and 12 level DOJO
management levels Process Improvement expectation Centers
& Professional Skill
End-To-End Training Solution

1 2 3 4
Competency Training Need
Skill Mapping Pre Test
Definition Identification
8 7 6 5
Training
Post Training Project Course Design &
Effectiveness Post Test
Support Delivery
Measurement
Strategy & Management Workshop

Business Growth Strategy Sustainability Strategy
Balance Score Card (BSC) Audit Carbon Foot Print & Carbon Credit Trading
Bench Marking and Best Practices in Mfg Green Building Audit & Execution Methodology
Business Simulation – Multi Layer Domain Specific Sustainability
Change Management Green Manufacturing Systems : Applications
Entrepreneurship Performance Management
60 Workshop Modules Ethics & Values in Organisation
Hoshin Kanri and X-Matrix Strategy Deployment
7 Effective Way of Performance Management
Focused Performance Improvement – KRA KPI JD
Leadership Skills Job Description and Analysis
Project Management (Certification) Performance and Competency Mapping
For Sales and Customer Relation
Data Analysis
Strategic Performance Management
Team Management and Leadership
Big Data Science for Data Analysis in Mfg/SCM Training Need Analysis by Statistical Approach
Business Analysis - (ECBA, CCBA, CBAP) Skill Mapping & Training Need Identification
Top & Senior Leadership Advanced MS Excel - Dashboards & MIS
Innovation Strategy
Quality Strategy
Shanin Quality Principle
Design Thinking The Taguchi Method
Problem Solving and Strategic Thinking Global Sourcing
To Problem Solving by System Thinking Supplier Relationship Management
SCAMPER for Innovation Supply Chain Certification - (CSCP, CSCM)
TRIZ – Theory of Inventive Problem Solving (TIPS) SS - Critical Negotiation Skills in Procurement
Design + Deploy + Drive Manufacturing Strategy
Daily Work Management (DWM)
Developing a World-class Procurement Strategy
Developing and Managing Contracts and SLAs
Enterprise Risk Management Effective Tendering and Supplier Management
Finance for Non-Finance Managers Finance for Procurement Professionals
Strategy Industry 4.0 – Preparation Strategy
Sales & Operation Planning (S&OP) & IBP
Fundamentals of Purchasing & Procurement
Fundamentals of Strategic Sourcing
SAP Training ( MM, ME, SD, FICO, HR) International Procurement Programme
Theory of Constraints (TOC) Legal Aspects in Sourcing & SCM
Value Stream Mapping - VSM Managing Procurement Risk
World Class Quality & World Class Manufacturing Managing Total Cost of Ownership
SCM Selling Procurement Business Cases
Supplier Relationship Management Spend Analysis
Supply Chain Analytics Strategic Sourcing and Category Management
Understanding Incoterms
Technical Workshop
Automation System Data Analysis
Advance Hydraulics BI (Business Intelligence) Tool
Automation and Control Minitab
Controllers Regressing Analysis
Industrial Automation and Control Sampling Theory
Industrial Instrumentation Statistical Methods For Scientist and Engineers
160 Workshop Modules Machtronics and Manufacturing Automation
Neural Networks and Application
Design & Development
Advance Finite Element Analysis
Pattern Recognition and Application APQP (Advanced Product Quality Planning)
PLC Integration to LAN and WAN Auger Design
For Robotics
Robotics:Advance Concepts and Analysis
B&P Diagram - Boundry and Parameter Diagram
CAD for VLSI Design
SCADA CATIA
Sensors
All Mgmt Level Wireless Ad Hoc and Sensors Network
Distributed Control System: Siemens+Emerson
Collaborative Product (Process) Development CPD
Creative Engineering Design
Design FMEA (DFMEA)
Industry 4.0
Design for Manufacturing & Assembly ( DFM/A)
Algorithms for Big Data
To Artificial Intelligence (AI)
Design Fundamentals
Design Review based on Failure Mode (DRBFM)
Certied ScrumMaster (CSM)
Design Verification Plan and Report (DVP & R)
Virtual Reality (VR)
Destructive and Non-Destructive Tests
Ensure Right Technical Quality Management
Design for Quality (DFQ) Engine Testing & Vehicle Testing
Engineering Drawing
Measurement System Analysis
Measuring Uncertainty in Calibration (MUC) Environmental FMEA
Skill MSA + SPC

