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45 January 2020STEELWORLD
n the current business Iscenario, every
organization is striving to
increase profit and grow its
market share. To realise the
growth vision, products
offered by company must
be globally competitive.
Cost is one the most
important factors for global
competitiveness, saleability,
and profitability of every
company.
The book “Increase your
PROFIT by Radical Cost
Reduction”, just released is a
good initiative to address
the most important issue for
Indian Steel industry.
The conventional cost
reduction practices followed
by most of the organisations
are reactive, symptomatic,
top-down, compromising
“cost-cutting” approach with
financial controls on
purchasing, learning, and
improvement activities that
becomes counter-
productive in most of the
situations. Radical cost
reduction technique follows
a remedial, bottom-up
structured “problem
solving” approach
implemented at the root-
cause level of processes to
develop sustainable
solutions with a new
mindset to manage costs.
Radical Cost
Reduction uses TLS
Problem Solving
Technique developed by
benchmarking and
synergistically blending
three most powerful
world-class problem
solving techniques; Theory
of Constraints (TOC),
Lean, and Six Sigma with
an integrated approach to
manage cost.
Ÿ TOC is used to
discover the constraint
(process) which is the
weakest link resulting to
higher cost
Ÿ Lean focuses on
detection and selection of
cost-adding problems (cost
reduction projects) in the
constraint process
Ÿ Lean Six Sigma is
used to manage cost
reduction projects by
applying an unique and
highly effective TLS problem
solving technique. The book
facilitates managers to
identify real Cost Reduction
Projects in their processes
and develop Action Plan for
implementation of Radical
Cost Reduction Technique
to reduce cost by
addressing following critical
cost management issues;
Ÿ What makes your
products costlier than your
competitors?
Ÿ How to discover the
process problems which are
causing higher cost?
Ÿ How to select critical
cost reduction projects
impacting the bottom-line?
Ÿ How to reduce cost
using TLS problem solving
technique?
The innovative cost
reduction methodology is
Increase your PROFIT byRadical Cost Reduction
Using TOC-Lean-Six Sigma Problem Solving Technique
Analysis
46 January 2020STEELWORLD
explained in seven
practical steps and
supported by real case
studies of steel industry
and engineering industries.
A unique case study
explains how an integrated
large steel plant has made
recurring saving of more
than Rs. 90 Crores per
annum by reducing setup
time of steel refining
furnace by few minutes
using Toyota’s most
popular technique SMED.
Inventory reduction is
one of the most burning
issues for every industry,
as per TLS approach
inventory management is
the easiest and fastest
way to reduce cost.
Another case study
describes how a metal
product industry has
drastically reduced
working capital and
inventory carrying cost by
linking the sales,
production, and purchase
processes and managing
with JIT technique.
An engineerings industry
improved its productivity
just by measuring, analysing
and improving cycle time of
its production processes by
balancing the TAKT time
(demand rate) with
Production rate?
This book is especially
written for the managers
to introduce most effective
world class problem
solving techniques being
used by leading companies
of the world.
Senior Managers and
Engineers managing
various functions
including; Operations,
Production Planning,
Maintenance, TQM,
Materials Management,
Supply Chain, Logistics,
Cost Accounting, Sales &
Marketing can learn and
apply the problem solving
technique to improve their
performance.
The author Akhilesh N
Singh, a Management
Consultant is Metallurgical
Engineer having over 46
years hands-on industry
experience. After working
three decades in leading
steel industries, since last
seventeen years fully
involved in operational
excellence consulting in all
kinds of industries.
He has undergone
training in Lean
Management, Value Steam
Mapping and TQM at Lean
Enterprise Academy UK,
Toyota Motor Co. Japan,
Kaizen Institute Japan,
Asian Productivity
Organization and Yokohama
Kenshu Center Japan,
Armco Inc. USA.
Six Sigma Black Belt
from American Society for
Quality, ISO 9000 Lead
Auditor, BEE Certified
Energy Manager and NLP
Practitioner.
Executed more than 250
Lean, Six Sigma training
and consulting
assignments in 5 countries;
India, Bangladesh, Saudi
Arabia, UAE and Qatar.
Provided training and
consulting to various
leading manufacturing
industries in business of
steel, ferroalloys, metals,
petroleum, engineering,
electrical machinery, food
products, pharmaceuticals,
paper, chemicals, etc.
Based on his hands-on
experiences he has
authored 14 books.
An engineering graduate
from Indian Institute of
Technology, Banaras Hindu
University with postgraduate
qualifications in business
management, industrial
management and
Gembakaizen (Japanese
Management).
This book is
especially
written for the
managers to
introduce most
effective world
class problem
solving
techniques
being used by
leading
companies
of the world.
Analysis