Q Ultima has domain experts in range of industries, who have helped companies in resolving the variety of problem and together tread the path of success.

The consumer products company have large number of Third Party (3P) manufacturing, packaging and outsourced process units. The control over these has always been a challenge which Q Ultima has helped in addressing in variety of ways.

• Operational Control over 3Ps – Using world class quality & data warehouse systems like Enact, we are able to notify any abnormal situation on real time basis. The situations can be defined based on product, process, vendor or specific condition. This is done on real time basis so that actions can be taken before the actual problem comes.
• Data Analysis for Development Share of Business – The data gathered is analysed to assess overall capabilities of partners and using it for developing specific development plans as well as deciding on share of business.
• Measurement Controls – Standardization of measurement systems across locations is very important as they all are sold under one brand. We help in establishing standard measurement systems so that same product is received from all locations.
• Quality Skills – We also enable for developing quality skills of 3Ps so that consistent product is produced across locations.
• New Product Development – We also enable team to convert ideas into concepts, evaluate concepts, do necessary trials and field tests and launch / industrialize new products.

The interventions given are most common ones, while specific customizations are done based on specific needs.

The challenge faced by automotive are pressing needs to increase volumes and reduce costs at the same time. Also, the plants are continuously assessed by customers and third party, which in most cases, is condition of continuity of supply. Some of the common interventions in automotive are

• Lean for Operational Efficiency & Effectiveness – We enable VSM based continuous improvements for debottlenecking as well as cost reduction. We develop teams to internally operate it and achieve high operational efficiency and effectiveness, Most of the automotive organizations have significantly gained through this.
• Quality Management System (IATF 16949) Requirements – We support in effectively deploying all QMS requirements in organizations making them perpetually ready for external audits. We also help managing internal auditing system by certifying internal auditors, witnessing their audits and grading their competencies. Our clients do not prepare for audits but learn from them.
• Core Tools Deployment – Quality Core tools are not only essential part of IATF requirements, but also has become part of normal working in product / process development and manufacturing. Q Ultima trains and certifies individual experts as well as handhold shop floor deployment using innovative techniques.
• Customer / Third Party Audit Support – We help organization to develop systems such that they are perpetually ready for any external audits. Also, in case any customer has specific requirements like GM, Nissan, Ford etc., we help in understanding specific requirements and develop systems around it, if needed. For some customers, during initial periods, we also guide entire process of audits.
• Six Sigma Deployment – Automotive companies have ready made projects on which they want to systematically work. We have trained large number of their employees and support success of projects.

The interventions given are most common ones, while specific customizations are done based on specific needs.

High variation in inputs products requiring immediate actions for consistent products, seasonal raw materials requiring highly reliable assets and control over large number of plants (own & 3P) are the major challenges faced by this industry. Our key interventions with our clients in this industry had been

• Operational & Quality Control over Manufacturing Units – Using world class quality & data warehouse systems like Enact, we are able to notify any abnormal situation on real time basis. The situations can be defined based on product, process, vendor or specific condition. This is done on real time basis so that actions can be taken before the actual problem comes to maintain consistent output quantity.
• Asset Management Systems (ISO 55001) – We helped agro-based units to deploy asset management systems esp. for sugar, coffee, milk etc. where investments in assets are high and flow of inputs is seasonal. This enabled highly reliable assets in the company to perform at their peak when needed that too at optimal costs and volumes.
• Total Product Maintenance (TPM) – TPM is integral part of 55001, but we also help implementation of these concepts esp. in food based industry. This was very effective in Sesame, hazel nut, cashew, spices and similar industries. This has also been useful with beverages.

The interventions given are most common ones, while specific customizations are done based on specific needs.

The key issues in Chemical companies seen are related to yields, sub-optimal operations, long stabilization periods and reliability of machines. Issues related to measurement of final product features are also common. Some of the key interventions done in this industry are

• Yield Improvement Projects – We use out experts and process optimization techniques to achieve best results in yields of chemicals. We also train teams in systematic experimentation and statistical modelling.
  Asset Management Systems (ISO 55001) – Support to deploy asset management systems in Chemical companies where investments in assets are high and reliability of equipment key success driver. ISO55001, if done in the spirit guided by us, enabled highly reliable assets in the company to perform at minimum risk that too at optimal costs and volumes.
• Total Product Maintenance (TPM) – TPM is integral part of 55001, but we also help implementation of these concepts as separate program. This was very effective in making operating team responsible for their equipment and hence early warning of possible failures.
• Vertical Start Ups – Quick start up and stabilization of existing processes as well as new lines using effective control mechanisms is also supported by our team of experts.
• Measurement Controls – Standardization of measurement systems using statistical techniques is very important as they are often challenged by B2B customers. We help in establishing standard measurement systems so that same product is received again and again and if challenged by customer, necessary documentation is available.