PPAP (Production Part Approval Process)
Failure Mode Avoidance (FMA)
Failure Mode Effect & Criticality Analysis (FMECA)
Principles of Mechanical Measurements Failure Mode Effect Analysis (FMEA)
Process FMEA (PFMEA) Finite Element Analysis (FEM)
Product Quality Control - Advanced Approach Front End Engineering Design (FEED)
Quality Function Deployment (QFD) GD&T (Geometric Dimensioning and Tolerencing)
Reliability Engineering GD&T Advanced- Tolerance Stack-Up Analysis
SPC (Statistical Process Control) New Product Development
Theory and Practice of Non Destructive Testing PLM
Technical Workshop (Contd…)

Six Sigma Electric Vehicle
Analysis of Variance and DOE Advance Electric Drives
Applied Multivariate Analysis Electric Vehicle Design & Assembly
Design for Six Sigma (DFSS) Electric Vehicle Maintenance and Repair
Design for Six σ & Design of Experiment Introduction to Hybrid and Electric Vehicles
Design of Experiment (DoE) Manufacturing Engineering & Management
160 Workshop Modules Standards & Audits
Assurance Audits & Reviews
Advance Machining Processes
Advance Manufacturing Processes
Mechanical Measurement and Metrology Advances in Welding and Joining Technologies
Sustainability Strategy Braking System (Including Tyres)
For Green Manufacturing CNC Lathes and Mills
Water Management Compressors
TPM ESD Controls In Manufacturing
All Mgmt Level General Inspection eduction and Exectuion
Minor Stop + Speed Loss + defect Loos
Flexible Manufacturing Systems (FMS)
Fluid Power
Morden Maintenance and Predictive Maintenance Gear Technology
Reliability & Maintainability (R&M) Grinding & Shaping Finishing
To Reliability Centered Maintenance (RCM)
TPM - 10 Pillar Approach
HVAC System
Industrial Drives:Power Electronics
TPM - 16 Losses and 8 Pillars Machine Fault Diagnosis and Signal Processing
Ensure Right Technical TPM - 7 Steps of PM

TPM - Figure of 8 Appraoch
Material science
Pipe Stress Analysis & Practice Using CEASER - II
TPM - JH Step 1 to 4 & 5 to 7 Surface Treatment /Paint Technology
TPM - Makigami Analysis Theory and Practice of Rotor Dynamics
Skill TPM - PM Analysis - Figure of 8 Approach
TPM - QA / QM Matrix
VFD Parameterization and Maintenance
Vibration Control
TPM - SMED (Single Minute Exchange of Die) Weld Technology
TPM - Tag Attach - Remove - Analysis Pipeline Integrity Management System with ASME
TPM - Total Productive Maintenance Vibration Monitoring & Analysis + Simulation
Set Up & Start Up Loss Improvement Advance Manufacturing Process
Work Place Management Ergonomics For Industrial Design
Industrial Engineering Industrial Oil Hydraulics and Pneumatics
Time Value of Money Concepts and Calculations Smart Material & Adaptive Structure
Process Improvement Workshop

Quality Management Safety & Work Place
Quality Control System Safety Audits and Safe Work Place
Quality Management System Safety Proactive / Reactive ; Leadersip in Safety
TQM - Total Quality Management Santei and 5S+Safety+Work Place Management
Advanced Quality Assurance & Quality Control SCM
Lean Methodologies Operations and Supply Chain Management
60 Workshop Modules Cellular Manufacturing Concepts
Supplier Development and Improvement
Supplier On-Boarding & Development
Lead Time Reduction in Manufacturing
Tender and Contract management
Lean Logistics and Material Handling techniques
Six Sigma
For Lean Manufacturing
Line Balancing
Advanced Lean Six Sigma
Six Sigma (Black Belt)
Manpower Productivity in Manufacturing Six Sigma (Green Belt)
Senior & Line Managers One Piece / Single Piece Flow
Problem Solving
Six Sigma (Yellow Belt)
Standards & Audits
7 New QC Tools Conducting Safety, Energy & Pollution Audit
7 QC Tools ISO 14000
To CAPA (Corrective And Preventive Action) ISO 16949 & IATF
ISO 18000
Kaizen Approach & Implementation Technique
Root Cause Analysis (RCA) and Problem Solving ISO 9000
CI and Problem Solving Why Why Analysis

