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Manufacturing Services Offered

Cycle Time and Lead Time Reduction; Inventory Reduction; Cost Control; Quality Improvement; Factory Layout Design; Delivery Performance Improvement; Set-up/Changeover Time Reduction; Kaizen Events; Cash Generation and Floor Space utilisation Through Inventory Reduction; Strategic Planning Facilitation.

Brief Description Of Service

AKK Associates is a hands-on group was formed in 1993 with the sole purpose of helping companies achieve dramatic, tangible results in short time periods. What resulted was a powerful process, which actually synergises the rapid transformation of traditional manufacturers to World Class Manufacturing.

Industries Served

	Most Industries
	Manufacturers
	Retail / Distributor
	Healthcare / Medical
	Non - Profit / Professional Bodies

Areas of Key Competence

	Just In TimeCycle Time Reduction
	World Class Manufacturing
	Lean Manufacturing
	Pull System
	Demand Flow Technology
	Continuous Flow Manufacturing
	Flexible Manufacturing

CELLULAR MANUFACTURING

PIC1                                           PIC2

These pictures shows two views of a Manufacturing Plant designed & set-up by us for manufacturing a Sheet Metal Fabricated Systems using World Class Manufacturing techniques. Pic 1 shows a panoramic view of two cells. Notice there is absolutely no Work In Progress inventory. Pic 2 shows how it is done using Cellular Manufacturing & Single Piece Flow techniques. Single Piece Flow is made possible by a technique called Set-Up Reduction or Quick Change Over. This Plant has very little total inventory, in the form of Raw Material & Finished Goods, with little or no Work In Progress inventory. Their manufacturing lead times are extremely small and the cells are extremely flexible.

	Cellular Layout
	Visual factory
	Set Up Reduction / SMED / QCO
	Supply Chain Management
	JIT Supplier / Supplier Partnering
	Inventory Reduction
	On Time Delivery
	Kanban

SET-UP REDUCTION

PIC1                                           PIC2

Pic 1 shows a Set-Up Reduction project in progress, the operator is explaining a point to rest of the team, while Pic 2 shows the Class Room session which preceded the Practical Shop Floor practical session. This project reduced the initial set-up time from the previous 6 hours to 30 minutes, in three stages. Pic 1 & 2 were taken during stage 1 of the implementation Program.

	Total Quality Management
	Quality Function Deployment
	Fail Safe / Fool Proofing / Poka Yoke
	ISO 9000 / Quality System

INVENTORY REDUCTION PROJECTS

PIC1                                  PIC2                                  PIC3

Racks & Racks of Precut Plastic Sleeves Pic 1 which were prepared by a sizeable Casual Work Force, were eliminated by positioning a worker directly supplying to the Packing Line. Eliminating both the sizeable casual work force and inventory. Pic 2 shows before and Pic 3 shows after the improvement. Casual Labourers saved 4. Work In Process Inventory saved upto 95%.      

	Placement Services
	Kaizen
	Total Employee Involvement
	Employee Empowerment
	Small Group Activities
	Team & Working Together as Teams
	Quality Circles

QUALITY IMPROVEMENT PROJECTS

PIC1                                                PIC2

Pic2 showed the frequent rework which used to be done in a large structural workshop, this was reduced through tooling. Pic 1 shows one of our facilitator examining a ingenious jig which eliminated reworks and was able to accommodate a large no of similar structural products. Earlier it was left to the skill of the structural fitter to assemble the various members before welding. Time saved by this jig amounted to about 80% of the original time.

       email: anupkelkar@vsnl.com