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

Email

Mobile

Web

:

:

:

balaganesan.k@4quadra.com

+91 96770 96136

www.4quadra.com

4Quadra

We look forward to hearing from you…. Soon.