8D Problem Solving
Process / System Audit Skill
Work Place Management
Plant Layout Improvement and Space Creation
A3 Method
Visual Management and Visual Factory
Process Enhancement
Skill Poka Yoke – Mistake Proofing - 100 + Examples
Flow Focused Lean Layout
Layout Planing for Proiductivity Improvement
PQCS (Process Quality Control System) Manufacturing Engineering & Management
Process Modeling and Simulation Business Process Re-engineering
Service Operations Management Consumption Based Production System
Simple & Low Cost Automation - 100+ Examples Materials & Spares Management
VA & VE ( Value Analysis and Value Engineering) Statistical Interference
Standard Work, Motion and Time Study (TWI) Production & Project Management
MS Excel: For Production & Supply Planning
Soft Skill 7 Behavioral Workshop

Anger Management Being a Good Team Player
Being Positive in Negative Situation Business Communication
Communication Skill Commitment to Work
Conflict Management & Resolution Creative Thinking
40 Workshop Modules Dealers, Associate and Workshop Training Creativity & Innovation
Emotional Intelligence Customer Focus
Enhancing Personal Effectiveness Dealing with Emotions
For Motivation and Team Building Decision Making
Multi Taksing & Work Effectiveness Goal Setting
All Managers Outbound Training, Adventure Training Grievane Management
Presentation Skill Improvisation
Prioritisation Techniques Taking Initiative
To Soft Skill in Manufacturing Companies Integrity & Self respect in Work Place
Stress Management Leadership
Professional Attitude The Art of Delegation POSH, Legal & Statutory Compliances
Negotiation Skill
Time Management
Work Life Balance - Win Win Strategy Nonverbal Communication
Skill Accountability & Responsibility
Planning & Proritisation Skill
Problem Management
Accurate & Active Listening
Team Time and Task Management
Analytical Thinking
The Art of Delegation
Answering a Complaint
Verbal Communication
Assertiveness & Positive Attitude
Written Communication
Attention to Detail
Development Workshops
MDP SDP GMDP ODP
Managerial Supervisory GET / MT Operator
Development Development Development Development
Program Program Program Program
20 Modules 40 Modules 24 Modules 2 Days
6 Months 6 Months 4 Months 6 Days
A perfect blend of As the back bone of Operators run the
Entry Level Graduate
Managerial, Technical, manufacturing line, the machine / work and add
Engg Trainee and
Commercial and Problem SDP covers 40 Modules value. ODP provide
Management Trainee
Solving Skill for that addresses Process behavioral, people skill
would learn all critical
Experience Manager Improvement, Daily and align them to to
aspects of working and
that will enable them to Management, Emotional organization VMO
sustaining in the industry
take quick and informed Intelligence, in technical, Managerial
decision
and Behavioral
DOJO Center Design & Set Up Safety DOJO

Safety Pledge
Production DOJO
Production Rules
Safety Symbols & Signals SOP’s
Know Your Company Fire Exit Simulation (VR) Do’s & Dont’s
Fire Safety & Hydrants
1 Harness :Safety in Height Quality DOJO
Innovation 12 2 Safety Safety Shoe Quality procedures
Safety Mask Measuring Instruments
Safety Helmets
PPE Matrix Maintenance DOJO
Ergonomics 11 3 Product Different PPEs Electrical maintenance
First Aid Mechanical maintenance
CPR Spare Parts
5 Senses DOJO OJT Evaluation

