The document provides an overview of Mattcons' Operational Excellence Model (MOPEX). Key points include: - MOPEX helps companies achieve business goals through standardizing processes, lowering costs, and improving cycle times. - Using methodologies like TPM, Lean Manufacturing, and Kaizen, MOPEX can reduce costs by 20-30% and improve productivity by 30-60%. - Mattcons has implemented MOPEX for clients in various industries like steel, cement, food processing, and more. Client case studies show improvements in metrics like OEE, downtime, inventory levels, and safety.

1. Operational Excellence
Model (MOPEX)
DEVELOPED BY :-
Mattcons Services Private Limited

2. ABSTRACT
 What is Operational Excellence and our Process.
 Key Results from Operational Excellence
 Time line for OE Model.
 Methodologies we used.
 Sector’s that MOPEX model Cover.
 Our Client Achievements
 About Mattcons
 Mattcons Client’s
 Contact us
Bakery Industry

3. OPERATIONAL EXCELLENCE
 Operational excellence model helps achieve
business goals while lowering costs and
improving cycle times.
 It standardizes processes and integrates
operations across multiple channels of supply
and distribution, supporting high-volume, low-
margin business strategies.
MOPEX Model

4. KEY RESULTS FROM OE
 Reduction of Manufacturing Cost by 20 – 30 %
 Improve the Net productivity up by 30 - 60 %
 Number of Breakdown reduced by 10 - 80%
 Overall Plant Effectiveness by 30 - 50 %
 Reduction Defective Products by 50%
 Customer Complain down by 40 - 60%
 Inventory (Only Spare parts) down by 30%
 Major Accidents reduced by 50%
 Minor Accidents reduced by 40%
 Enhance the Employees Moral by 5 times
 Improvement of Suggestion 10 times minimum.
 Workforce uncertain absent-ism down by 5 times.
Benefit’s

5. INTANGIABLE BENEFIT’S
 Achieving full Self Management – Operators have
ownership on their equipment.
 Enhancing skill and knowledge of workforce by
training.
 Building CANDO attitude by eliminating breakdowns
and defects.
 Enhancing the communication among all team
members.
 Make the workplace clean, bright and lively and Giving
plant visitors a better image.
 Making all losses more visible and enhance safety of
plant.
 Making the plant with more visual display.
Benefit’s

6. MOPEX
Mattcons Operational
Excellence Model
PROCESS

7. Increase Profitability and Cash Flow
Driving Culture Change
Supporting the Growth initiatives
New product Development
Supply Chain Management
Focus on Maintenance
Beyond the Basics
OE Process

8. Increase Profitability and Cash Flow
Mattcons strategies, tools and techniques and
our methodologies designed for
 Improving business performance.
 Improve equipment uptime (OEE).
 Reduce scrap.
 Improve yield.
 Improve quality & productivity.
 Accelerate set-up/change-over times.
 Reduce lead times.
 Optimize inventory.
OE Process

9. Driving Culture Change
Companies who successfully leverage operational
excellence as part of a strategic platform for
growth often achieve market performance well
beyond their nearest competitors.
 We can help you how to expand continuous
improvement into non-manufacturing areas.
 Enhance sales force productivity.
 Optimize the maintenance activities.
 Enforcing the employees in all level.
OE Process

10. Supporting the Growth initiatives
 Creating growth initiatives without losing focus
on the core business.
 We will share Industry best Kaizens, Suggestions
that really works and One point Lesson (OPL).
 Help your bottom line to develop more small
ideas which will help ultimately transform your
business
OE Process

11. New product Development
 We will share best practices for applying
process excellence to new product development
and commercialization, Efficient product
development processes closely integrated with
the operational processes .
 You will gain important advantages, such as
reduced lead time to market, improved quality
and increased development capacity.
OE Process

12. Supply Chain Management
 The complex and often costly internal supply
chain processes is one area that many
businesses seek to improve.
 By “killing complexity” in the overall supply
chain system, companies will experience
better, faster delivery with lower costs.
OE Process

13. Focus on Maintenance
 Proper maintenance of plant equipment can
significantly reduce the overall operating cost,
while boosting the productivity of the plant.
 Hence another perspective of looking at
maintenance function is not only to maintain
but also to enhance the process or the plant
operation system as a result of turnaround
planning.
OE Process

14. Beyond the Basics
 Many manufacturing organizations need to expand
continuous improvement throughout the enterprise
and seek training to expand capabilities into
marketing, customer service, engineering ,new
product development and quality control.
 Mattcons web Matrix is the helps the organization
to increase web penetration, getting higher orders
from online, increase the site rank & traffic.
OE Process

15. TIME LINE FOR MOPEX MODEL
12 months
18 months
TPM Certification.
ISO Certification.
6 months GMP Certification.
TPM Kaizen Award.
Implementation.
Lean Manufacturing.
5S. Quality
Management.
KRA Set up.
Focus on Online
RCA . Marketing.
Basic Training to
Operators.
Time line

16. TOOLS THAT WE USED
 TPM- Total Productive Maintenance and 5S.
 SMED and RCA – Root Cause Analysis.
 Kaizen and FMEA – Failure Mode Effect Analysis.
 Lean Manufacturing.
 Value Chain and Value added analysis.
 Management System.
 Strategic Alignment.
 RCM and TQM – Total Quality Management.
 Mattcons web matrix.

