With 4 years of continuous efforts, the yield of continuous casting plant (Stand Pig Casting Machine) could not be improved beyond 92 to 93% by any of the available improvement theories as well as techniques like:
- TPM (thru JIPM)
- Theory of Constraints
- TOP (McKinsey model)
- Six Sigma and others
However with application of Design Out For Reliability (DOFR), the yield increased to 98%. Further, in barely three months with minimum efforts, the company gave additional profit increase by 8% on a continuous basis (the reported profit margin of company is around Rs. 35 crores).