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Ravi Vaidiswaran

Ravi Vaidiswaran’s Post

Ravi Vaidiswaran
Consulting Services
1d · Edited

I see many GETs (fresh graduate engineers) unwilling to sweat it out on the floor to learn and
understand the technical side, but are seeking air-conditioned comfort at the first opportunity to get
away from the floor (sometimes with excuses).

Many times I see them back in office doing something on their desk, while senior teams are still on the
floor addressing issues.

Agree it is hot and humid on the shop floor but you need to sweat it out to learn as well. Workmen are
also working...

If you have opted for an engineering career, you have to be on the floor to learn. Gemba is the only
place where actual learning takes place.

Things were very different in our times, 30 years back.

#management
#learninganddevelopment
#learnandgrow
#hardwork

27 · 11 Comments

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Hitesh Sharma 1d
Director, Xpertpack transport packaging pvt Ltd

Ravi Vaidiswaran I was on site yesterday , sweating it out with the team. amazing feeling .
shop floor is where the action happens.

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Sandeep A Hingne (PhD) 1d

Global professional with 30+ years of exp in India, UK, Africa & SE Asia | Always delighting stake holders

Spot on as I just witnessed this from IIT folks

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 Raj Sanne 1d

I agree and cannot add anything more. I have sweated it out on shop even as a consultant
ranging from generating leads, giving proposal, doing the job, writing the report and
discussion for implementation.
Working in manufacturing I have to be on floor to look, listen and resolve issues to ensure
numbers are made and products are shipped on time.
As I see it is a generational crisis and I am not sure what the solution is or else
manufacturing will face crisis in long run much bigger than what it is facing today with older
generation fading away along with accumulated knowledge and lost foe ever.

Like · Reply 1 Reaction

Ravi Mummigatti 1d
Supply Chain Expert | Business Analytics and Business Intelligence Enthusiast | Great Lakes | Former- Cisc…

Nothing is more fulfilling than "Going to GEMBA"... GEMBA is where the real transformation
occurs.... This is true both for both Companies building Product and Companies offering
Services

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VG Rajendran 1d
Entellus - India Operations Head.

Well said

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Ravichandran Duraisamy 1d
Production Manager at Roca II Ex.Saint Gobain II Ex.Delphi TVS

100% agreed. To find the way of smart work, freshers need to know how to work by which
sweat it on the floor is very important in the early days of career.

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Vidyut Bapat 1d
Director, SigmaGuru / SixSigma - DOE Specialist

Everybody learns at their own time and pace eventually!

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Jeetendra Girme 23h

GM- FACTORY OPERATIONS at Vighnaharata Technologies Pvt Ltd , formerly Realty Automation & Security …

Very truly said Ravi. All cut paste generations..

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Ravi Vaidiswaran
Consulting Services
41m

Value Stream Mapping

While driving back today, I had a thought :

"Why do we call it VALUE STREAM?

I observe a majority of value streams have very less value added work content. In the end we are
actually identifying waste in the processes. Many lean practitioners see VSM as a fundamental tool to
mostly identify waste (and reduce process cycle times, and implement process improvement).

Should we start calling them WASTE

STREAM?"

What do you feel?

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Ravi Vaidiswaran
Consulting Services
2d · Edited

Why don't we have a room right in the middle of the shop floor in which only customer issues are
discussed?

Put a board-CUSTOMER FIRST or something-on the glass outside.

We are in business only for the customer.

Then why is there no area in the whole factory dedicated to customer?

Think....

6 · 4 Comments

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Ravi Vaidiswaran
Consulting Services
2d · Edited

This is not the way to display SOPs, WIs or Quality plans... on the shop floor. Not at all. Pasting on
electrical panel??? Who has allowed it? Safety???

Put a display board next to the machine, make a std location and keep a file folder to hold previous
documents also.

(There is a display standard mentioned in Visual Management handbooks).

The intention to make systems is good but do not cut corners to save minor costs and do shoddy work
and besides create unsafe environment as well.

Think...

32 · 4 Comments

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Ravi Vaidiswaran
Consulting Services
3d
What do we say to the person who has done this (maybe contractor) and left the job midway as it is or,
maybe felt this is the best he could do.

Also why did the co people (say maintenance department) accept this?

