1. LEAN
MANAGEMENT
- Anand Narayan Shukla

2. Store Photo & Team photo
HELIOS SEC 18 GLADIATORS

3. WEEK-WISE 5 S SCORE TREND
77%
84%
82%
88%
92%
65%
70%
75%
80%
85%
90%
95%
3rd Oct13 20th Oct13 10th Nov13 24th Nov13 8th Dec13
5S Audit score

4. TEAM DOING 5 S

8. KAIZENS

9. Store: Sector 18 Helios (HNOI) KAIZEN:1 (House keeping material)
Before: racks spaces were going wasted
After: adjusted all the pantry and house
keeping materials in the racks
Before After

10. Store: Sector 18 Helios (HNOI) KAIZEN: 2 (CHS drawer)
Before: CHS’s drawer was not neat and
clean
After: cleaned it and removed all
unwanted items
Before After

11. Store: Sector 18 Helios (HNOI) KAIZEN: 3 (Power room)
Before: Power room was not neat
After: cleaned it and removed all
unwanted items
Before After

12. Store: Sector 18 Helios (HNOI) KAIZEN:4 (Service center)
Before After
Before: Service room was not neat
After: cleaned it and removed all
unwanted items

13. Store: Sector 18 Helios (HNOI) KAIZEN:5 (Cash Counter)
Before After
Before: monitor was on the right side of
the table which was inconvenient to
operate PC
After: Vault shifted to right and monitor
shifted to left and leg space made
available for convince

14. Store: Sector 18 Helios (HNOI) KAIZEN: 6 (Cash Counter)
Before: cash counter was a mess and
was not neat
After: rearranged all the items and
removed unwanted items
Before After

15. Store: Sector 18 Helios (HNOI) KAIZEN: 7 (Cash Til)
Before: cash counter not neat and there
were no partition in it
After: removed all the unwanted items,
made partitions for cash and created a
shadow board for all the materials
required for billing
Before After

16. Store: Sector 18 Helios (HNOI) KAIZEN: 8 (Leg space at the cash)
counter)
Before: leg space at the cash counter
was not clear as many wires were
coming out
After: adjusted a white board to block
all the wires from coming out
Before After

17. Store: Sector 18 Helios (HNOI) KAIZEN: 9 (Cupboards and)
drawers)
Before: none of the drawer/ gate was
labelled
After: each and every gate and drawer
got a number (lable)
Before After

18. Store: Sector 18 Helios (HNOI) KAIZEN: 10 (Power room )
Before: none of the switches were
labelled
After: all the switches are labelled
Before After

19. Store: Sector 18 Helios (HNOI) KAIZEN: 11 (Power room)
Before After
Before: none of the switches were
labelled
After: all the switches are labelled

20. Store: Sector 18 Helios (HNOI) KAIZEN: 12 (Wires)
Before After
Before: none of the plugs were labelled After: all the plugs are labelled

21. Store: Sector 18 Helios (HNOI) KAIZEN: 13 (Indexes)
Before: there were no indexes/ item list
inside the drawers
After: pasted indexes inside all the
drawers reflecting the items inside it
Before After

22. Store: Sector 18 Helios (HNOI) KAIZEN: 14 (Files and folders)
Before: registers and files were not
arranged properly
After: all the files got a number and
arranged properly
Before After

23. Store: Sector 18 Helios (HNOI) KAIZEN: 15 (Water dispenser)
Before: there were no markings on the
water dispenser for Hot and Cool water
After: water dispenser is labelled for Hot
and Cool water
Before After

24. Store: Sector 18 Helios (HNOI) KAIZEN: 16 (Stationary)
Before: Stationary items were not
arranged neatly
After: all the stationary items are
arranged neatly with a dividing line (red)
for defining spaces
Before After

25. Store: Sector 18 Helios (HNOI) KAIZEN: 17 (Stationary)
Before After
Before: Stationary items were not
arranged neatly
After: all the stationary items are
arranged neatly with a dividing line (red)
for defining spaces

26. Store: Sector 18 Helios (HNOI) KAIZEN: 18 (Key Hook)
Before: there was no key hanging hooks
Afters: created a hook for keys using
unused C-clamps
Before After

27. Store: Sector 18 Helios (HNOI) KAIZEN: 19 (Pantry)
Before: Pantry was not neat and clean
After: cleared unwanted stuff and
cleaned the pantry
Before After

28. Store: Sector 18 Helios (HNOI) KAIZEN: 20 (Store layout)
Before: there was no layout of the store
available to locate a particular drawer
After: took the printout of the layout
and marked each and every drawer on it
to simplify the search
Before After

29. Store: Sector 18 Helios (HNOI) KAIZEN:21 (Store layout)
Before After
Before: there was no layout of the store
available to locate a particular drawer
After: took the printout of the layout
and marked each and every drawer on it
to simplify the search

30. Store: Sector 18 Helios (HNOI) KAIZEN: 22 (Store layout)
Before After
Before: there was no layout of the store
available to locate a particular drawer
After: took the printout of the layout
and marked each and every drawer on it
to simplify the search

31. Store: Sector 18 Helios (HNOI) KAIZEN: 23 (Lean File)
Before: there was no separate file for
Lean retailing
After: Created a special file for
documenting Lean retailing at HNOI
(Noida Helios store)
Before After

32. Store: Sector 18 Helios (HNOI) KAIZEN: 24 (Stairs)
Before: There were no markings at the
stairs
After: every step of the stair is marked
with yellow tape
Before After

