1. P. Ulaganathan
No. 38, Sathalwar Street,
(Near Vijaya Bank),
Mugappair West,
Chennai – 600 037.
9444 22 61 71 / 99 523 844 14
ulaga1967@gmail.com

2. Generate
Wealth from Waste
Objectives Profitability
 Sustainability
 Growth
Organisation Growth Project
Training & Implementation of
World Class Practices & Waste Elimination Concepts
Key Results Assured
Productivity Improvement – 10%
Quality Improvement – 10%
Cost Saving – 10%
Employee Involvement – 100%
Customer Satisfaction - 100%
By
Globe Management Consultancy
Chennai.
Low Cost Consultancy
9444226171 / 9952384414
nodiversity@gmail.com

3. “Organisation Growth Projects”
Cost Saving thru’ Waste Elimination
Organisation Growth...
Productivity Improvement
Quality Control
Cost Saving
Employee Involvement
Training & Implementation

4. “Organisation Growth Projects”
Why this important?
 Customer Satisfaction
 Waste Elimination
 System Implementation
The utmost objectives of every organisation are
 Sustainability
 Profitability
 Growth
To be achieved
only through

5. “Organisation Growth Projects”
Training & Consultancy
Relevant
Training
System
Implementation

6. Training
 Training on Organisation Growth
 Supervisory Skill Development
 Transformation Training for Fresher
 Entrepreneurship Training
 Motivational Training
 5S & Kaizen
 Training on PQDCSM
 Communicative & Interpretive Skills
 Factory Administration
 Leadership Skills
 Quality of Life
 Quality Analysis (G8D & 7QC Tools))
 Waste Elimination
 World Class Practices

7. Training Programs…
Workers & Staff Fresh Engineers
 Organisational Growth & Their
Responsibilities
 5S & Kaizen
 Waste Elimination
 Cost Saving
 Productivity Improvement
 Quality System
 Process Development
 Total Employee Involvement
 World Class Practices
 Transformation Training
 Career Building
 Factory Administration
 Customer Satisfaction
 Production System
 Quality System
 Time Management
 Break Thru’ Concepts
 Material Management
 People Management

8. “Customer Satisfaction”
System Implementation
Improved Productivity, Zero Quality Complaint,
Delivery at right time & At affordable cost
PQDCSM Improvement
Objective

9. PQDCSM Improvements
Product Design
Idle Time Waste
Inventories
Over-Production Process Related Waste
Transportation
Defective Products
Thru’ Waste Elimination

10. “System Implementation”
Long Term Goal Setting
World Class
Practices
5S Kaizen VCS
Flow
Concept
Poka-
Yoke
Pull
System
Quality
System
Storage
System
QCT
Jishu
Hozen

11. Productivity
Improvement
Quality Improvement Cost Reduction Customer Satisfaction
OEE - 95%
Cycle Time – 100%
Idle Time – 0%
Setting Time – 50%
Down Time – 50%
CLR – 0 ppm
Inhouse Rejection-100ppm
COPQ – 50%
Quality Rating – 100%
Material Cost – 25%
Manpower Cost – 25%
Scrap Cost – 25%
Consumable Cost – 25%
Delivery Rating – 100%
N P D – One per month
Reporting System – 100%
Satisfactory Level – 100%
Employee
Involvement
Documentation Inventory Control
Continuous
Improvement
Attitude Change – 100%
Skill Level – 100%
Quality Conscious –100%
Safety Conscious – 100%
ISO Documentation
Customer Audit Report
Inspection Standards
SOP
Inventory Days – 4 days
Inventory Cost – 10%
Storage Space – 25%
Traceability – 100%
Suggestion – 2 per
employee/month
Kaizen Projects – One per
Engineer/month
Accident – 0
Key Results Assured

12. Approach
 SWOT Analysis
 Proposal Submission
 Activity Planning
 Training
 Budgeting
 Date Collection
 Team Formation & Target Fixing
 Execution
 Assisting & Monitoring
 Results & Effectiveness
 Standardisation
 Continuous Improvement

