🇮🇳India

क्षमता अध्ययन संसाधन अनुकूलन विफलता (Capability Study Resource Optimization Failure)

4 verified sources

Definition

Capability Studies quantify whether a manufacturing process (injection molding, assembly, testing) can reliably meet tight tolerances. Six Sigma methodologies require Cpk ≥1.33 for critical dimensions. Without pre-production studies, manufacturers discover during FAI or mass production that a mold, equipment, or operator setup cannot hold tolerance. This triggers in-process corrections: equipment recalibration, mold rework (polishing, cavity adjustment), operator retraining, and scrap of out-of-spec parts. In India, cost pressure and lack of statistical expertise lead manufacturers to defer capability studies, causing high-cost firefighting.

Key Findings

  • Financial Impact: Unplanned overtime (capability troubleshooting): ₹10-30 lakhs/incident (typically 200-400 additional labor hours at premium rates). Mold/equipment downtime and rework: ₹5-25 lakhs per incident. Material scrap from low-capability runs: ₹15-50 lakhs. Total annual loss (2-3 capability failures/year): ₹60-180 lakhs. Cost of pre-FAI capability study: ₹3-8 lakhs (avoided by deferring).
  • Frequency: 2-3 incidents per year for manufacturers running 3-5 concurrent product lines without systematic capability validation.
  • Root Cause: Weak statistical process control (SPC) culture in Indian SMEs; lack of trained process engineers; absence of capability study contractual requirements from customers; cost-cutting mindset prioritizing upfront savings over process confidence.

Why This Matters

The Pitch: Indian plastics manufacturers waste ₹40-180 lakhs annually on unplanned process corrections and overtime due to skipped pre-production capability studies. Pre-FAI statistical validation ensures Cpk ≥1.33 before line start, eliminating emergency rework cycles and premium labor costs.

Affected Stakeholders

Process Engineers, Manufacturing / Plant Operations, Quality Assurance, Finance (managing unplanned spend)

Deep Analysis (Premium)

Financial Impact

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Methodology & Sources

Data collected via OSINT from regulatory filings, industry audits, and verified case studies.

Evidence Sources:

Related Business Risks

स्क्रैप चोरी और अनधिकृत उपयोग

2-5% inventory shrinkage from poor tracking (industry standard)[2][5]

क्षमता हानि

Lost production from idle equipment; minimized by SPC (industry standard 5-10% capacity recovery)

मोल्ड योग्यता में प्रदूषण अनुपालन लागत

₹2-5 लाख per delayed consent application + 20-40 hours/month for documentation[2]

मोल्ड रखरखाव शेड्यूलिंग में देरी से उत्पादन क्षमता हानि

₹10-20 lakhs annual downtime cost per machine; up to 30% reduction in downtime achievable with proper scheduling

मोल्ड रखरखाव कमी से खराब उत्पाद गुणवत्ता

2-5% production scrap rate; rework costs equivalent to 10-15% of output value

BIS प्रमाणीकरण अनुपालन विफलता

₹10-50 लाख+ per machinery batch (full sales prohibition post-28 Aug 2025); testing/audit costs ₹5-15 लाख per certification.

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