Adopting a structured approach to continuous improvement, we leverage global methodologies such as Lean and Six Sigma, as well as Japanese management techniques, such as Gemba9 walks and Kaizens10 and other methodologies like 5S11. Our focus on harnessing digital technology and driving process automation continues to transform our operations.
We routinely monitor six performance parameters: safety, quality, delivery, engagement, compliance and cost, while equipping employees with the appropriate frameworks and tools for the early identification and resolution of issues. Visual dashboards, strategically placed in every department, offer real-time insights into the relevant metrics which form the basis for a daily stand up meeting to resolve issues promptly and efficiently.
To further promote a culture of continuous improvement and enhance employee engagement, we upgraded iConnect – our idea management portal – with new features:
We continue to improve quality and efficiency through Lean and Six Sigma training programs. Training includes White Belt for new hires and advances to Yellow, Green, and Black Belt. The trainees identify and implement operational efficiencies through projects as part of their training.
White Belts
Yellow Belts
Green Belts
Black Belts
9 Gemba is a concept which involves seeing where the work happens and engaging the front line workers in finding the solution.
10 Kaizen is a Japanese term for finding improvements through association with Lean methodology and principles.
11 5S is a methodology that focuses on Sort, Set in order, Shine, Standardize and Sustain for creating an organized and efficient work environment.
We introduced ‘Syngene Kaizen League’ to involve all employees in continuous improvement. It’s a month-long competition for sharing operational excellence ideas. Over 5,000 Kaizen ideas were submitted by employees in FY24, around 2.5 times more than the previous year.
We hosted the ‘Operational Excellence Expo FY24’ to showcase our continuous improvement journey. The expo displayed over 150 Lean Six Sigma projects and Kaizens, enabling cross-learning and insights into diverse business projects.
Why-Why analysis is a vital tool for root cause identification, extensively used in our SQDECC boards and for routine problem resolution. We have introduced a new Why-Why portal to further improve this process, Key features include: enhanced cross-learning and knowledge-sharing by providing access to previous relevant Why-Why analyses; and improved ease of analysis through improved user guidance.
The 5S concept is a core pillar of our operational excellence framework. During the year, we upgraded the approach to reflect our increasing maturity in using this tool
Our commitment to operational excellence was recognized at various external forums during the year including 21 awards in National and South Asia level competitions. All four teams at the National Competition of Six Sigma 2023 received ‘Platinum’ awards, with one awarded ‘Best Project’ in ‘Improvement Projects in Manufacturing/Operations’ and another securing second position in ‘New Product/Process Development’.
CII National Competition of Six Sigma - 2023
4 Six Sigma projects were recognized with Platinum awards and 1 of them came out as a category winner
QCFI - the 7th Conclave on Pokayoke, Jidoka & Smed
3 POKAYOKE (Mistake proofing) Kaizen won Gold awards
14th CII National Poka Yoke Competition Syngene won 1 Gold award and 3 Silver awards
ASQ - South Asia Team Excellence Award - 2023
2 of our Six Sigma project participated in the South Asia Team Excellence Award – 2023 organized by American Society of Quality and both the project recognized with Bronze Awards
