Sample Copy. Not For Distribution. · Gurus like Prof. S. Yamaguchi San, Prof. Takao San of Japan and Chief mentor of ... Why some START UP fail? Because strategy is misaligned with

Sample Copy. Not For Distribution.

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PRE-FIT for PROFIT

Uncover, Discover, Recover


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Publishing-in-support-of,

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PRE-FIT for PROFIT Uncover, Discover, Recover

S.B. Kumar

EDUCREATION PUBLISHING (Since 2011)

www.educreation.in


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Dedication My parents (Late Shri R.P.Sinha& Late Smt.

Ramsamhari Sinha) Who carried me on their shoulders and encouraged me to

touch the sky. I am who I am because of you and I know that right now

as ever you are watching over me and blessing me. And

To my family My wife Sanju for keeping faith in me and encouraging me to embark on this journey.

My lovely daughters Shivani and Shahiba for keeping my tea warm and my heart even warmer, when I burned at mid night by oil, writing this book. Mr. Deepak Kumar,

My son Shashank for the valuable IT support. And

To all the nuts and bolts and tools and grease, that made me the engineer I am today.


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About The Author An accomplished management professional with an eventful

career of 24+ years studded with professional brilliance

predominantly in the areas of Manufacturing/Production -

Business Models, Operations Management, Quality Assurance,

Financial Management, Resource Optimization and Team

Management. Exhibits excellence in career progression of

bridging process and managerial acumen in business delivery &

roll-out, planning & vision for projects and process management.

Functional prudence in managing business operations with

creative planning and strategic inputs to maximize footfalls and realize desired growth

and profitability objectives.

A Complete Manager with expertise in handling business dynamics, developing,

nurturing and strengthening teams by deploying evolving management practices and

innovative thoughts. Strong credentials in Value Engineering & Value Analysis, Lean

Manufacturing, Six Sigma, TPM and TQM. Deft experience in ISO 9001, TS16949,

GMP, SEDEX Audit, BRC Ion, HACCP & EHS, etc. Demonstrated strengths in handling

business change impact, business readiness and business transition planning. Expertise in

establishing and governing manufacturing business models.

Kumar is a Mechanical engineer (B.E) with MBA (operations) and have gathered

rich first-hand experience of the entire manufacturing processes (P, Q, C, D, S, and M, E)

while working for industries leaders like Clutch Auto limited, Rockman Industries

limited (a HERO group company) and Hitech Plast limited. He also got the rare privilege

of working along with and following manufacturing & quality system developed by

Gurus like Prof. S. Yamaguchi San, Prof. Takao San of Japan and Chief mentor of

ACMA- ACT cluster Mr. C Narsimhan. He has completed exhausting training for

production management form AOTS, Japan and Quality Management training form AP,

Italy.

A consistent performer & excellent communicator with exceptional mentoring &

interpersonal skills in transforming a low performing team to a high calibre work force

coupled with proven abilities to understand people psychology backed by confidence to

interact with individuals at all levels .

******


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About The Book What you think, you create! What you feel, you attract!! What you imagine, you

become!!!

An entrepreneur is not someone who starts a business. He/ She is someone who

makes things happen. The only thing standing between you and your goal is the bullshit

story you keep telling yourself as to why you can't achieve it.

Great things happen when you pick yourself up, dust yourself off, and go after life with

determination and courage.

PRE-FIT for PROFIT -- The title of this book is self-explanatory. To hit the target

and to achieve your Goal, every resource must be absolutely FIT for that. Without good

fitness, you can't become a great cricket player or world No.1 cricket team. Most of the

problems in life are because of two reasons, we act without thinking or we keep thinking

without acting. The proactive approach is the key for reduction of variation & prevention.

Why some START UP fail? Because strategy is misaligned with the vision,

business model is flawed or team is weak or not fit for achieving the goal. The method of

determining an organization’s approach to its business is to evaluate its workplace

organization capability & management standards.

Methodology to achieve process robustness by providing guidelines/steps is the main focus of this book.