The interventions given are most common ones, while specific customizations are done based on specific needs.

The key challenge faced by our clients in metallurgical industry are process capability of critical parameters (esp. some key ingredients), batch to batch consistency and cycle time variations. We have addressed these problems by

• Capability Establishment – Enabled organization to develop short term and long term capabilities of critical parameters and its analysis to identify critical control factors. We used Enact as a system for early triggers of variation as well as long term analysis to determine benefits.
• Six Sigma Program – Identification of projects, training, certification and hand hold the projects to success has helped company to reduce batch to batch variations and reduce several cost elements esp. energy.

The interventions given are most common ones, while specific customizations are done based on specific needs.

The key challenge in this industry is to come back to action after annual overhauls, Plant reliability, PLF, waste management and variable inputs. Some of the common interventions with our clients in this industry have been

• Shutdown / Overhaul Management – We train team in project planning and execution control. Also enable team to plan overhauls and reduce time 30-50% of baseline.
• Waste Management – Innovative techniques for utilization of waste are enabled through our experts and our partners.
• Asset Management Systems (ISO 55001) – Support to deploy asset management systems in Energy companies where investments in assets are high and reliability of equipment key success driver. ISO55001, if done in the spirit guided by us, enabled highly reliable assets in the company to perform at minimum risk that too at optimal costs and volumes.
• Total Product Maintenance (TPM) – TPM is integral part of 55001, but we also help implementation of these concepts as separate program. This was very effective in making operating team responsible for their equipment and hence early warning of possible failures.

The interventions given are most common ones, while specific customizations are done based on specific needs.

The key challenges which we have helped in education industry is positive customer referrals, faster feedback and development of processes. The key interventions have been

• Understanding Customer Requirements – Survey among key stakeholder of present and potential clients to understand what drives decisions. Enable client to develop processes and systems around those requirements and linking present clients to potential.
• Faster Feedback – Develop several IT enabled systems to gather customer issues and quickly address them. See repeated issues and resolve them through changes or development of new systems.
• Development of Processes – Develop key processes and identify key data to be managed for better control and planning.

The interventions given are most common ones, while specific customizations are done based on specific needs.

These are mostly discrete manufacturing companies finding difficulties in managing large number of small parts. This includes managing its supply chain, manufacturing, assembly and related resources. The key interventions with these companies had been

• Lean for Operational Efficiency & Effectiveness – We enable VSM based continuous improvements for debottlenecking as well as cost reduction. We develop teams to internally operate it and achieve high operational efficiency and effectiveness, Most of the automotive organizations have significantly gained through this.
• Supplier Quality Control – Enabling supplier selection, supplier validation, supplier evaluation and supplier improvement processes. Help development of DOL supplier based and effective control over them.
• Operational & Quality Control over Manufacturing Units – Using world class quality & data warehouse systems like Enact, we are able to notify any abnormal situation on real time basis. The situations can be defined based on product, process, vendor or specific condition. This is done on real time basis so that actions can be taken before the actual problem comes to maintain consistent output quantity.

The interventions given are most common ones, while specific customizations are done based on specific needs.

The key issues in Pharma companies seen are related to yields, sub-optimal operations, long stabilization periods and reliability of machines. Issues related to measurement of final product features and data integrity and management for FDA audits are also common. Some of the key interventions done in this industry are

• Yield Improvement Projects – We use out experts and process optimization techniques to achieve best results in yields of APIs. We also train teams in systematic experimentation and statistical modelling.
• Asset Management Systems (ISO 55001) – Support to deploy asset management systems in Pharma companies where investments in assets are high and reliability of equipment key success driver. ISO55001, if done in the spirit guided by us, enabled highly reliable assets in the company to perform at minimum risk that too at optimal costs and volumes.
• Total Product Maintenance (TPM) – TPM is integral part of 55001, but we also help implementation of these concepts as separate program. This was very effective in making operating team responsible for their equipment and hence early warning of possible failures.
• Measurement Controls – Standardization of measurement systems using statistical techniques is very important as they are often challenged by B2B customers & FDA auditors. We help in establishing standard measurement systems so that same product is received again and again and if challenged by customer, necessary documentation is available.
• Operational & Quality Control over Manufacturing Units – Using world class quality & data warehouse systems like Enact, we are able to notify any abnormal situation on real time basis. The situations can be defined based on product, process, vendor or specific condition. This is done on real time basis so that actions can be taken before the actual problem comes to maintain consistent output quantity.The interventions given are most common ones, while specific customizations are done based on specific needs.