In the fast-evolving landscape of the manufacturing industry, embracing transformative technologies and methodologies has become imperative for sustainable growth. By using a LEAN-first and SMART-next approach, IDOS Consultants implements a distinctive methodology with the audacious goal of preparing all Indian enterprises for Industry 4.0. Established in Mumbai, IDOS Consultants is a trailblazer in industrial engineering, specializing in everything from SLP (systematic layout planning) to green field factory design and execution. A LEAN manufacturing expert, IDOS is establishing the flow for effective execution and timely delivery of value to its clients.
“Navigating change requires a complete cultural transformation and IDOS addresses this through a collaborative approach, emphasizing lean culture transformation. Our highly trained consultants work across the client's team, fostering collaboration and knowledge sharing. We implement brainstorming sessions, Kaizen workshops, and motivational programs, recognizing outstanding achievements with rewards. Deep-rooted knowledge of lean principles and their functional implementation is a cornerstone of our approach, delivered through thorough training sessions. At IDOS, we demystify lean, making it accessible and impactful for our clients”, states Shailesh Oak, Founder, IDOS Consultants.
Optimizing systematic approaches
IDOS optimizes manufacturing processes across diverse sectors, implementing lean strategies in over 70 factories.
The systematic approach begins with data collection, analysis of product trees, demand patterns, and portfolio standardization. Time and motion studies drive cycle time improvements, supported by value-added and non value-added analysis. IDOS Greenfield projects typically involve SLP and Visual Management deployment with Lean tools such as Kan Ban, SMED, Poka- Yoke, and TPM being implemented strategically throughout the project lifecycle.
The company emphasizes efficient material handling, low-cost automation, and employee involvement from shop floor to top floor. This holistic approach culminates in Standard Operating Procedures (SOPs), ensuring the sustainability of lean practices through audits and reviews. Hence, comprehensive philosophy defines success in Greenfield Lean projects.
Subsequently, IDOS offers a range of services, categorizing them into core lean implementation projects and specific Lean implementation projects. Tailored training programs cover all levels within client organizations, addressing lean tools, basics, advanced implementation, ergonomics, material handling, and materials management. Industry 4.0 and IoT training, along with quality management initiatives like Six Sigma and ISO implementations, showcase IDOS's comprehensive approach.
Shailesh highlights two flagship programs: IDOS SSFM (Smart Shop Floor Management) and IDOS SIM (Smart Inventory Management). SSFM is a cloud-based solution focusing on lean principles, encompassing production scheduling, productivity monitoring, OEE calculations, tool life monitoring, and responsive alarm systems. SIM, dedicated to materials management, integrates digital processes from incoming raw materials to finished goods dispatches, employing Digital Pull- Kan Ban, point-of-use tubing systems, spider management, and material storage systems. Both systems are cloudbased and seamlessly integrate with existing ERP, MES, or WMS systems, with the potential for evolving into percolate systems, besides AGVs and AMRs integration, marking a strategic move towards smart manufacturing.
Furthermore, IDOS maximizes digital tools and analytics for manufacturing optimization, emphasizing 3D walkthroughs using the latest software like Revit. Complementing traditional 2D planning, these walkthroughs offer clients a vivid preview of their futuristic factories, leaving a lasting impression. Simulations play a crucial role in proofof- concept, ensuring confidence in automation investments. Additionally, in smart manufacturing, IDOS extensively employs IoT and collaborates with associates to deliver top-notch solutions.
Looking forward, IDOS asserts that while lean manufacturing is essential for all sectors, the journey doesn't end there; smart manufacturing is the next frontier. The company is actively developing affordable smart products, including smart inventory management, smart storage, spider trolleys, pick-to-light, place-tolight, smart fixturing, and innovative Index Smart SMED tools. This visionary approach aims to empower the MSME sector, aligning with IDOS's commitment to making smart manufacturing accessible and cost-effective.
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