CASE STUDY
A Machine Builder
“I am sinking.” Shop-floor teaching cut lead times 84–92%; the company broke even in six months.
Four decades of writing and teaching, in one place — the thinking behind the transformations, not just the results. Every piece is readable here; the original PDFs are a click away.
Anonymized, first-hand accounts — the situation on arrival, what was taught on the floor, and what changed.
“I am sinking.” Shop-floor teaching cut lead times 84–92%; the company broke even in six months.
Business process re-engineering across many suppliers at once — one connected value stream instead of a dozen local optima.
A stalled turnaround, restarted. Flow rebuilt from the customer backward — inventory down and on-time delivery restored.
An automotive supplier under OEM pressure. Quality and delivery brought to standard without adding cost or headcount.
Total Lean is not merely an efficiency tool — it is a powerful, enterprise-wide differentiation strategy. Drawing on Toyota Production System, Port…
AI can enhance Lean tools and analytics, but leadership, culture and people development remain fundamentally human responsibilities. Lean is not primarily a problem-solving system — it is a people-development system.
Organisations can achieve manufacturing excellence by changing the way they think about leadership, processes, waste, quality, and continuous impro…
Lean manufacturing succeeds when every employee owns both execution and continuous improvement, eliminating waste through standards, problem-solving, and kaizen culture. The root cause of failure: jobs are not defined to include continuous improvement and human development.
“Lean” has become a cliché’, one of the most discussed and misinterpreted concepts in modern management. It is…
Lean is not just a way to run a business better, but a way to win differently — and keep winning. True Lean elevates itself from an…
In lean manufacturing, a “job” is not merely the execution of assigned…
VALUES OF GOOD THINKING Philosopher Benjamin Disraeli, once said "Nurture great…
The word sensei is often translated simply as "teacher." But does this definition fully capture what a sensei truly represents? In the context…
16 INDIAN MANAGEMENT J U LY 2 0 2 5 A sensei teaches you about more than just information, surpassing other teachers. SANJEEV BAITMANGALKAR, STRATM…
Why Lean triumphs? The article describes how Lean production management can be considered a high risk – Sanjeev Baitmangalkar, Founder & Principal…
Dinesh Bhogale 30 INDIAN MANAGEMENT FEBRUARY 2023 What makes such a huge difference in the efficiencies of a Just-in-Time Lean company compared wit…
What is your philosophy? A Just in Time ‘high returns’ or a Just in Case ‘low returns’? Why should the product alone be a differentiator when process can build strong competitive advantage? Wouldn’t you want a…
Sometimes, even the best laid plans can go awry.But a lean mindset can change it all. SANJEEV BAITMANGALKAR, STRATMANN CONSULTING STRATEGY I t was…
WAYS TO BUILD A LEAN CULTURE A successful company culture is one that can be easily accepted or embraced by everyone, from the newest employee to t…
It was with great optimism and expectations that Bridgeport USA and Texmaco Indonesia came together to set up a joint venture for CNC and conventional machine tools, but sometimes, even the best laid plans can go awry,…
‘Lean’ for any business process has become so very famous for the benefits it brings to the customer, desired by most CEO’s, celebrated by a successful few, envy of the vain, evaded by the skeptics. Simple though, it…
Yash Chittal 34 INDIAN MANAGEMENT FEBRUARY 2022 Building a lean culture is about developing competence and behaviour in people to see waste, solve…
I have often been asked, “How did you build the Lean culture in the companies you transformed”? In this article I will share with you some important things that helped me build the Lean culture .. Some define company…
Changing the behavior of individuals is one of the greatest challenges in a business and in society as well. Recently we introduced our methodology on how to implement Lean within a municipality. We were then asked by…
I read the case and was extremely impressed. It certainly followed all the principles that I talk about. Your vision and faith in the process, when…
“Start with what they know. Build with what they have. The best of leaders when the job is done, when the task is accomplished, the people will say…
Finishing work with a client, my associate and I were driving down to deliver a talk at a Technical University. Sighting a roadside fruit vendor, and on a hunch, we stopped to pick up some fruits. At the institution,…
