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One of the major reasons of layout-related difficulties faced by manufacturing industries is non-value-adding and redundant work. Plant layout study aims at economic production with larger volumes and variety as well. Method studies focus on the effectiveness with efficiency by a systematic critical scrutiny of work being done. The intention is to identify logical sequence of activities highlighting and eliminating the unnecessary mudas. Time and motion study is a combination of time study and motion study analysing and eliminating any unnecessary movement for productivity optimization of that job or process. Thus, through the elimination of unnecessary motions, times for performing the processes may be reduced and productivity increased. The intention is to subdivide the different operations of a job or process into measurable elements. Hence this case has been developed based on the primary data. The primary data was collected using Industrial Engineering Studies like layout study, method study and time and motion study. This case has been classroom tested with MBA students in their Lean Management Course.

Arin Synthetics Ltd. (ASL) though had installed modern machinery in its facility, process efficiency and optimization were a concern. Top Brass at ASL believed that ASL was overstaffed and its processes had creep as far as efficiency is concerned. This case focuses on ways to improve the process efficiency to rationalize the manpower at ASL. Presence in large growing global markets put cost pressure on ASL, thus mandating improvement in the efficiency of its processes through manpower rationalization. This case, therefore, discusses one of the highly staffed process of waste collection. Could ASL achieve reduction in the manpower in waste reduction without affecting the overall process? Was there a strategic mistake in the thought process of disposing of the waste generated by the manufacturing complex?

Operations management, Productivity and performance, Quality management, Lean management.

Production management and personnel management.

Production management modules of undergraduate business and management courses.

The case describes the implementation of 5S by a Polish production company, namely Bianor. It presents not only the literature base and benefits of 5S but, in particular, shows the specificity of the implementation process, taking into consideration attitudes of employees; moreover, the study devotes some attention to aspects of organizational culture.

The case shows how to implement the 5S method in a production company, and how effective communication of processes is essential to implementing business change.

Teaching note.

An instructor could link the case to lean production principles and Kurt Lewin’s change management model, key reading materials on these theories are, namely,  Lewin, K (1947) Frontiers in group dynamics: concept, method and reality in social science; equilibrium and social change. Human Relations 1(1): 5–41  Stewart, J. (2012). The Toyota Kaizen continuum: a practical guide to implementing lean. Boca Raton, FL: CRC Press. Wickramasinghe, V. and Wickramasinghe, G. L. D. (2020). Effects of human resource management practices, lean production practices and lean duration on performance. The International Journal of Human Resource Management, 31(11), 1467–1512.

This case was developed from both primary and secondary sources. The primary source included three face to face meetings with Mr CK in University Putra Malaysia (two meetings) and WSAE factory (Rawang, Malaysia – one meeting), respectively. Interviewed three workers at Rawang factory. The secondary source was taken from the company website and company reports.

Dr Wan, the Chief Executive Officer of WSA Engineering Sdn Bhd (WSAE) accepted the invitation from Small Medium Industries Development Corporation to participate in a Malaysian-Japanese Industry Cooperation program that focused on Lean Production System (LPS). Dr Wan was worried about Malaysia’s culture incompatible with Japanese-originated LPS. The case shares how the organization and behavioral change took place, for LPS buy-in. Successes and challenges WSAE faced in the 10-year journey of implementing LPS were elaborated.

This case was written for use in an operations management course, on the topic of lean production. It can also be used as a training material targeting the operation managers of a manufacturing company aiming to implement lean production or any change management process.

Business transformation processes, change management and business strategy.

The case can be used to study business transformation processes and would be relevant for courses on change management and business strategy. It shouldbe studied in the context of behavioral and organizational challenges in implementing an organization-wide change. The case is targeted at MBA students and/or executive participants with professional experience who would be able to link the learningto corporate experience. It can be used for courses on organizational change, business strategy, and change management.