13. Module – 1 Analysis Module–2 Project Planning Module – 3 Basic Concepts
SWOT Analysis
Capacity Analysis – Factory & Admin
Organisation Structure
Roles & Responsibilities
Product & Process Analysis
Rejection Analysis
Growth Potential
Training Schedule
Team Formation
Road Map
Activities with Target
Financial Budgeting
Debate & Discussion
Identifying Key Persons & Training
Informal Training - Growth
Layout Modification
Organisation Structure
Roles & Responsibilities
5S Training
5S Implementation
Module 4 – Prime Concepts 1 Module 5 – Prime Concepts 2
Module 6–Continuous
Improvement
Training on Productivity Improvement
Process Simplification
Cycle Time Balancing
Optimized Production Plan
Training on Quality Improvement
Inspection Standards System
Rejection Analysis
Storage System
Documentation
Training on Cost Reduction
Process Integration
Proper Utilization of 4M
Setting Time Reduction
3R System
Customer Complaints – Action &
Effectiveness
Material Issue Control
Tools, Fixtures, Gauge management
Training on Kaizen
Process Modification
QCT/SMED
Poka-Yoke
Suggestion Scheme
New Product /New Business Development
DRM
Documentation
Activity Plan

14. Company Project Duration Results
Karthigeya Group of
Companies, Chennai
5S, Waste Elimination
From 2005
onwards
5S Award from ABK AOTS
consecutively for 4 Years
Prabha Auto Ltd., Chennai 5S, Waste Elimination 6months
Flow Production, Process
Simplification
Brite Brothers Ltd.,
Pondicherry
5S, Waste Elimination One Year
Store Modification, Space
Saving, Inventory Reduction
Srimukha Precision P Ltd.,
Chennai
5S, Waste Elimination 6 months
Rotor Flow Production,
Productivity Improvement
Packaging India P Ltd,
Pondicherry
Training – 5S, TEI &
Kaizen
One Day
5S Awareness & Employee
Involvement
Clients vs Projects
Journey towards excellence….

15. Company Project Duration Results
Supreme Treves P Ltd,
Sriperumpudur
5S, Kaizen, Lean
System
6 months
Process Simplification, Cycle
Time Reduction
Micro Tech Engineers
5S, Kaizen, Lean
System
6 months
Process Simplification, Cycle
Time Reduction
ARV Engineering P Ltd.,
Chennai
5S, Kaizen, Lean
System
One Year
Process Simplification, Cycle
Time Reduction
Elchem P Ltd.,
5S, Kaizen, Lean
System
3 years
5S, Kaizen, Cycle Time
Reduction, Process
Simplification
Unitech Plasto
Components P Ltd.,
5S, Kaizen, Lean
System
2 months
Process Simplification, Cycle
Time Reduction
Clients vs Projects
Journey towards excellence….

16. Company Project Duration Results
Vetri Pressing India P
Ltd.,
5S, Kaizen, Lean
System
6 months
Flow Line Production, 5S
Kaizen Implementation
Precision Machines &
Equipments P Ltd.
5S, Kaizen, Lean
System
2 months
Process Simplification,
Cycle Time Reduction
Anabond India Ltd.
Pondicherry
Training – 5S, TEI &
Kaizen
One Day 5S Awareness
Precision Hydraulics P
Ltd., Gummidipoondi
Training – 5S, TEI &
Kaizen
One Day 5S Awareness
Sels Automotive and
Fabrication P Ltd.,
Training – 5S, TEI &
Kaizen
One Day 5S Awareness
Clients vs Projects
Journey towards excellence….

17. Day 1 Day 2 Day 3 Day 4
Know Yourself Know your Company 5S – Work Place Environment Regular Documentation
Day 5 Day 6 Day 7 Day 8
DRM Quality System Leadership Quality Skill Development
Day 9 Day 10 Day 11 Day 12
ISO 9000 : 2001 Ethics & Enthusiasm Know your Customer 8D Analysis
Day 13 Day 14 Day 15 Day 16
Production System 4M Utilization Inspection Standards Visual Control System
Day 17 Day 18 Day 19 Day 20
Employee Motivation Quality of Life Kaizen QCC
Day 21 Day 22 Day 23 Day 24
Get rid of wastes World Class Practices Autonomous Maintenance Organisation Structure
Day 25 Day 26 Day 27 Day 28
Delivery Adherence Production Planning Quality Improvements Women Power
Day 29 Day 30 Day 31 Day 32
Innovation & Creativity at work
place
Get rid of Worries & Confusions Discipline & Attitudes Safety at Work
Day 33 Day 34 Day 35 Day 36
Health Management Productivity Improvements Training on Training Family Development
Day 37 Day 38 Day 39 Day 40
Supervisory Skill Development Social Thoughts Performance Monitoring Team Building
Day 41 Day 42 Day 43 Day 44
Supplier Development Spirituality Cost Reduction Human Empowerment
Day 45 Day 46 Day 47 Day 48
Family vs Factory Storage System Security System Happy & Peaceful Life
On going projects
2015-16
Enlightenment in 48 Days
48 Days Special Training Program for MSMEs
Training

18. Generate Wealth from Waste
Project Consultancy on Waste Elimination
On going projects
2015-16

19. P. Ulaganathan
 Certified 5S Coordinator
 16 Years experience from Lucas TVS Ltd
 12 years experience as a consultant for TQM
implementation (2005-2016)
 So far 52 clients in Tamilnadu & Pondicherry
 Clients varied from Plastic Mfr. to Fabrication
 125 Projects on Waste Elimination
 180 Training Programs on 5S, Kaizen & TEI
Prime Mover….
B.com., PGDFM, PGDCA.

