My Vision

Increasing profits today and tomorrow through Productivity, Efficiency, and Quality improvement in our customer's manufacturing operations through execution.

My Mission

Execution and knowledge focussed organization to support customer's profitable growth

Mr. MK Khanduja

About Me

I am an engineering graduate from Harcourt Butler Technological Institute and have been engaged in consulting and execution of manufacturing excellence initiatives comprising of Plant Performance Improvement, TPM, Six Sigma, Analytics, QFD, Balanced Scorecard, WCM, Reliability Engineering and CMMS application for more than 25 years, while operating from Gurugram and Pune. I lead Inter Alliance, the consulting division of Werardt Systems Pvt. Ltd. and Inversio Solutions LLP. I have worked on several prestigious assignments for over 60 top Indian and International clients.

Some of my recent assignments have been executed for companies like Bajaj Group, Hero Motocorp, Bikanerwala Food Pvt. Ltd., Dantal Hydraulics Pvt. Ltd., Pernod Ricard, Alstom, Hamdard labs, ABD Blenders & Distillers Pvt. Ltd., RACL Gears Pvt. Ltd., Bonn Nutrients (P) Ltd., Alsorg Interiors Pvt. Ltd., Pritul Machines etc.

I am a certified professional in the field of Reliability Engineering (TUV Rheinland), BI Tools (IBM certified), Six Sigma, QFD, QMS, NLP and Executive Coaching (David Rock) etc. from various national and international organizations. I have been personally associated with globally renowned professionals in the automobile sector.

I have executed measurable advanced blended e-learning modules on Quality Function Deployment “QFD", Design of Experiment “DoE” and GRT Standards for an automobile major in India. I have published four research papers in the fieldof Interpretive Structural Modelling, Six Sigma, Machine Failure Forecasting and World Class Manufacturing.

My current focus is largely on emerging trends in technology such as BI, AI, AR/VR, IOT that are going to take manufacturing to the next level under Industry 4.0. As the availability of technology is becoming a commodity, therefore, the challenge, is now more towards real-time execution and sustainability in manufacturing.

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Resources - Mk Khanduja

Our Products and Services

Consulting

The prime objective of a business is to manage a perpetual profitable growth in the current competitive environment. However, for last few years, business variables have become too complex to manage with ease, due to globalization, technology convergence and intense competition.

| alongwith my team have a proven track record to execute excellence in client's business operations through consulting services to bring in more profits and growth. I understand the depth and breadth of business processes. My endeavour is to focus on traditional values with results and return on investment (ROI) in mind through consulting services.

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Execution

Contemporary manufacturing practices right from production planning, inventory planning, supply chain management to six sigma etc all have been derived from the real-time common sense. But companies still struggle to implement these practices effectively. The real difference is the execution.

I along with my team have collectively several years of experience in implementing over 30 manufacturing excellence tools viz TPM, TQM, Lean manufacturing, QFD, QMS, Reliability engineering, Six Sigma etc in over 60 Indian and International companies.

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Learning

The rapid technology development and changing business environment has made people development and skill enhance-ment an essential requirement for the growth of an organisation. But the conventional training methods are unable to deliver the desired results in present times.

I alongwith my team have developed a blended learning solution for measurable output. This is a well-balanced mixed of conventional training and technology based learning system (including e-learning etc) to deliver powerful results.

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Our Core Competence

TPM | Total Productive Maintenance Youtube Thumnail - MK Khanduja
Total Productive Maintenance Youtube Thumnail - MK Khanduja
Lean Manufacturing Youtube Thumnail - MK Khanduja
Business Wisdom

Reputed Clients

Happy Client 4
Happy Client 9
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Happy Client 5
Happt Client 3
Happy Client 2
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Happy Client 1

Testimonials

What our clients say about us

Mr. MK Khanduja has good grasp on Quality process methodolgies e.g QFD. He has quite basic approach in coaching the teams and reaching to final results with the team sessions. He also apply tools and analycal methods to check the survey results and point out deficiencies to improve the same.

Sameer Jindal

Director Engineering at MG Motor India , Earlier Program Mgmt head at Hero Moto Corp and Director GM India.

We have engaged Mr. M.K. Khanduja, – for “- Time & Motion “Study for our Aurangabad Plant and also facilitate ” -Lean Manufacturing” Training for all our employees in the plant. We found Mr. Khanduja’s approach with respect to the above study very scientific and comprehensive which is praise worthy. Also, the training imparted by him was found to be very value adding by the participants. We wish him all success in his endeavors.

Sanjeev Dixit

Vice President – Human Resources
Allied Blenders & Distillers Pvt. Ltd.

This is to certify that Inter Alliance Werardt Consultants have conducted the Lean Manufacturing project in our production units at Kinauni, Distt. Meerut; Palia, Distt. Lakhimpur and Kundarki, Distt. Gonda. There has been substantial improvement in 5S, Kaizen and elimination in non value added -activities. The lead time has been also improved in the process. Customization of project and connect with target audience is their core competence. Inter Alliance Werardt professionals are committed and punctual.