68 INDIAN MANAGEMENT OCTOBER 2019 Unwavering focus, relentless practise, and a high degree of dedication alone can shape success. Talent may just b…
It is four decades since University Professors and Researchers have been studying Toyota and trying to understand what they do and how. Toyota was the mother of ‘Efficiency Innovation’ yet contributing to economy,…
Managements believe that people’s talents are what turns them into worldclass performers. But, in fact, talent has virtually nothing to do with performance. True worldclass performance is built over a long period of…
Misconceptions about Value Stream Map Many lean practitioners see Value Stream Mapping as a central tool to detect waste, cut process cycle times,…
STRATEGIC SOLUTIONS AND COMPETITIVE ADVANTAGES It’s almost four decades that University Professors and Consultants have been studying Toyota and tr…
Leading India’s first total lean enterprise transformation back in the early 1990’s we often huddled on the shop floor to discuss layout changes to improve flow and pace production while answering variable demand…
VOL 2, ISSUE 3 - SEPTEMBER-OCTOBER 2018 The Official Magazine of WHY DOES COMMON SENSE ELUDE DISCRETE MANUFACTURING? Lean Manufacturing has long si…
Give Lean implementation the status of your company’s number one strategic intent, lead it from the top and see it succeed! A CEO with deep commitment to lean thinking and lean practice stands the best chance of leading…
Indian manufacturing organisations should aspire to build the brand tag ‘Made in India’ as a value offering. This will mean building core competence values like reliability, safety, value for money, dependability, and…
I could say 'another testimonial' (zoom to read), but the thing that makes this special is it was given to me on 26th January the day when the highest gallantry award winners receive their citations from the President…
Once the Sales Manager had converted the customer order into a Visual Signaling Card at Mysore Kirloskar Hubli factory and placed it in its location on the assembly line, the entire execution thereafter was completely…
Eighteen years ago I had the most enviable job. Yes! Back then many people wanted my job because it had everything that anyone in a job would want (except my salary) – success, rich cash flow, profitable, successful JIT…
Does VSM (Value Stream Map) maximise profitability? If it did, would that be the only lean tool most companies would use? Have those organisations that have used the VSM tool maximised their profits? Are there factors…
Organising the workplace (or Workplace Organisation 5S) and maintaining it the way it should be, is a good work culture. Why then do we see variations? A good culture strives to improvise; a bad one creates…
Ethics in business is about who you are If owners fail to back business managers on bonafide decisions, it’s a case of ethical deficit. Ethics dema…
Turnarounds with Lean Management It was with great optimism and expectations that Bridgeport USA and Texmaco, South East Asia came together to set…
CHARACTER Most important asset What were the ingredients that made some of the greatest leaders of all times? First in the series on ‘leadership’,…
Power of possibility thinking An open mind is your doorway to success, a closed one spells doom. Have you noticed how easily people give up? Why do…
Commencing initiative steps Reflect within, are you an initiator? Do you look out for opportunity or do you wait for it to come to you? Are you wil…
The passion perks! People spend time trying to figure out what can make them successful. They look at education, intelligence, credentials and othe…
SUCCESS Attitudes & strategies Ask yourself, what does success mean to you or what is success to you? You could come up with more than one answer.…
How to handle hurdles? The ability of a leader is gauged by his problem solving techniques or the statistical methods employed to resolve hurdles o…
Are you listening? According to Woodrow Wilson, the ear of the leader must ring with the voices of the people. I was in the middle of a seminar on…
Building lasting relationships Successful people have the ability to develop relationships that last. And, building relationship requires the build…
Teachability Teachability is the quality that makes one continually strive to grow, learn and improvise. There has to be a desire to learn, adapt a…
Unconditional leadership As said by General Colin Powell, ‘leadership’ is the art of accomplishing more than what the science of management says is…
COMMITMENT A leader’s secret strength Where does commitment begin? I think it starts in the heart. Commitment precedes achievement. You will achiev…
F ailure to build trust is damaging particular process is better, why this tool as it can build the fear of conflict.