The case, set in India in the year 2011, is positioned in the business consulting domain, and provides insight into managing change from the perspective of a consulting partner. The case discusses challenges and presents processes followed by Wipro Consulting Services (WCS) in conducting an integrated business transformation exercise at Brigade Enterprises Ltd (BEL), a leading firm in India's real estate sector. The BEL engagement had busted the myth that an integrated business transformation could not be conducted in an unorganized sector, and resulted in savings of overUSD 2 million for BEL. The case traces the journey of WCS into business transformation consulting, outlines the solution framework proposed by WCS, and discusses the decisive nature of the Brigade project for WCS' growth trajectory.

The case has been written with the following objectives, to: familiarize students with the processes and phases of a business transformation project; examine transformation barriers and challenges from a consultant perspective; and providestudents an appreciation of the complexities and challenges, decisional criteria and parameters of a large-scale, integrated business transformation exercise.

Teaching notes are available; please consult your librarian for access.

This case study concerns self-managed teams (SMTs) and high-performing work stations.

This study is applicable to training, employee satisfaction and developing economy in the society at large.

High-performance work systems (HPWS) are processes in which organizations utilize a fundamentally different approach for managing work in place of the traditional hierarchal approach. HPWS uses an approach that is fundamentally different from the traditional hierarchical or bureaucratic approach otherwise known as the control-oriented approach. The fundamental difference between control-oriented and involvement-oriented approach is in organizing and managing at the lowest level in an organization. The basic purpose of HPWS is to create an organization based on employee involvement, commitment and empowerment. In these kinds of highly involved organizations, employees demonstrate more responsibility and commitments because of high empowerment and have access to information/knowledge and awareness to perform at the highest level. In this case study, the authors make a complete study about the ten pillars of SMTs in Dr Reddy's Laboratories Private Ltd. and the situation of FTO-4 at the Yanam plant and FTO-7 at the Visakhapatnam plant post-implementation of the SMT concept. This paper attempts to demonstrate how SMTs differ from conventional teams, as well as how effectively they contribute to the organization objectives.

To understand HPWS and concept of SMT; to understand how the concepts of HPWS and SMT were implemented in Dr Reddy'S Laboratories in *FTO-4 AND *FTO-7; to understand the key difference between traditional hierarchical systems and SMTs; to find out how continuous process improvement has made SMT initiative an evolving one (from 2002 to 2011); to understand how involvement of different stakeholders has made SMT initiative a sustainable one; and to understand the importance of SMT in this twenty-first century as they lead to a better and brighter future for everyone.

Teaching Notes are available for educators only. Please contact your library to gain login details or email support@emeraldinsight.com to request teaching notes.

This case describes the knowledge management (KM) initiatives at the level of a unit of one of the largest chemical companies in India. The unit, Tata Chemicals Ltd, Mithapur, has a unique knowledge base accumulated over generations of experiments, trials, and errors. It is in the midst of implementing a rejuvenation plan that has created opportunities for external knowledge assimilation and new knowledge generation. With details on the initiatives for knowledge collection, sharing, measurement of performance and the systems for rewards and recognition, the case provides an opportunity to the participants of a programme on Knowledge Management to analyze the initiatives and make recommendations for the future to the head of Knowledge Management function at the company. The participants would be able to map the realm of knowledge management in an organization and discern - how KM initiatives contributed to the transformation of the organisation from manufacturing centred mind-set to customer focused one.

This paper aims to understand the subject of entrepreneurship and project management through techno-economic intervention.

Postgraduate students of management and graduate students of engineering and management.

Multiple challenges existed at the ground level in the Moradabad Brass Cluster in terms of gaps in technology, skill, infrastructure and market that all needed to be improved upon.

The objectives and learning outcomes were proposed to understand the cluster economic crisis, entrepreneurship, project management, technical improvements and better understanding of certain theories.

Teaching notes are available for educators only. Please contact your library to gain login details or email support@emeraldinsight.com to request teaching notes.

The case introduces students to aspects of operations management (OM) and management theory and provides examples of the real-world challenges facing a practitioner. It requires students to think about the operational manager’s responsibilities and how organisational context influences choices and possibly even fit within an organisation.