Hand Movement &Graduation
Certification 10
12 Level DOJO 4 Walking Speed
5 Senses Ambidexterity ERGO DOJO (Ergonomic)
Sequence Hand Eye combination Standing Posture
Hand (Feel –Measure) Sitting Postures
Hand ( Feel – Shape) Pushing & Pulling Postures
Hand ( Feel – Weight) Walking speed
Heat Sensing Material lifting Postures
OJT & Test 9 5 Process Vibration Sensing
Torque Measurement INNO DOJO ( Innovation)
Brainstorming Process
Process DOJO Kaizen
Maintenance 8 6 Production Process Flow Low Cost Automation /
Assembly sequence Karakuri
7 Takt Time Adherence Mind Mapping
Quality Problem Solving
Case 1
Automation for Quality Improvement of Assembly Line
India’s Largest Two Wheeler Manufacturer
(Before Tetrahedron –
1. Problems in Engine Assembly Line ; Part Mismatch and Missing Components
2. Frame Assembly Quality Issue”)
Tetrahedron studied the Assembly line in detail and suggested changes; more over
made sure that the engineers are comfortable with the existing technologies
Following results were achieved :-
1. Development and Implementation of Poke Yoke Device in order to churn
assailable products
2. Implementation of Low Cost Automation to reduce product rejection issues to
zero.
3. Manpower saved / Heater = 8 /Machine to 3 Per Machine
Case 2
Automation Implementation and
Manpower Reduction (On going)
India’s Largest uPVC Manufacturer
(Before Tetrahedron:
1. High Cost due to High Manual Manufacturing
2. Low Productivity due to non standardized product
3. High WIP because of Material Handling
4. High Manual Packaging leading to high labour Costs ”)
Tetrahedron studied the entire production line and helped in identify at least 43
opportunities to implement automation . With this in mind, 17 high impact
projects were taken on. Following results were achieved:-
1. 36% Manpower Reduction
2. Ideation and Implementation of end to end Material Handling
3. Material Handling breakages reduced by 70%
4. 40% Line Productivity Enhancement
Case 3
Material Handling and Process Automation
India’s Largest Precious Metal Exporters
(Before Tetrahedron
1. Extremely labour intensive operations resulting to high costs
2. High pilferage of precious raw materials
3.Quaterly INR 40 Lacs of raw material unaccountable or pilfered )
Tetrahedron helped the company to turn around the operations of the

company in an industry which resistant to change. Following results
have been achieved:-
1. 15% reduction in Manpower; 20% reduction still on going

2. Developed In-House Machines with company’s engineers to Automate
Workflows.
Case 4
Innovation & Strategy Management
Leading Manufacturer of Electric Vehicle Parts & Energy Solution
Before Tetrahedron
1. Stagnant Market for last 2 years due to competition
2. Missing Linkage between Operations and Revenue Generation
3. Top Management looking for Innovative New Approach
Tetrahedron implemented various Innovative Approach like TRIZ, Design Thinking, Five Step
Discovery Process to hand hold senior managers for new product development with clear
focus on customer need and revenue potential. Implemented Balance Score Card, Hoshin
Kanri and Daily Work Management Principle to link each individuals activity with annual
target on Customer Focus, Financials, Internal Process and Learning & Growth
• 2 New product Developed for EV market
• DWM Dashboard developed for each department and individual
Case 5
Gearing-Up for Industry 4.0
Leading Automotive Part Manufacturer
Before Tetrahedron
1. Struggling with managing supply chain of 12 plants across India
2. Deadline by OEM customer for implementing Industry 4.0
Tetrahedron Conducted Pre-assessment and strategizing a blueprint of

implementation of Industry 4.0 elements with respect to company’s strengths.
Conducting ROI Analysis and Cost Benefit for 9 elements of Industry 4.0 made
action plan for 2 yrs for implementation. The main focus was to streamline supply
chain of all 12 plants to reduce cost and improve efficiency
• 3 out of 9 elements selected for Industry 4.0 implementation
• Delivery efficiency to customer improved by 12 % in 6 months
• Inventory level reduced by almost 20% ( on going)
Case 6
Automation for Feeding of Rubber to Improve Productivity and
Quality
Leading Tire Manufacturer in North India
(Before TMS – Long cycle time for weighing the natural rubber and chemical that would feed
the heater for base preparation. Long Cycle time as well as manpower fatigue, incorrect
batch composition was leading to productivity loss as well as quality problems. When
enquired by TMS, the manager said “we need more manpower to execute/produce given
quantity and quality”)
Tetrahedron developed the automation map of the company and identified 3