Success attitudes beyond money The roulette of change has spun India’s Silicon City Bengaluru in the decade beyond the expectations of most; some s…
Be a secure leader High self esteem is the hallmark of good leaders; it comes from quality thinking that has produced positive results. Read on to…
The critical difference One basic principle in leadership, as great leaders practise, is ‘to get ahead, put others ahead first’. To know all about…
The five pillars of teamwork (Part IV) Commitment or lack of it W Sanjeev Baitmangalkar e have seen the I have seen many staff meetings, importance…
Communication Keep it direct and simple Communication simply stated is what we say and how we say it. Direct communication is the best form of comm…
Five pillars of teamwork (Part V) Accountability, or avoiding it I n the words of the Swamiji, “to be committed is not being Last month I have talk…
Competence & courage Competence and Courage are essential qualities of a leader. Be it, ‘the in the ability to take risks’ or, ‘make vital decision…
Discernment This article is the fifth in the leadership series. And the fifth attribute that defines a leader is discernment. It is the ability to…
The five pillars of teamwork (Part III) Pay attention to results Sanjeev Baitmangalkar S it through any team meeting and a team – more than being c…
Positive attitude DO YOU HAVE IT ? The lives of those who are successful are governed and guided by the thoughts of their best hour, greatest optim…
Drop your smokescreen If you are willing to change your thinking, you can change your feelings. If you can change your feelings, you can change you…
The focussing ‘fundaas’! Learning to focus is quite possibly one of the best things you can do to invest in yourself. This is probably one of the m…
Gift of generosity Generosity, in the proper sense of the word, is the virtue, which elevates us to do actions worthy of our kind, nature, descent,…
Core competence A company's most valuable resource range of products or For Toyota, it is in Sanjeev Baitmangalkar services. Have you its culture a…
A plan for this recession It will be hard for a company to make significant reductions in costs, if the employees in that company, including the wo…
Attenuate ‘throughput’ times The problems that the machine building companies need to combat are several.
Beyond tools and techniques The importance of building leadership for the next generation of lean I t is people, their routine, leadership, vision…
Built to change The success of any organisation depends on its culture and leadership. If either is strong, the organisation will survive. However,…
Every individual reaches a point where he feels stagnated. Suddenly he feels drained of all good ideas. It begins to affect his performance drastic…
From a manager to a leader Crossing the great divide predicament. In such a cenario, the Sanjeev Baitmangalkar answer lies in not having the requis…
Does it merit your consideration? Lean manufacturing makes manufacturers nimble; react quickly to changes in customer demand with minimum inventory.
Drop your smokescreen If you are willing to change your thinking, you can change your feelings. If you can change your feelings, you can change you…
Drop your smokescreen If you are willing to change your thinking, you can change your feelings. If you can change your feelings, you can change you…
Innovate! Invest!! Grow!!! Disruption, disruptive technologies, disruptive innovation … the race seems unending. Disruptions are the engine of grow…
“Go Lean…!” …says Sanjeev Baitmangalkar, Principal Consultant (Strategy & Lean Manufacturing), Stratmann Consulting.