Jitendra Kumar Sharma

Sr. General Manager – HR
Bajaj Eco-Tec Products Ltd.

Mr MK Khanduja has a deep understanding of advanced excellence techniques like Six Sigma ,Reliability Engg, WCM and Analytics etc. wish him all success in his endeavours. In recent project of manufacturing excellence in Bonn Group of Industries we can observe big change.

Pankaj Agarwal

Executive Director Group Bimbo Harvest Gold
Earlier Vice President at Bonn Nutrients Pvt. Ltd.

Mr. MK Khanduja always delivered something extra in assignments awarded to him. He provides innovative but pragmatic solutions within committed delivery schedule. I am thoroughly convinced about his capabilities in projects related to Performance Management & Management Development Programmes.

Sajeev Nair

General Manager, Human Resources at Galfar Engineering & Contracting SAOG, Oman

Mr. Khanduja had been associated with Dantal Hydraulics Pvt Ltd.,for the execution of Plant performance improvement practices. A reduction of 25% breakdown time and 15% spare parts consumption has been observed by the manufacturing excellence practices mutually implemented by him and my team. He is a committed professional for ensured delivery.

Yogesh Tyagi

Agm Plant Engg.
Dantal Hydraulics Pvt. Ltd

Our machines breakdowns were reduced by 40% within a time span of 5 months, leading to good productivity and better profits.

Gurmeet Singh

CEO
SS Food Industries
Manufacturer Bonn Biscuits

Books by M.K.Khanduja

Total productive maintenance Book Available on Amazon- MK Khanduja
TPM - Total Productive Maintenance,Challenges for Today and Tomorrow in Machine Maintenance Engineering MK Khanduja

This book covers comprehensive intricacies of TPM in an easy to understand language. 50 important TPM tips written in blog style is its USP that supported by a lot Of illustrations makes the reading light and interesting. Fundamentals of machine maintenance, machine performance parameters, 8 pillars of TPM, beyond TPM, CMMS, RCA etc are relevant topics covered in details.

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Total Quality Management buy Click here to Buy Book on Amazon - MK Khanduja
TQM - Total Quality Management,Implementation made easy MK Khanduja

Reduction of defects is the life-line of the quality initiative. The initiative to plan, achieve, control, and sustain the quality output in the entire organisation is philosophy behind TOM. All aspects of quality have been discussed in this book, step by step, while covering the contribution Of quality gurus for almost last 100 years.

Advanced quality concepts like Six Sigma, DOE, Taguchi methods etc have been treated with so much ease to make the reader comfortable to understand and implement quality effectively.

TQM - Total Quality Management - Amazon
lean Manufacturing Book Available on Amazon - Mk Khanduja
Lean ManufacturingImplementation Made Easy MK Khanduja

This book covers comprehensive intricacies of Lean Manufacturing in an easy to understand language. 20 Lean Manufacturing tips written in blog style is the book's USP. Reduction of waste or non-value added activity is the spirit behind Lean manufacturing.

In fact, the famous Toyota Production System popularly known as TPS intensively based on lean principles, 5S, Kaizen, VSM, kanban, hejunka, poka yoke and JIT assembly all the important principles have been covered in details. The overall focus has been to establish balance between theory and practice. The entire subject has been treated to enlignten the audience to have deep understanding of lean practices.

Lean Manufacturing Implementation Made Easy
Profitable Growth, Today and Tomorrow

My Thought Process

Business Model to deliver results today and tomorrow

Business Model to deliver results today and tomorrow

Last century manufacturing business model

In the last century, doing business was relatively easy. As is often exclaimed, "Earlier, times were simpler" holds true for the businesses operating in the last century. The customer behaviour was predictable, the number of options available to him were much less than what we see these days and due to a much lesser number of companies offering the same kind of products resulting monopoly was established by several companies. Even the business system was much simpler than it is today. It only consisted of more or less 6 functions, sales, production, material, people management administration, and accounting. Manufacturing companies for example in Indian automobile sector had established monopoly in their own right. Each of those companies offered products that were suited for a different type of buyer. Hence, there was a much lower degree of competition among them.

My thought process

Research Papers

Application of Interpretive Structural Modeling (ISM) in improving quality of Slice Bread in manufacturing: A case study

M.K. Khanduja

Director, Inter Alliance Consultants, Managing Partner, Inversio Solutions LLP

Abstract

Bread manufacturing is a complex process. It involves baking of refined wheat flour dough under various controlled parameters. Wheat flour, water and yeast are the main ingredients in bread but some additional ingredients such as salt, fat sugar and improvers are added to produce specific variety of bread.

