Growth through Incremental Changes!
4Quadra 4Quadra Management Consultants
Human Capital
Management
Sale & Marketing
Operations & Supply Chain
Finance & Accounts
4Q will Reengineer your Business
around Least Cost processes resulting in increased profits.
Focusing here
D2D Experts(Design to Delivery)
4Quadra 4Q Philosophy
1Waste Identification And
Reduction
Why Invest When you
can eliminate?
2 Simplify to Scale Up
Mundane Reports Vs Exception Handling?
3Re-aligning around the
Business Processes
Cost of Human Capital
4 GEMBA Approach
Identify Hidden Costs /
Potential
4Quadra 4Q Approach
1“As – Is” study (Before
Improvements)
Data Collection
and On-Site Observations
2 Questioning the Status Quo
Are there Better / Simpler Methods
available?
3 Evolve “To – Be” Processes
Involve the Stake
Holders ? Cost Benefit
Analysis
4Arrive consensus and
Collective Implementation
Demonstrate PQDCM Savings.
4Quadra
Time
TypicalOrganization
TraditionalImprovement
Kaizen WasteReduction
MajorImprovement
NVA
NVA
NVA
VA
VA
VA
Original Lead Time
Minor Improvement
4Q Focus
Sorting
Counting
Moving
Expediting
Inspecting
Measuring/Checking
Repackaging
Scrap
Loading / Unloading
Paperwork
Rework/Repair
Waiting
Recruiting
Training
Auditing
Storing
4Q Focus Area
4Quadra
Our Services
4Quadra
ERP Functional Consulting Business Process Blueprint and Functional Consulting for
Materials Management
Work Flow Management
Data Analytics & MIS Reports
ERP Design & Implementation
AS IS and TO BE mapping of Business Processes
Liaise with ERP Implementation team for mapping the Process in ERP.
Lean Management & Six Sigma Initiatives Training Programs in Lean & Six Sigma Methodology
Study, Execute and Hand hold Turnkey 6 Sigma Projects through DMAIC phases and final Handover.Gage R & R and Attribute Agreement Analysis
Sigma Level calculations
Yield and Process Capability studies
Process Flow Charts / FMEA / Hypothesis Testing
Design of Experiments (DoE)
Etc.
4Quadra
Total Supply Chain Management Total Supply Chain Network Design
Warehouse Design - Capacity and Workflow Planning
Inventory Management & Supply Chain Optimization
Transportation Planning and Optimization Modelling
Strategic HR Initiatives Job Evaluation & Job Description
Organization wide Surveys
Job Levelling & Compensation Benefits Survey
Employee Engagement / Satisfaction Survey
Internal Customer Satisfaction Surveys
Organization Climate Surveys
Middle Management & Leadership Training
Recruitment and Assessments (thru’ Partnering)Bottom of the Pyramid Recruitment (Mass Recruitment)
Design of Assessment Center Models / Tests for Bottom of Pyramid recruitment (Diplomas, ITI’s and Graduates)
Executive Search
Middle, Senior Management & Leadership levels.
4Quadra Case Study #1: Warehouse Design & Operations
Client
Reliance Retail (Chennai, Madurai & Coimbatore DCs)
Saint Gobain Glass (Chennai Plant – Mother WH, Delhi – Feeder WH)
Project Outline
Warehouse Capacity Workings – Receiving, Put Away, Storage, Picking & Delivery
Warehouse Layout & Facilities Planning
Area Calculations
No of Racks / Bins Required – Mezzanine / Non Mezzanine
Facilities / Utilities Planning
MHE requirements
Manpower Planning
Warehouse Management Systems (WMS) – Design, Implementation & Training
Receipt, Put Away, Inventory Management, Picking, Staging and Delivery
Benefits to Customer
Error Proof Layout – Single Flow concept, No scope for mixing – leading to High Inventory
Accuracy Levels
High Productivity levels – Avg 900 lines per Picker achieved. Highest across 23 DCs in India.
4Quadra Case Study #2: Supply Chain De-Bottlenecking in F & V
Client
Saravana Stores, Chennai
Before
3 Hyper Stores operating in Chennai.
Mostly manual Process except payment Processing to Vendors.
High level of Stock inaccuracies. For instance
Few lakhs of Stock Write Off only for Kareel Leaves over 6 months.
Duration : 1 Month
After
Process Blue Print developed for SAP WMS operations
Complete integration of Data between SAP – WMS to Billing System leading to Zero Inventory
loss.