solutions for automating the process described above. Following result achieved in
2 months:-
1. Cycle time standardized for all 6 Heaters
2. Batch consistency improved from 67% to 92 %
3. Manpower saved / Heater = 8 /Machine to 3 Per Machine
Case 7
Productivity Improvement
Automotive Assembly Manufacturer (Gurgaon)
(Before TMS – Not able to match customer order despite of 24 Hrs X 7 Day operations resulting
in 20% business/revenue loss every month. Client was planning to take additional space on
rent to set up new line to cater to existing customer order)
Tetrahedron conducted Time & Motion Study on Horn Assembly Line as a pilot and
later horizontal-deployed to all Inspection line. The result achieved in 3 months:-
1. Improved the Parts / Man-Hour by 28 %
2. Identified bottle neck operation and created sub-tier set up
3. Deployed Manuf. Line Assembly set up ( earlier batch set up)
4. One Piece flow implemented
5. Line Balancing Implemented
6. Formation ratio (Work Sequencing Improved & idle time reduced)
7. WIP reduced by almost 70%, 5S improved
Case 8
Lean Management in Fettling Operation
Leading Global Automotive Part Manufacturer (Bhubaneswar)
(Before TMS – Operating as a batch process fettling operation leading to huge WIPs and
frequent delivery failures due to unavailability of finished goods)
Tetrahedron conducted Time & Motion Study for Shot blasting to painting operation
of the fettling line with a target to develop a Lean Line with 5 Yrs capacity
projection.
The result achieved in 6 months:-
1. 3 Shifts (24 Hrs ) operation reduced to 19 Hrs
2. Line Balancing Implemented – Sequential Flow of Goods, FIFO
3. Line formation with exact manpower requirement with projections
4. Identified 20+ Simple Automation
5. Multiple Operation by single workman by formation improvement
6. WIP reduced by 50%
Case 9
Manpower Cost Standardization
Medical Diagnostic Equipment Manufacturer (Manesar)
(Before TMS – Management was concerned for high / fluctuating manpower cost /piece and
unavailability of skilled manpower. When enquired by TMS, the supervisor said “we need
more manpower to execute/produce given quantity”)
Tetrahedron conducted Time & Motion Study for the existing assembly line to see the
deviation on manufacturing cost
The result achieved in 3 months:-
1. Identified 12 bottle neck operations (more than average) in the line
2. Developed SOPs for 78 process with end-to-end standardisation
3. Number of manpower allocated reduced from 23 to 17
4. Skill level improvement and multi-skilling of line operator
5. WIP reduced by 30%
6. Simple Automation to removed 12 manual operation and reduce the cycle time
by 18%
Case 10
Manufacturing Excellence in Flock Manufacturing
India’s Leading Velvet Cloth Manufacturing
Before Tetrahedron
1. Low Productivity Leading to Lower VAPE
2. High WIP and Inventory due to improper Planning
3. Manual Loading leading to high labour and time
Tetrahedron implemented S&OP to improve the Production planning reduce WIP reduction due
to reduce order production mismatch , Designing of low cost automation for material
handling
1. VAPE improved by 17%
2. WIP reduction by 23%
3. Truck Loading Time Reduced by 28%
4. Contract Worker Cost Reduction by 42% (18 to 10)
Case 11
Manufacturing Excellence in Cement Manufacturing
Leading Cement Manufacturer (French Conglomerate)
Before Tetrahedron
1. High Process Variability Leading to uncontrolled quality & B Grade Cement
2. High Truck Retention Time in side plant : 8 Hr
3. INR 75 Lakh / Month Demurrage to Indian Railway due to loading delays
Tetrahedron implemented Six Sigma concept to standardize / reduce the variability in input
material and by using online monitoring controlled the parameter to reduce B Grade
output. Implemented lean logistics concepts to trigger series based on truck reporting in
gate to reduce the truck retention time and railway wagon loading process
• A Grade : B Grade ratio increased from 79:21 to 89:11
• 50% reduction in loading and unloading time (12 Hrs to 6 Hrs)
• 75% reduction in truck retention time ( 8 Hrs to 2 hrs)
Case 12
Over Time Reduction in Jewelry Manufacturing
India’s Largest Silver Jewelry Manufacturer & Exporter
Before Tetrahedron
1. 7 Lakhs/ Month Over time expenses in Manufacturing
2. Material Mismatch and Poor Delivery Adherence ( 85%)
3. Increasing Absenteeism for Overtime Allocation (14%)
Tetrahedron implemented Lean Flow Management with FIFO ( First In and First Out ) with
multi-colur bin tracking system on Delivery Dates. Manufacturing Data analysis and
visualization of real time data helped identify the real time bottle neck and take immediate
and appropriate corrective actions.
• Over Time Reduction from 2,20,000 to 1,05,000 in 2 Months in Mfg Dept
• Delivery Time Line Adherence improved to 92 %
• Employee Morale Increased due to less pressure on Over time
Safety DOJO
Safety Pledge
Fire Exit – Real Simulation
Fire Safety & Fire Hydrants
PPE Matrix
Harness – Safety in Height
Safety Shoe
Safety Mask
Safety Helmets
Different PPEs
First Aid
CPR
Product DOJO
Different Product
5 Senses DOJO
Hand, Hand Eye, Ambidexterity, Hand (Measurement, Shape, Weight)
Hand Movement
Ambidexterity
Hand Eye combination
Hand (Feel – Measurement)
Heat Sensing Vibration Sensing Walking Speed
Hand ( Feel – Shape)
Hand ( Feel – Weight)
Walking Speed
Heat Sensing
Vibration Sensing
Torque Measurement
Process, Production, Quality & Maintenance DOJO
PROCESS DOJO PRODUCTION DOJO
•Process Flow •Production Rules