Flour mixing, dough viscosity, temperature and moisture during dough preparation, proving and oven baking play key role in determining the quality of bread. Consumer preferences compel bread manufacturers to maintain a high quality standard of appearance, texture and flavor. Managing a constant quality output on regular basis is always a great challenge. Over 10 critical parameters play vital role in managing the quality of bread. Due to such complexity, managers are not able to identify the critical enablers which are responsible for enhancing quality and productivity. Normally, the effort applied is misdirected and they don't foresee any improvement in the productivity. A similar kind of situation was experienced by a leading bread manufacturing unit in north India. The organization was facing 3.5% rejections due to poor quality of breads. This research paper presents a case study which employed Interpretive Structural Modeling (ISM) technique to identify the high driving power enablers. The managerial intervention on the enablers and subsequent corrective measures taken, reduced the overall rejections to 2%. This paper presents a successful implementation of the outcomes of the ISM methodology and advocates the inception of ISM as a first tool to be adopted in problem solving by all the practitioners.
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A CNC Machine failure forecasting and Reliability analysis using data from a CMMS (Computerized Maintenance Management System) software.

M.K. Khanduja

Director, Inter Alliance Consultants, Managing Partner, Inversio Solutions LLP

Satish Nande

Director, Werardt Systems Pvt. Ltd.

Abstract

The Machine performance of a manufacturing plant directly affects the profitability of an organization. Managing optimum machine performance has become very challenging due to emergence of advanced technology and complex processes. The need for precise machine performance information on time has become a crucial input parameter.

Hence, CMMS is mostly used in good manufacturing organizations as a reliable tool for recording breakdown events. Untimely machine breakdowns increase the downtime as well as reduce the machine life, in both cases profitability of an organization gets severely affected. Understanding and estimating the machine failures before time by using Reliability Engineering method is a very powerful technique now being used in leading companies in the world. A proactive action to maintain the machine before the breakdown occurs can bring in substantial increase in OEE and profitability of the organization. A failure forecasting analysis of a CNC machine is being demonstrated using Reliability Engineering method on a data recorded in a CMMS software (FTM*)

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Achieving Excellence in Manufacturing in Contemporary Globally Completive environment - A World Class Manufacturing (WCM) Perspective.

M.K. Khanduja

Director, Inter Alliance Consultants, Managing Partner, Inversio Solutions LLP

Abstract

In least 15 years the difficulty levels in manufacturing have been accelerating rather than growing. Easier access to knowledge, technology, capital and connectivity worldwide has been one of the key drivers for Global competition.

Reduction of product life cycle, increased customer expectations due to wider availability and price competitiveness have become the prime characteristics of today's business world. This all is termed as VUCA (volatility, Uncertainty, Complexity & Accelerating) world. The nature of a successful business execution has been transformed from local to Global domain. One should be able to manufacture world class product cost effectively as well as should be able to sell Globally today and tomorrow. This is the true spirit. of WCM. In this paper the concept of world class manufacturing is being defined from implementation perspective in Indian scenario in manufacturing sector. Some pragmatic models have been discussed which can transform conventional manufacturing practices into new age initiatives using WCM methods.

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Reduction of defects in welding of Cylindrical tube with metal end- head through DOE (Design of Experiment) applying Six Sigma method.

M.K. Khanduja

Director, Inter Alliance Consultants, Managing Partner, Inversio Solutions LLP

Abstract

A robust welding joint of steel tube with end- head is a critical requirement in manufacturing equipments for chemical plants, construction equipment and other engineering fields.

A minute leakage through a welding joint is a non-acceptable requirement in critical applications. Cracks, metal penetration, blow holes and lack of fusion are the typical defects being observed. Welding on a cylindrical surface further complicates the process. A design of experiment (DOE) has been conducted to study the effect of critical variables viz current rating, rotation of tube during welding process and welding torch electrodes distance from the job. Best values of these critical variables have been determined by using Six Sigma technique to standardize the particular manufacturing process. Non destructive ultrasound testing method has been deployed to identify the defects. An improvement of 40% in defects reduction has been observed through this process.

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Associates

Satish Nande

An engineering professional, began his career in industrial automation and then was actively involved in the Development and Implementation of various Shop floor systems including systems for Maintenance management. Under him FTM, Weradt's Computerized Maintenance Management Software solution, has become a leading software with installations in large scale industries in India and abroad.

Ashish Yardi

A Software Engineer by profession, was actively involved in Software Development in his earlier career. He has a sound knowledge in SDLC and has also done an International Level Certification in System Audit. He heads Werardt's Enterprise Solutions division that offers SOHAM an ERP for the SME segment, and provides apt Solutions for customer needs using his domain knowledge across various business verticals.

Vivek Sovani

A Software Engineer by profession, gained a sound Domain experience in various business verticals. He is Instrumental in conceptualizing and designing most of the Products of Werardt. He has also done an International Level Certification in System Audit. The latest Solutions designed by him are in Supply chain and Engineering domain for FMCG and Pharma companies. He currently leads Werardt's CONNEKT range of offerings designed for Field Level Operations using latest mobile technology.

Indranil Bapat

A Software Engineer by profession, has a sound understanding of technology and its adaptability in various businesses. Played key role in developing the software solutions offered by Werardt and leads Werardt's Product Development effort for domestic and international customers. Involved in Nucleus, Werardt's Rapid Application Development Framework for developing a suit of centrally deployed and managed Enterprise applications, like CONNEKT and FTM. Has been instrumental in web-based software platform for integrated water planning, operations, maintenance, and regulatory compliance portals.

Any Query?