Same Manpower for 5 Hyper Operations – No Increase in Manpower. Job Enhancement
projected.
Benefits to Customer
Error Proof Operations – Frequent Write Offs eliminated.
Highly Visible Inventory at every stage – Sales Counters, Back End Stores, In Receipt etc.
Faster Replenishment to Sales Counters – less Opportunity loss.
4Quadra Case Study #3: Vendor Base Streamlining / Lean Purchase
Client
Autoprint, Coimbatore,
OPG PowerGen Pvt Ltd, Chennai
Before
Autoprint, CBE OPG Power Gen, Chennai
Delay in Machine Building – Delay in Delivery.
Hence, dissatisfied Customers
• Primarily due to Non-availability of Critical
parts
Average No of Purchase Requests per month – 300
to 400.
Ad-hoc Purchase – As & when and in Small
quantities
What was done
ABC – XYZ analysis done on Components / Parts / Consumables.
Criticality to Machine Building arrived. Highly Critical, Can be managed, Not Critical
Inventory Norms (Min / Max Stock, ROL, ROQ) arrived at based on lead times of Procurement.
Benefits to Customer
Autoprint, CBE OPG Power Gen, Chennai
Predictability improved on Delivery Commitments
made to Customers.
Less Queuing effect. Better planning made possible.
Lean Inventory. No unnecessary parts in Engg Stores.
Average PRs reduced from 300 per
month to 30. Most of the Regular parts &
Consumables brought under Auto
triggering based on ROL.
Manpower in Purchase Department from
10 to 3.
4Quadra Case Study #4: Performance Management Systems
Client
Autoprint, CBE
OPG PowerGen, Chennai
Before
Less Clarity on Roles & Responsibilities.
Individual Goals not aligned with Business Goals.
Performance Review – Highly Subjective.
Duration : 6 ~ 12 Months
What is done?
Organization Structure and Job Descriptions
HR Policies and Procedures
Performance Management Systems – Goal Setting, KRA / KPIs for each Department / function /
Role
Rewards & Recognition System
Leadership Development Program / Individual Development Plan (IDP)
Benefits to Customer
Transparency in HR function
More Objective in Appraisals
Right Man at the Right Job.
4Quadra
Client
Chettinad Cements
Asian Paints
Kaleesuwari Refineries
Malladi Pharma
Before
No Industry Benchmark while Salary fixing.
Lost talented Manpower due to Poaching
Unable to attract Good Talent due to wrong Salary Structure.
Duration : 2 ~ 3 Months
What is done?
Job Analysis and Position Classification to arrive at Job Family and Career Level.
Pre Survey Contact with Comparator Employers for Primary & Secondary Data on Salary.
Customized Salary Survey Questionnaire to Target Companies / Employers.
Data Collation & Findings
Benefits to Customer
Industrial Salary Benchmarks and Best Practices
Case Study #5: Compensation & Benefits Survey
4Quadra CASE STUDY #6 - SHELF READY PACKAGING FOR MNC
Brainstorming
• Data was collected on time taken for fast moving SKUs of Johnson & Johnson, HUL, P&G, Godrej.
• It was decided to display the master cartons on shelf in “Cut-Open” Display
Impact
• Nil impact on Planogram.
• Inner pack retained
• Modification of dotted lines on Master carton from supplier end
• Customer nil impact. No mixing of Articles
Result
• 122 articles were converted to Shelf Ready Packaging over 1 month
• 5 pickers “cost” was saved and were redeployed
• Per piece shelf loading time reduced from 20 seconds to 2 seconds.