•Assembly sequence with part •SOP’s
•Takt Time •Do’s & Dont’s
QUALITY DOJO MAINTENANCE DOJO
•Electrical maintenance
•Quality procedures
•Mechanical maintenance
•Measuring Instruments
•Spare Parts
OJT, Evaluation & Graduation
OJT & Evaluation Graduation
•On job Evaluation & Support •Appreciation & Certification
Ergo and Inno DOJO
ERGONOMICS DOJO INNOVATION DOJO

Standing Posture Brainstorming Process
Sitting Postures Kaizen
Pushing & Pulling Postures Low Cost Automation / Karakuri
Walking speed Mind Mapping
Material lifting Postures Problem Solving
Ⓒ Tetrahedron Manufacturing Services Pvt Ltd, 2019
Contact Us
Phone : +91 7042140046

Email : tms@tetrahedron.in
Web : www.tetrahedron.in
Delhi Office
Building H3/39, Shri Hari Enclave
Sector 18, Rohini, Delhi – 110089
Regd Office
Golf Course Road, Sector 54
Tetrahedron Manufacturing Services Pvt Ltd Gurgaon, Haryana - 122002

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Ⓒ Tetrahedron Manufacturing Services Pvt Ltd, 2019

Tetrahedron Manufacturing Services Pvt Ltd

& Industry 4.0

Centre Of Manufacturing Excellence

Achieving World Class Manufacturing System & Sustenance

3 QMS and Safety Management

5 SCM, Logistics & Inventory Mgmt

7 Time Study & Motion Study

8 Supplier Development & Up-Gradation

9 Business Process Re-Engineering

10 System and Process Audit

11 Costing & Budgeting

12 NPD, Engineering Design & Analysis

• Waste Identification ( TIMWOOD)

2 – Flow Focused Layout Development

• Layout Design for Green Field Projects

• Layout Improvement for Existing Facility ( 30% Space

• Flow Simulation in Layout for Lean Management

• Structural Analysis for Plant Layout

3 – Quality Management and System

• Implement ISO / IMS System

• Energy Cost Reduction and Carbon Foot Print Reduction

• Process Innovation Focus Reduce Material Consumption

5 – SCM, Inventory and Logistics

• Supply Chain Design and Cost Optimization

6 – Data Analysis & MIS

• Identify Strategic Parameter for MIS

7 – Time Study & Motion Study

• MOST – Maynard Operation Sequence Technique

• MSM – Method Standard Measurement

8 – Supplier Development & Up-Gradation

9 – Business Process Re-Engineering

• Business Process Improvement – 3D Approach

– Deviation in Standard Process

• New / Modified Process Simulation

10 – System and Process Audit

11 – Costing and Budgeting

• New Product Development Costing

• Manpower Investment Planning

12 – NPD, Engineering Design and Analysis

Automation & Industry 4.0

Technology & Innovation for Cost Reduction and Sustenance

Principles Used Reduce

Tools and Systems 7 Quality Control Automation Improve

•3 ~ 4 Day Prelim Visit to •Detail Engineering •Implement by Clinet In-

Auto load / unload after processing

Machine auto detect defects during

Machine / Equipment auto run

and post processing

Using Jigs and Fixture

LCA • RoI < 18 Month

3 Robotic Process Automation (RPA)

Industry 3.0 4 Additive Manufacturing – 3D Printing

Industry 2.0 6 Simulation & Analysis

Smart Factory Business System Organisation &

Training & Skill Development Workshop

End-2-End Training & Skill Development Solution

Training & Skill Development Expertise

E-2-E 300+ 70% VR / AR DOJO

Training & Skill Development Expertise

E-2-E 300+ 5 70% DOJO

End-To-End Training Solution

Strategy & Management Workshop

Skill MSA + SPC

Technical Workshop (Contd…)

Ensure Right Technical TPM - 7 Steps of PM