Industrial Engineering Techniques and Measures used by Godrej and Boyce and benefits incurred

1)   Use of Industry 4.0 in Manufacturing for Improving Resource Utilization and Reducing Conversion Cost

Source : Godrej Appliances report

Here we can see that how effectively Godrej and Boyce has used effectively industrial engineering techniques such as Lean tools, TPM , Digitalization, Automation and Flexible Manufacturing to increase their turnover by 169% and reduce manufacturing cost by 94%  in the last 10 years

Some of the innovative programs at Godrej and Boyce using industrial engineering techniques for improving productivity are as follows

1.1)     Labour Training and Development Program (LTDP)

Godrej annually conducts programs to improve the skill sets of the labourers. This vocational training aims at improving their skill sets and helps them to learn the tricks of the trade in a more systematic and technical way.

Different methods for productivity improvement including the use of Kaizen for workplace management are also imparted to the workforce in this training programmes which helps in improving productivity

1.2)     Customized Supervisory Development Program (CSDP)

The main purpose of this program for training supervisors to acquire skills they need to effectively communicate, create a positive work environment, handle different personalities and inspire long-term change.

In this two-day Supervisory Development program, both new and experienced supervisors develop the practical skills needed for dealing with day-to-day challenges. They also learn techniques to better understand your own leadership style and your team members’ needs.

This program helps the supervisor understand the needs of the workforce and work efficiently which helps to increase productivity at work.

1.3)     Training program for management level for productivity improvement

The CII Naoroji Godrej Centre of Manufacturing Excellence organises short duration training programmes for the middle and senior level executives of Indian industry on a wide range topics including :

·       Developing People Potential

·       Finance, Taxation, Risk Management

·       Industrial Safety

·       Marketing & Sales

·       Operations Management

·       Supply Chain

·       Welding, etc.

In a year approximately 70-80 programmes are held. The uniqueness of this Centre is that it promotes learning through small groups and intensive interaction with the faculty, which is predominantly drawn from industry experts and practitioners.

1)   Wellness at Work Godrej Program for better ergonomics

From an organizational perspective, having a larger workforce adopting static posture for a long time is a definite red flag. Over time, these issues can have a serious impact on employee wellness and organization productivity. As experts in office ergonomics, Godrej strongly believes that education and awareness is the key to ensuring a healthy workforce in organizations, reduce medical costs and retain optimal levels of productivity at all times across all age groups. To this end, the GI Ergonomics Cell has a 3 step A-C-P approach:

1. Awareness: Spread the Wellness Message

2. Correction: Work Space Improvements

3. Prevention: Employee Behavior Training

1. AWARENESS:  It is important for organizations and its employees to understand the effects of static posture on their health, wellbeing and productivity which can be addressed through education and awareness. In line with the same, Godrej offers knowledge support via weekly Wellness Tips. It has two key purposes: a) Ways to take care of one's health in the light of changing work pattern b) Improve work productivity by encouraging correct work postures at workplace.

 2. WORKSPACE DESIGN IMPOVEMENTS It is important to develop workplace wellness policies that reflect their commitment to create a safe, positive and healthy workplace with special focus on overall ergonomic improvement. Some ways of ensuring wellness while at work are listed below:

• Ergonomic and Workspace Assessment: Ergonomic assessment is a brief assessment of user interaction with workspace, work desk interaction and suggest improvements to enhance ergonomic & wellness quotient of workspace

• Opportunity to integrate change in present seating systems by introducing sit-stand workstations. Experts state that doing work by both sitting and standing mimics natural movement of human body and results in lower level of reported whole body discomfort and reduced back pain. Also, standing while at work keeps the user alert, and increases chances of interaction with colleagues around.

• Provide different seating options that can be used by employees across the work day, like bean bags, bar stools, standing tables essentially furniture that would encourage change in posture.

3. EMPLOYEE BEHAVIOR TRAINING

Wellness at Work is an initiative of Godrej where a team of experts conducts training for employees across organizations. The training introduces the participants to the changing work trends and its implications, correct postures to be adopted at workplace and simple techniques which help improve overall employee wellness. In short, employers are encouraged to help their employees to develop awareness about avoiding the static posture, and to include exercise and movement into the daily routine. The move to having an active work-life is not a short-term project that an organization or an individual can adopt and implement quickly.

2)   Kaizen competitions at work

Kaizen (Japanese for "improvement" or "change for the better") is a philosophy or set of practices that focus on continuous improvement of processes in manufacturing, engineering, supporting business processes, and management. The Kaizen Competition of Godrej is organized every year to recognize and encourage member companies which give importance to continuous improvements through Kaizens. The competition is conducted for operators and supervisors of member companies from manufacturing and service sectors. In order to encourage competitiveness through Kaizens among small scale industries, a special recognition is given for the best small-scale organization which participates in the competition. The competition awards member companies who have adopted Kaizens not only at the shop floor but also from the office area, scrap yard, stores etc. It includes many workplace management, housekeeping contests to increase productivity.

3)   Total Quality Management Workshops

  Godrej started TQM workshops in 1995 to inculcate a positive work culture in the company. In 1997, all the 5000 employees of GSL were put through a three-day workshop as the "visioning-session" of the TQM. Instances of innovation have been few and far that Godrej has never been identified with innovative practices. Kaizen has attempted to change the mindset but it has primarily been aiming at improving existing processes rather than innovation.