8.3 lakhs per
annum costs saved
4Quadra
Supplier Johnson & Johnson
Description Johnson baby powder 400 g
Before After
Shelf Quantity (as per planogram) 48 48 ( 2 cartons)
Time taken to fill ( in minutes) 3 min 1 min 20 seconds
CASE STUDY #6 - SHELF READY PACKAGING FOR MNC
4Quadra
Supplier Reckitt Benckiser
Description Robin Cuffs and Collars 200ml pack of 4
Before After
Shelf Quantity (as per
planogram)
144 144 ( 3 cartons)
Time taken to fill ( in
minutes)
17 min 3 min
Cut open box
CASE STUDY #6 - SHELF READY PACKAGING FOR MNC
4Quadra CASE STUDY #7 - LEADING VALVE MANUFACTURER
PROBLEM
• A leading Valve Manufacture had supply issues
• Vendor not aligned with client due to capacity constraints, power issues, lack of followup
Requirement
• To increase fill rate from 55% to 90%
• To keep close control on deviations
Approach
• Visited all vendors in the geography to understand the bottlenecks
• Process study and Gemba approach
4Quadra
Observation
• No fixed collection plan
• Increase cost of collection due to random placements of vehicles
Solutions
• Milk route plan devised
• Window timings fixed and agreed with vendors
• Requirements plan aligned with collection plan
• Placed Vendor Follow up expeditors at 3 key vendor locations to manage 8 troublesome vendors. Daily exception reports tabled with vendor. Trigger on forthcoming shortages indicated to factory to adjust production
Results
• Increased fill rate from 55% to 68% in first 3 months of operation
• Vendors on their toes to fulfill needs as per realignment
• Supply chain cost decreased by 18% over 6 months
CASE STUDY #7 - LEADING VALVE MANUFACTURER
4Quadra
Delivery Point
CASE STUDY #7 - LEADING VALVE MANUFACTURER
4Quadra
Client
KYB Motorcycle Suspension India Pvt Ltd,
Sakura Autoparts India Pvt Ltd
Apollo Tyres, Daimler, ITC – ILTD, TITAN Industries, Ashok Leyland John Deere
Sectors Serviced – Auto, Auto Components, Process, Engineering, Aero Space
What is done
Design & Develop Assessment Center for testing
Knowledge
Attitude and
Skill
Source and Send Invitation Letters to Eligible Candidates
Administer the Test, Evaluate them, Move them to next stage.
End to End Data Management
Hand Hold the Candidates till joining.
Benefits to Customer
Complete RPO (Recruitment Process Outsourcing).
Less Stress
Case Study #8: Bottom of Pyramid (BoP) Recruitment
Knowledge
Skill Attitude
4Quadra CASE STUDY #9 – Executive / Leadership Search
Start
Recruitment Inputs / Job description
Job Portals
Social Networks
Internal Database
Head Hunting
Screening & Shortlisting
Share Profiles with Client
Profile Selected
No
Yes
Documentation
End
Personal / Technical Interview
Selected
No
Email Notification
Documentation
YesCoordinate Offer & DOJ
Notification
Offer Accepted
by Candidate
Follow Up and Ensure Joining
Yes
Record Reasons for Not Joining
No
DocumentationEnd
4Quadra
Team 4Quadra
4Quadra Our Mentor
V.Sivagnanam: BE , MBA (IIM-A)
Mr.Sivagnanam, during his stints at various blue chip organisations like HMT, NISSAN, TVS, RELIANCE, brings over 33 years of experience in best practices in Marketing, Supply Chain and is a proven:- Lean Management Specialist- Balance Score Card Champion- Turnaround Expert
4Quadra Profile
Balaganesan K, Sr Consultant & Managing Partner
• Lean Six Sigma Black Belt (Licence Number : B201510062, Examplar Global)
• B Tech - Mech (NIT, Calicut) and PGDM – HR & Operations (TAPMI, Manipal)
• Over 25+ Years in Manufacturing Systems Engineering, Total Supply Chain – Auto, FMCG & Retail Sectors
• Expertise in HRM, Assessment Centres, Manufacturing Systems Engineering, Total SCM, Kaizen / 6 initiatives, TQM Best Practices.
Shivakumar H, Sr Consultant
• B Tech – Production, (NIT, Calicut)
• Over 25+ Years in Manufacturing and Total Supply Chain Management – Auto, FMCG, Manufacturing & Retail Sectors.
• Expertise in Total SCM Solutions from Design to Delivery.
• Expertise in Total Supply Chain Solutions
• TQM, LEAN MANAGEMENT & VALUE ENGINEERING EXPERTISE
• COST REDUCTION AND KAIZEN
4Quadra
Technology Partner• 4Quadra has partnered with Nextapp Services for developing the
solutions into Android / IOS / Windows Phone based Applications. • Application Development based on Workflow.
• Web : www.nextappservices.com
Recruitment Partner
• Amor Management Consultants - Boutique consultancy specialized in Auto OEM & Tier -1 Talent Acquisition Space.
• 25 + Greenfield projects till date in the Auto OEM & Tier -1 Space Pan India
• Web : www.amormc.com
Our Partners
4Quadra Our Coordinates
K Balaganesan
Sr Consultant & Managing Partner
Mobile
Web
:
:
:
+91 96770 96136
www.4quadra.com
4Quadra
We look forward to hearing from you…. Soon.
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