20. Journey towards excellence….
Enable Micro, Small & Medium
enterprises to achieve Customer
Satisfaction through PQDCSM
Improvements
Objectives

21. Journey towards excellence….
Training & Implementation
World Class Practices
Learnt from The Great Gurus
Mr. Hirano San
Chairman – JIT Lab, Japan
Dr. N.Ravichandran
CEO – Lucas TVS Ltd.,

22. Focus Areas
Journey towards excellence….
5S Implementation
OEE Improvement
Down Time Reduction
Setting Time Reduction
Cycle Time Reduction
Storage System
Inspection Standards
Employee Involvement

23. Results Assured
Journey towards excellence….
Capacity Building - 10%
OEE Improvement – 10%
Cost Saving – 10%
Quality Improvement – ‘0’ ppm
Employee Involvement – 100%
Customer Satisfaction – 100%

24. Training Session
Journey towards excellence….
Karthigeya Group of Companies, Chennai.

25. Journey towards excellence….
Training Session

26. Training Session
Journey towards excellence….
Brite Brothers P Ltd., Pondicherry

27. Organization Growth
Journey towards excellence….
Elchem P Ltd., Chennai.

28. Organisation Growth
Journey towards excellence….
Karthigeya Group of Companies, Chennai.

29. Training
Journey towards excellence….
Mando Auto Components, Chennai.

30. Training Session
Journey towards excellence….
KK Press Tools & Components P Ltd.,

31. Organisation Growth
Journey towards excellence….
Karthigeya Group of Companies, Chennai.

32. Training Session
Journey towards excellence….
Apollo Tyres India Ltd, Chennai.

33. Training Session
Journey towards excellence….
Apollo Tyres India Ltd, Chennai.

34. Training Session
Journey towards excellence….
Polaris IT Park, Chennai.

35. Training Session
Journey towards excellence….
Daimler, (Bharat Benz) Chennai.

36. Journey towards excellence….
Some of our Social Responsibilities
Our own Training Centre
Workshop on “Entrepreneurial Skill Development for Students & Youth

37. Journey towards excellence….
Some of our Social Responsibilities
‘Dream Team Concept’
Students’ Skill Development Program
at Govt. School, Padalam Village,
Madhuranthagam, TN

38. Journey towards excellence….
Some of our Social Responsibilities
‘Rural Youth Development’
Rural Entrepreneurial Skill
Development at Pulipura Koil Village,
Kanchipuram, TN

39. Journey towards excellence….
Some of our Social Responsibilities
Students’ Skill Development Program
at Govt. School, Mugappair,
Chennai, TN
‘Dream Team Concept’

40. Journey towards excellence….
Some of our Social Responsibilities
‘Yoga Practices’
Free yoga classes at week
end for Men, Women &
Children

41. Journey towards excellence….
Some of our Social Responsibilities
‘Public Speaking’
Pattimandram Training to
Govt. School Students at
Tindivanam.

42. Journey towards excellence….
Some of our Social Responsibilities
Students’ Skill Development Program at Brittania Hr.
Sec. School, Padi, Chennai, TN
‘Dream Team Concept’

43. Journey towards excellence….
Some of our Social Responsibilities
Students’ Skill Development Program at Govt. School,
Rameswaram, TN
Dr. Kalam School
‘Dream Team Concept’

44. Journey towards excellence….
Some of our Social Responsibilities
Career Growth Program for Socially backward
youth & students at Dindigul, TN
‘Dream Team Concept’

45. Journey towards excellence….
Dr. N. Ravichandran, CEO of Lucas TVS Ltd. (My Guru)
Mr. Dhandapani, MD of Karthigeya Group of Companies
Mr. Hariharan, MD of Srimukha Group of Companies
Mr. Pujar, GM of Brite Brothers Ltd.,
Mr. Chitrarasu, MD of ARV Engineering P Ltd.,
Mr. Gurumoorthi MD of Maxwell Training Centre,
Mr. Raghavan of UNIDO & ILO Score Project,
Mr. Shankar of Maven Training Centre
…… and many more particularly the Employees and Staff of all
the client companies who are all supported us to make our journey as
Excellence
My Sincere Thanks to…