How to make safe factory, higher equipment availability, lower defect rate, reduce

manufacturing cost, breakthrough in throughput ,improve production agility and

flexibility, improve employees morale, better assets utilization & enhanced enterprise

image to customers, suppliers , employees and management are some of the key

questions this books tries to answer.

Health of the organisation can be checked without checking balance sheet of the

plant. Status of 5S is the reflection of the health of the plant. The flexibility and ability to

change are within bounds and not open-ended and therefore often don’t need expensive

capability requirement. More importantly, all of these concepts have to be understood,

appreciated and embraced by the employees who build the products and therefore own

the processes that deliver the values.

This book will help organizations in improving waste elimination processes. No

process is perpetually perfect. Operation must be improved continuously. Striving for

innovation and evolution for all these dramatic change will only be possible when a team

can learn the methods of improvement tools deployment.

******


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Contents

Sl.no. Descriptions Page No.

1. The GOAL 1-25

2. Pre-fit of Mfg. Systems

- 5S 26-46

- TQM 47-79

- Quality Movement 80-96

- LEAN Management 97-113

- SMED (Case study) 114-138

- TOC 139-148

- TPM 149-160

3. Pre- Fit for Resources

- Health check-up sheet 161-192

4. Results (Trends VS Targets) 193-206

5. Learning & Sharing with New Start-up 207-215

6. Pre-fit of People 216-243

7. Top Management roles 244-246


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PRE-FIT FOR PROFIT

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THE GOAL

Pre-fit” is pro-active & value added efforts, which leads to profit. Semi- fit or Unfit is

reactive & cost addition, which leads to business losses and demotivation. At the end, all

business operations can be reduced to these three words: People, Process and Profits.

Unless you have good team, you cannot do much with the other two.

So, any organizational goal should be based on these answers - Can you run the business,

make money and provide higher pay back to the board and the investors with happy

customers, suppliers & employees?

Dhuoondhoge agar..., to hi raaste milenge …!

Manjilon ki fitrat hai…, khud chalkar nahi aati !!


S.B. Kumar

2 | P a g e

Pre-fit for Profit Pre-fit is prevention. Survival of the fittest is the law of nature. It is the one that is most

adaptable to change.

A “GOAL” is dream with deadline. The goal without a Plan is just a wish! The secret of

life has inbuilt limits-road has speed limit, bank has money limit, exam has time limit but

thinking has no limit. So think big & achieve big!

“Who” is the most important factor & this must come before “What” questions, even

Before Vision

Before Strategy

Before Action plan

Before methodology

So the top most agenda during goal setting is, to build deep and strong executive team

first ( strengthening of WHO part ) .

“Set a goal that makes you want to jump out of bed in the morning. Big Goal ……. Very

big. Wow !

A comfort zone is a beautiful place but nothing ever grows there.” Old proverb comes

true-No pain, no gain. Success is a vehicle ,which moves on a wheel called-Hard Work,

but the journey is impossible without fuel-called Self-confidence. So right quality of

people & optimum numbers are very important to drive the vehicle to destination. A

negative employee sees a difficulty in every opportunity but a positive person sees an


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opportunity in every difficulty. We hire & train them for sharing the burden & not adding

the negativity. They are here for searching & providing solution &and not always

registering only problems. The size of any problem is nothing compared with one‟s

ability to solve them. Don‟t overestimate your problems, and underestimate yourself. We

don‟t grow when things are easy; we grow when we face challenges. Make the system

more fitter to face the future challenges.

Koi to hai..jo Faisala karta hai, Kise thokron pe rahna hai aur kise bhagwan hona hai !!

The right people don‟t need to be highly managed or fired up. They will be self-

motivated by the inner drive to produce the best results and to be part of creating

something great. These are steps to achieve success after goal setting.

Set the highly ambitious goal.

Devise the right strategy

Formulate result oriented action plan.

Unleash real action.

Review actual progress.

Be flexible to change strategy depending upon incremental output.

If un satisfied, then crush resistance with no mercy.

Hit the goal post!