17. INDUSTRY COVER
 Steel Plant  Food Processing Plant
 Cement Plant  Pharma and Healthcare
 Sponge Iron Plant  Bottling Plant
 Power Plant (Coal Based)  Automobile Company
 Chemical Plant  Glass Manufacturing
 Fertilizer Plant  Oil and Gas
 Formaldehyde Plant  Textile Plant
 FMCG Many more visit our Client Portal
for more details.
 Bakery Plant
www.mattcons.com

18. CLIENT’S ACHIVEMENT
Plant OEE - Productivity Machine Down Time
90 1200
80
1000
1,064
70
80
60 72 800 642
50 63 600 400
40
30 400
20
200
10
0 0
2010 2011 2012 (EXPECTED) 2010 2011 2012 (EXPECTED)
R&M Budget Avg. Delivery Lead Time
EGP 14,000,000 70
10804525
EGP 12,000,000 60 53
EGP 10,000,000 11756450 50 64
EGP 8,000,000
40
EGP 6,000,000
8000000 45
30
EGP 4,000,000
EGP 2,000,000 20
EGP 0 10
2010 2011 2012 0
(EXPECTED) 2010 2011 2012 (EXPECTED)
Formaldehyde Plant Located in Egypt

19. CLIENT’S ACHIVEMENT
M/C Break Down(Major) 5S Score
40 100
37
35 90
30 80
25
70
83 90
60
20 50
15 40 28
10 11 30
5 20
1 10
0
0
2010 2011 2012 (EXPECTED)
2010 2011 2012 (EXPECTED)
Inventory - Spare Parts Energy Consumption - KWH
90 9000000
80 8000000 6500000
70 7000000
80 50 7873514
60 6000000
6782805
50 5000000
40 4000000
55 3000000
30
20 2000000
10 1000000
0 0
2010 2011 2012 (EXPECTED) 2010 2011 2012 (EXPECTED)
Formaldehyde Plant Located in Egypt

20. CLIENT’S ACHIVEMENT
Mattcons Web matrix Number of Suggestions
600
100 500
90 95
80
73.6 500
364
70 400
60
50 300
40
200
30
20 100 10
10 10.8
0 0
2010 2011 2012 (EXPECTED) 2010 2011 2012 (EXPECTED)
Website Global Rank
25,000,000
19,785,320
20,000,000
Visit our website for
15,000,000 More details :
10,000,000 5,421,678
www.mattcons.com
5,000,000
800,000
0
2010 2011 2012 (EXPECTED)
Formaldehyde Plant Located in Egypt

21. ABOUT MATTCONS
 The company was setup with the objective of providing
senior managers, Top management with a more effective
resource to help resolve complex strategic and operational
issues.
 Our reputation and credibility have been built through
delivering practical and implementable solutions to clients –
both domestic and international covering both the
manufacturing and the service sector.
one stop company for all services that you need with most
cost effective way with higher return over investment value.
About Mattcons

22. MATTCONS OFFERINGS
Management Consulting
Green Consulting
Condition Monitoring
Project Management
Operation Outsourcing
Industrial Trainings
Maintenance Products.
For More details kindly visit our website www.mattcons.com or
Drop an email at askus@mattcons.com
About Mattcons

23. MATTCONS CLIENT’S
Visit our Client
Portal for More
details
Some of the project was executed with the help of AMC - Asset Management
Consultant & TPMWAY - A subsidiaries of Mattcons.
About Mattcons

24. CONTACT US
Email :: askus@mattcons.com
Open Line :: +91 – 902 900 5850
Phone :: +91 – 22 – 412 36 302
Office Location
Mumbai - India BBSR - India Mansura - Egypt
Mattcons Services (P) Limited. Mattcons Services (P) Limited. Mattcons – EMEA Region
Waghbill Naka, Thane – West, Kalyan Nagar, Pallahat, Business Development Center.
Mumbai – 400607 Khurda, – 752055 Aga-Dakahlia–Egypt – 35516
Email – askus@mattcons.com Email – askus@mattcons.com Email – askus@mattcons.com
Phone - +91 – 412 36 302 Phone - +91 – 986 101 5544 Phone - +20 – 106 378 4682
www.mattcons.com THANK YOU