Whose fault?

Nice to learn that co is OHSAS certified, ISO certified and what not.

I am not concerned about the certificates on the co walls, what is more important is what in on
ground.

Think....

1 · 3 Comments

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Ravi Vaidiswaran
Consulting Services
3d · Edited

Time Management is a key for any organization's success.

When you follow up with employees on pending work, many say :

1. I did not get time to do this...

2. I was totally busy yesterday, so could not complete the data....
3. I am busy with office work even at home after office hours....
4. We cannot discuss this before weekend, I have no time.....

And many more such comments....

Everyone has the same 8-10 hrs of work day. But some people are able to manage everything within
this time while others are not.

Why?.?

(BTW I have not seen much of training on time management and it's importance in organizations).
Is time management important? Send in your views......

6 · 6 Comments

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Ravi Vaidiswaran
Consulting Services
5d · Edited

While implementing KANBAN in a factory.....

Some observations :

1. The shop floor has several machines, making various different parts for different customers. If the
next machine in line needs to do the next operation, it will have to wait since other parts have to be
first made on earlier machine (as per ppc schedule plan).

So do we keep an inventory of each material regularly on second machine to ensure it doesn't run out
of material when needed? How will Kanban work here?

2. Since each part needs a separate kanban card, the system becomes more and more complex and
may fail later.

So does that mean KANBAN fails in a HMHV (or even HMLV) environment?

3. Our product(s) demand is highly fluctuating and is unpredictable even during the day. Customer
orders vary immensely with frequent changes. KANBAN is ineffective in this situation.

4. Maintenance breakdowns, varying cycle times, short production runs of each part does not seem
suitable for the Kanban system.

5. I am only trying to control WIP and cycle times for a successful Kanban throughput. Is that enough?
What else?

6. I feel JIT needs to work parallel to Kanban. Or else I will end up controlling inventory all the time.

Debate ?

#kanban #work
 16 · 15 Comments

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Ravi Vaidiswaran
Consulting Services
1w · Edited

Wouid it be wise to do Lean and Digital Transformation (LDT) at one go?

Or do Lean first and then digitise the optimum processes?

I feel from my on floor experience, developing a data driven decision making habit, is a must before
anything else. Many cos are still not clear on the power of data and it's role in decision making.

My suggestion to such queries wouid be to first create culture of embracing data driven working, then
start improving the processes using lean techniques, and then go for Digital initiatives.

Make Lean work a base and automate your data for ease of information. Let's not make a mixture of
tools to arrive at nothing spectacular at the end.

Your take?.....

8 · 7 Comments

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Ravi Vaidiswaran
Consulting Services
1w · Edited

A thought :
Would it be a good idea to have cos serve balanced breakfast to workmen?

I see many workmen working very lethargically early in the morning and lack comprehension,
concentration and poor reaction time.

The importance of a healthy breakfast and it's ability to boost human productivity has been
documented by health and related professionals time and again.

Many workmen are unable to have the privilege of a wholesome breakfast as they leave early plus due
to lack of awareness and other reasons.

Why is it important to start the day with a healthy meal? This is because your brain hasn't received the
energy (glucose) it needs to get going. Studies suggest that not having breakfast or an unbalanced
one, affects your mental performance, attention, ability to concentrate and memory. This can make
some tasks seem difficult and of course with adverse health effects in short and long term.

So there is more to productivity measurement than just floor studies.

Look into it.. I feel you will be more productive.

(And before we miss it, breakfast tables can be good bonding spots as well. The day is set on a
positive note)

#productivityboost
#productivity
#perfomance

10 · 9 Comments

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Ravi Vaidiswaran
Consulting Services
1w · Edited

I attended a morning meeting at a client's place today.

I saw that senior management is quickly judgemental about situations, often without even proper
understanding, listening and data analysis from the team.

One of the key lessons in leadership is to give an opportunity to your team to speak their mind, come
 out with their ideas, allow seamless cohesion and who knows, maybe someone has a brilliant idea,
that might work wonders for the organisation.

Instead, imposing your own thought process before walking out and closing the meeting, would not be
the right approach.

Now-

I can see the whole team has fallen silent. What great ideas were coming, are all gone now.

11 · 6 Comments

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