Zoru Bhathena

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The power of Visibility TOCICO 2008 Conference • We affixed a white board inside the entrance of our factory with the priority p y list • All persons entering whether customers, staff, workers and most importantly suppliers could see the list for themselves and decide on their course of action • We gave operations only 1 week notice before giving OK to start manufacture of a machine − In 1 week time they were expected to procure 100% of the RM required and manufacture the machine. N − No RM stock was permitted to be stored in the factory, the stores were not to be used for storing any longer longer. So we moved the stores from a 5000 sq feet room to a 100 sq feet room − The idea being if they did not have enough place to sit, they would stop buying & storing RM 16 © 2008 TOCICO. All rights reserved.
The power of Supply Chain TOCICO 2008 Conference • Do you feel it is possible to procure 100% RM in 1 week, when you have over 300 totally y different components p on each machine ! • Sounds difficult? • This was the easiest policy to implement, in-fact our suppliers lloved d us with ith thi this changed h d working ki environment. i t • They were amazed at our changed agility and quickly adapted to our requirement. Today if we need ANY part, I can guarantee that it will be delivered within 24 hours! • Obstacles: Some large suppliers have ERP (SAP) systems in place! p − How wonderful! These suppliers need just 5 working days to input our order into their system!!! − We learned, learned very soon soon, how to manipulate their ERP system & also who was the correct person to telephone, who was able to bypass the ERP system and deliver the RM 17 © 2008 TOCICO. All rights reserved.
Page 1 and 2: TOCICO CONFERENCE 2008 TOCICO 2008
Page 3 and 4: A Modest Start TOCICO 2008 Conferen
Page 5 and 6: With time there comes competition
Page 7 and 8: We had no idea about what is going
Page 9 and 10: We started measuring our performanc
Page 11 and 12: Choke the release! • Ravi’s Rul
Page 13 and 14: Never believe the customer TOCICO 2
Page 15: The power of Daily Meetings TOCICO
Page 19 and 20: Slide 18 SG2 Add Video Sanjay Ghosh
Page 21 and 22: Curse of TOC - Stagnation at a high
Page 23 and 24: Price Paradigm • Ravi a sugges su
Page 25 and 26: Ravi introduced Sanjay, who came eq
Page 27 and 28: Viable Vision in One Year! In 2007-
Page 29 and 30: Theory of Liberating Mind • In 20
Page 31 and 32: So what next? TOCICO 2008 Conferenc
Page 33 and 34: About Ravi Gilani • Ravi Gilani,

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