Publication: Economic Times Bangalore Date: Feb 22, 2007 Section: Special Report Pg Nos: 8 &9 Lean Manufacturing allows manufacturers to quickly re…
Manufacturers all over the world are adopting new marketing strategies to reach their target customers and prospects. Industrial marketing comprise…
It’s for you to figure it out The core competence theory of Hamel and Prahalad is not a panacea. There aren’t simple answers to many questions, but…
This is the concluding article of our two-part series on industrial marketing techniques. The basic concepts of marketing that allow a company to r…
Lean in financial domain Extra work done on products or services can lead to customer dissatisfaction in the long run. This includes unnecessary tr…
Lean manufacturing and management has become one of the best competitive strategies in this century. But is the implementation of ‘lean’ as simple…
Author: Pradip A. P. Da’Costa, Director, Astra Metal Systems Pvt. Ltd. and Vice President, Verna Industrial Association, Verna Goa. A few years ago…
Lean manufacturing and management has become one of the best competitive strategies in this century. But is the implementation of ‘lean’ as simple…
Lean manufacturing as a ‘competitive strategy’ Money mind, strategy lean T hrough one of its subsidiaries, volumes. Fragrance Engineers clearly did…
Lean manufacturing Why aren’t there more successes? Sanjeev Baitmangalkar Lean manufacturing allows manufacturers to be fast and nimble enough to q…
The great Indian quandary Lean or Six Sigma? The question at the top of the minds of many CEOs and their senior managers is “which is the best stra…
Competitive advantage Today’s manufacturers operate in an increasingly demanding environment that includes global competition, increasing pressures…
Lean: Why some find it hard In the 1980s, when the subject of lean production and its management were new to the greater part of this world, there…
Lean’ing On Six Sigma business, yet every company cannot apply them successfully. So, it had to come from a deeper philosophy of understanding peop…
Lean’s the way Lean manufacturing allows manufacturers to be fast and nimble enough to quickly react to changes in customer demand and do it with l…
Mantras for manufacturing excellence Process improvement is a way of life for many successful manufacturing companies.
Means to sustain growth Inspite of its infrastructure woes, India has succeeded in wooing investors and investments by serving as an excellent low…
Lean manufacturing as a ‘competitive strategy’ Money mind, strategy lean T hrough one of its subsidiaries, volumes. Fragrance Engineers clearly did…
Reduce inventory, improve performance Today, the ‘value’ that a manufacturer offers his customers is more important than having just the lowest ove…
The lean lessons Lean manufacturing system is a systematic approach to waste elimination throughout a supply chain. The main objective is to delive…
The lean lessons Lean manufacturing system is a systematic approach to waste elimination throughout a supply chain. The main objective is to delive…
Result of an attitude Call it the fall of a giant or the result of an attitude; in the closure of the present form of General Motors there are many…
Every organisation wants to be flexible enough to adjust quickly to changing market conditions, lean enough to beat any competitor’s price, innovat…
Strategic advantage Through Human Resource hat are the implications of the information-based, tal is the critical strategic resource and only the s…
The ‘changing’ consequences Changes occur in all areas of our life whether we want them or not, prepared for them or not. Change are positive or ne…
The lean mindset Thinking lean isn’t just about costs; it’s about customers. Once your manufacturing activity is centred around customer needs, qua…
The lean mindset Thinking lean isn’t just about costs; it’s about customers. Once your manufacturing activity is centred around customer needs, qua…
The news reporting about the culling of over two million jobs and more to come or the austerity drive by some auto majors would have sunk the heart…
By: Sanjeev Baitmangalkar This article is a tribute to the late Air Cmde K. D. Singh (AVSM ) – the first Principal of Sainik School Bijapur. The au…
Turnarounds with Lean Management It was with great optimism and expectations that Bridgeport USA and Texmaco, South East Asia came together to set…
Values of Good Thinking In our every day life we deal with things that are a better thinker is worth your effort because the exciting as well as th…
What is lean thinking? To go lean, it is necessary for the managements not to get stuck in the aggregated processes of product development, sales a…
When lean becomes a passion Mysore Kirloskar Hubli (MKL) was the first full comprehensive lean transformation in India; where to achieve reduced co…
Why are not more companies lean? In the hundreds of companies that he has either worked with or trained in, has brought him in contact with brillia…
Lean manufacturing allows manufacturers to quickly react to changes in customer demand and do it with little inventory. Gone are the days when comp…
X - Engineering Beyond the walls of your company Sanjeev Baitmangalkar In contrast to the concept of Re-engineering, which is done principally with…
“I am sinking.” Shop-floor teaching cut lead times 84–92%; the company broke even in six months.
Business process re-engineering across many suppliers at once — one connected value stream instead of a dozen local optima.
A stalled turnaround, restarted. Flow rebuilt from the customer backward — inventory down and on-time delivery restored.
An automotive supplier under OEM pressure. Quality and delivery brought to standard without adding cost or headcount.
Portland, OR and Bangalore, India — open to America, India, Asia, and Europe.