The document discusses KORTEK ELECTRONICS (INDIA) PVT. LTD., an electronics manufacturing company. It provides an overview of the company, its products and services which include karaoke systems, DVD players, televisions, set top boxes, and remotes. It describes the Greater Noida facility's manufacturing capacities and techniques used currently including auto insertion, SMT, and various inspection machines. It notes that some lean manufacturing techniques are already implemented but could be further improved and lists recommendations including goal deployment, benchmarking, and internal maintenance.

1. Navjot Singh Bindra – 91010AshutoshKumar Jha – 91011Harsh Sanchay Grover – 91021Nikhil Soni–91038Swagat Kumar Panda – 91058Chandra Vikas – 91129KORTEK ELECTRONICS (INDIA) PVT. LTD.

2. Flow of the presentationCompany at a glanceProducts and servicesFacilitiesCapacitiesOEM/ODM servicesManufacturing techniques (Current)Manufacturing techniques (Suggested)

3. KORTEK ELECTRONICS (INDIA) PVT. LTD.Greater Noida FacilityDate of Visit: 17th December 2010Contact Person: Mr. Sanjay Arora

4. Company at a GlanceA leading electronics manufacturing services (EMS) and OEM provider in the country Delivering high quality cost effective solutions for the consumer electronics marketAn ISO 9001:2008 certified companyKORTEK’s USP Supplier to big brandsRapid expansionOwn line of karaoke entertainment systems

5. Products/ ServicesKaraoke SystemsDVD Players (Several Non-Amplifier and Amplifier models)Colour TelevisionLCD TelevisionSet Top BoxesRemotes (for CTVs, ACs, STBs, LCDs etc.)

6. Equipments used in Greater Noida FacilityAuto Insertion MachinesEyelet & Gripper Insertion MachinesSequencer MachinesYCD Axial Component Insertion MachinesRadial Compound Insertion MachinesJUKI high speed SMT MachineAOI Inspection MachineICT Inspection Machine

7. Capacity of Greater Noida PlantSet Top Boxes :1,00,000/MonthAuto Insertion :1,50,000 PCBs/MonthSMT :1,00,000/MonthRemote Control : 4,25,000/Month

8. OEM/ODM Services OEM ServicesManufacturing of sophisticated electronic and mechanical assemblies

9. DFM / DFT (Design For Manufacturing/ Test), process control and rapid prototyping

10. PCB Assembly capability comprising of surface mount

11. Box-Build Assembly and System Integration capabilityODM ServicesProduct to market with exacting specifications and remarkable quality

12. Efficient sourcing and materials management

13. Qualifying the design

14. Quality Planning and control

15. Optimizing unit cost

16. Conducting frequent design reviews Lot of techniques already usedReduce waste and eliminate lots of redundancies and problem causing areasHowever, neither the workers nor the management at Kortek Electronics know that these are world class manufacturing techniques and application of lean manufacturing.Lack of Realization

17. Cross Functional Teamwork

18. Participative managementEmployee involvementTop Management believes that workers on shop floor are better informed.Workers free to talk about any issueRewards for valuable suggestions

19. Quick ChangeoverMachines that are in operation are scalable both up and downIn the complete production process, only 30% of the machines need to be changed while the others operate at the same capacity as alwaysEffective handling of these 30% machinesAchieved through proper training of the workforce

20. Cellular ManufacturingEarlierSimply placed their machines according to the order of machines required in the production processNowThey have clubbed all similar machines resulting in various cells of machines according to similar set of inputs and outputs from the machines in the production process

21. Supplier Partnerships Suppliers are keeping their raw material at their plants which reduces their inventory carrying cost.Also, maintaining a good relationship, Reduces their own inventory and safety stock levelsReduces cost of procuring raw materials in the long run

22. Standard Operating ProceduresISO9001: 2000 certified companyAdopted six sigma based standardization processOn a standard output scale, they are able to produce 76-80% products completely without defectsAim to achieve a defect free product percentage up to 85% by the end of 2011.