And for all the above mentioned steps, a good caliber, dedicated, excited, motivated,

target focused, Positive thinking, energetic & devoted Team required. People first!!


S.B. Kumar

4 | P a g e

Jindagi Kaanton ka safar hai,

Hausala iski pehchaan hai!

Raste par to sabhi chalet hain,

Jo raste banaye wohi sachcha insaan hai!!

Crush, squeeze, beat & grind!

Still we will shine!!

Success… huhhh… addicted to win the heart of customers !

Right-Left

So tell me…

Where shall I go …?

To the left , where nothing is right,

Or to the right, where nothing is left??

Now It‟s time to talk something about the ATTITUDE…!

Attitude is Everything!

Rate us, shake us….but you will not break us.

Badalna hai rukh hawaon ka, hum iraadon mei jaan rakhte hain !

Yes, it is called Attitude !

ATTITUDE= A+T+T+I+T+U+D+E=100%

HARDWORK= H+A+R+D+W+O+R+K=98%

KNOWLEDGE= K+N+O+W+L+E+D+G+E==96%

Attitude is everything!!

There are 3 types of attitude

Positive

Negative

Neutral

With the right attitude, you can attain and accomplish anything.

A bad attitude is like a flat tire. You cannot go anywhere until you change it.

Ability is what you are capable of doing , motivation determines what you do &

attitude determines how well you do it.

Negative attitude man is the poison/cancer for the company. They are liability ,

not assets.


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Quality of Skills

Innovative : Design. Features, process, product, concept

Creative : Thinking, idea, Differently, cost protector, value creator

Productive : Kaizen minded, consistent, Flexible , multiskilled

Analytical : Problem solving, Data analysis, symptom analysis

Presentation and Communication: Clarity, task management, E-mail

Required Skills to Excel

Time Management

Leadership Management

Conflict Management

Environmental Management

Talent Management

Emotional Intelligence

Personality Development

Positive thinking

Facilitation Skill

Eagle approach

Mushak-niti

Stress Management

Spiritual Management

Behavior Management

Fitness Management

Anger Management

Relationship Management

Priority Management

Aim Management

Habit Management

Culture Management

Fear Management


S.B. Kumar

6 | P a g e

Quality of People

Hatheli par rakhkar naseeb,

Har shakhs apna mukaddar dhoondhta hai !

Seekho us samandar se ,

Jo takraane ke liye pathhar dhoondhta hai !!

Capability - Don‟t be a Parrot in life, be an Eagle. A Parrot talks way too much

but can‟t fly high, but an eagle is silent and has the will power to touch the sky.

Consistent - Right people always be consistent.

Character : Transparent ,helpful, kind, supportive

Work Ethics: ethical,

Basic Intelligence : Sound, Thorough , well conversant

Dedicated: Querrel with his tools , Focused , time bound

Disciplined : Punctual, less talkative

Required numbers( Neither more, nor less= optimum)

„UNI‟ is the BEST!

Optimum is the yard stick.

Homogeneity required in manpower distribution

Normal Distribution

Need based distribution.

Left & right skewed based on demand/need.

Must be Technically, Emotionally and Psychologically balanced


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Required Policies to drive the business

Policies for Customers


S.B. Kumar

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Policies for Employees

Policies for Society


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Different nature of Processes

What is Stable & Unstable Processes ?

S-Systemic

T-Time bound

A-Achievable

B-Between

L-Limits with

E-Effectiveness & Efficiency


S.B. Kumar

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Which type of Vision & Mission to be set ?

Should be :-

Amazing

Invincible

WOW

Great

Touching Excellency

Imaginative

Beyond common reach

Superlative

Fantastic

Marvelous but Realistic too !!

Learn from the Ant , because----ANT IS Like “Really An

Industry”


PRE-FIT FOR PROFIT

11 | P a g e

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Sample Copy. Not For Distribution. · Gurus like Prof. S. Yamaguchi San, Prof. Takao San of Japan and Chief mentor of ... Why some START UP fail? Because strategy is misaligned with