In this case, a factory lead protagonist presents her OM challenges and choices within a for-purpose, rather than for-profit, a social enterprise in South Africa. The context presented unusual constraints that required thoughtful adaptation and judicious choices. The case introduces students to aspects of OM and management theory and provides examples of the real-world challenges facing a practitioner. It requires students to think about the operational manager’s responsibilities and how organisational context influences choices and possibly even fit within an organisation.

The case is aimed at postgraduate business students studying OM.

Teaching Notes are available for educators only.

CSS 9: Operations and logistics.

Illustrate the typical organizational responsibility of a small, medium industry dealing with precision manufacturing products. Introduce a balanced scorecard (BSC) as a concept about the case in the context. Introduce the parameters specific to small and medium enterprise (SME) that could be considered to be part of the key performance indicators. Understand the advantages and disadvantages of using a BSC in SMEs in emerging economies.

Gopika Rani, the recently hired Executive Assistant along with Sanjana M, the Business Development Manager of SEP India Private Ltd. (SEPI), a small medium enterprise, were finalizing a proposal for the forthcoming “India Small Business Excellence Awards 2020.” The proposal was to be considered by the Board of Directors scheduled to meet next week for approvals. Sanjana apprises Gopika on CRISIL’s policy advisory role and its annual awards scheme for SMEs in India. She also details recent modifications announced by the Government of India that had impacted SEPI and was pertinent for filling the application. Gopika understood that SEPI was well-known for the precision and durability of its component, and was poised for growth. The business catered to global suppliers (Tier-1 companies) of the Indian automotive industry that accounted for over 75% and the balance contributed to exports. SEPI’s unique products such as Starter Motor Ignition or the Fuel Vending pump (Automotive) or the non-automotive products such as arrowheads and bowstrings (sports) or the heart-valves (medical) have all the quality certifications. For new product development, customer feedback played a crucial role at all stages of development from prototype to pilot tests. SEPI’s mission “be our customers’ preferred supplier and business partner” drove their personnel and organizational objectives. Also, SEPI could get multiple benefits and be in a strong market position because of this award recognition. Gopika was, however, unclear about SEPI’s business strategies and use of appropriate performance measurement tools. Gopika desired to address the Board of Directors next week on her idea of applying a BSC as a useful “strategic planning and management tool.” The BSC methodology can be used to monitor the performance of SME firms against strategic goals. It can be successfully implemented in smaller organizations because of their simpler set-ups and tendency to arrive at a consensus quickly. However, implementation of BSC within the Indian micro, small and medium enterprises has been scant. Several studies found that the lack of ownership, resistance to change, a scarcity of training and coordination between the departments and lack of funds were among the challenges. The firms also had to make numerous changes to their strategies as business environments evolved. Gopika was convinced that the tool could blend in all the “four perspectives – customer, financial, internal business and learning and growth” and grow. The tool could demonstrate meeting all the prerequisites, “needs to have an exemplary vision, demonstrate outstanding business acumen, use best practices and create a legacy for the others to follow,” that were prerequisites for receipt of this award. Her next project would be to seek approval for the implementation of BSC, a beneficial and apt tool for SEPI. Do you agree with Gopika Rani that BSC is a suitable tool for SEPI? If yes, why? If no, why?

This case study titled leveraging the BSC – a tool for SME advancement is intended for use in the graduate management program (MBA) in subject electives, namely, entrepreneurship, strategy formulation, human resource management or production management.

Teaching Notes are available for educators only.

CSS 3: Entrepreneurship.

Teaching Notes are available for educators only.

This case describes the experience of Kanpur Confectioneries Private Limited (KCPL), a family managed company, in being a contract manufacturer for A-One Confectioneries Private Limited. The alliance had worked to the advantage of KCPL. It had prospered as a profitable contract manufacturer. It had used the surplus to diversify into unrelated businesses. The family members, however had doubts regarding the employment opportunities provided by the move. They were not sure whether the progress was sustainable. Alok Kumar Gupta, Chairman and Managing Director of KCPL, along with his brothers and son, is required to review the strategy and performance of his company and develop a course of action for the future.