33. Store: Sector 18 Helios (HNOI) KAIZEN: 25 (Charts and graphs)
Before: didn’t have enough space for
putting lean and store metrics graphs
After: used pantry cabin gates as white
boards and pasted graphs on it
Before After

34. Store: Sector 18 Helios (HNOI) KAIZEN: 26 (Door mat)
Before: Door mat was torn off from the
corners and store was planning to buy a
new one
After: removed all the corners and made
it as good as new
Before After

35. Store: Sector 18 Helios (HNOI) KAIZEN: 27 (Pantry)
Before: Water dispenser was creating a
space issue in the pantry
After: shifted the dispenser, now pantry
looks spacious
Before After

36. Store: Sector 18 Helios (HNOI) KAIZEN: 28 (Pre Stamped Invoices)
Before After
Before : We were doing the
stamping after the billing
process done it takes some
extra time
After : Now pre stamp billing
stationary saves some time during
billing process

37. Store: Sector 18 Helios (HNOI) KAIZEN: 29 (Pre Stamped encircle cards)
Before After
After : Pre-Stamp Encircle Card
Saves times in Billing Process
Before: We do stamping after
billing

38. Store: Sector 18 Helios (HNOI) KAIZEN: 30 (Hooks for hanging Cloths)
Before After
After: Now we have put Cloth
hangers behind the pantry door it is
now convenient for employees.
Before: There were no place where
employee can hang their cloths

39. Store: Sector 18 Helios (HNOI) KAIZEN: 31 (Space for carry bags)
Before After
After: Now we have put all the carry
bags in 2 separate bins with the
demarcation and use other bin
option
Before: Carry bags were all together,
so it was difficult to identify the qty
left

40. Store: Sector 18 Helios (HNOI) KAIZEN: 32 (Space for Trays)
Before After
After: Now we are keeping all the
Tray at a one place keeping mind so
that it will not lying here and there.
Before: Earlier Trays were lying here
and there.

41. Store: Sector 18 Helios (HNOI) KAIZEN: 33 (Labeled key hooks)
Before After
After: Now We put all store related
keys at the respective demarked
place
Before: Earlier the all keys were lying
at the counter.

42. Store: Sector 18 Helios (HNOI) KAIZEN: 34 (Details of nearby ATMs)
Before After
After: Now we can suggest those
customers where the ATM is
situated
Before: when swiping/EDC machine
don’t works/ links down/Terminal ID
fail/Decline then the chances are
that customer may not comes back
and also we don’t know the ATM
address.

43. Store: Sector 18 Helios (HNOI) KAIZEN: 35 (Shortcut keys for faster billing)
Before After
After: we have derived shot cut to
billing so that the entire process gets
easier.
Before: it takes 10-12 minutes for
bills invoices and customer get
irritated because of this.

44. Store: Sector 18 Helios (HNOI) KAIZEN: 36 (Store Index)
Before After
After: Store index is added to both
the floors indicating which item is
kept where
Before: it was tough for staff or any
new comer to identify which item is
kept where

45. Store: Sector 18 Helios (HNOI) KAIZEN: 37 (Numbering on every file)
Before After
After: Numbering on every file has
been done for identification and
setting
Before: it was tough for staff to
maintain files at one place in an
organized manner

46. Store: Sector 18 Helios (HNOI) KAIZEN: 38 Lock for meter box
Before After
Before: Helios’s meter box was
open
After: applied lock at the gate so
that no one else can open it

47. Store: Sector 18 Helios (HNOI) KAIZEN: 39 Hook for hanging Shutter lifter
Before After
Before: there was no space for
keeping shutter opener
After: designated a space and
applied a hook inside the meter box
where it is safe as meter box has a
lock now

48. Store: Sector 18 Helios (HNOI) KAIZEN: 40 Pre-stamped warranty cards
Before After
Before: warranty cards were
not pre stamped, stamping
these cards at the time of
billing was taking few seconds
After: 3 warranty cards of every
brand are pre stamped during idle
time for speeding up the billing
process

49. Store: Sector 18 Helios (HNOI) KAIZEN: 41 Carry bags kept near to the cash counter
Before After
Before: carry bags were kept
away from the cash counter,
resulted in delay in billing
After: 20 carry bags are kept at the
counter for faster billing

50. Store: Sector 18 Helios (HNOI) KAIZEN: 42 (using tab for communicating offers)
Before After
Before: apart from tent cards
didn’t have anything else for
communicating offers inside
the store
After: Now communicating offers
inside the store using tab

51. Store: Sector 18 Helios (HNOI) KAIZEN: 43 (Lean Billing)
Before After
Before: Billing used to take
huge amount of time
After: With the help of lean and
KAIZEN billing time reduced
drastically
Scenario Without
Lean/KAIZEN
Billing with 1
CRO
14.5 min
Billing with 2
CROs
9.2 min
Scenario With
Lean/KAIZE
N
Time
saved
Billing with
1 CRO
9.2 min 5.3min
Billing with
2 CROs
4.5 min 4.7 min

52. Store: Sector 18 Helios (HNOI) KAIZEN: 44 (Easy identification of old stock)
Before After
Before: It was quite impossible
for Staff to identify old variants
in the stock and apply FIFO
After: White tags for watches more
than 90 days old (so that CRO can
easily apply FIFO on the variants in
every brand )

53. Store: Sector 18 Helios (HNOI) KAIZEN: 45 (Visual representation for watch box management)
Before After
Before: No properly managed
watch boxes
After: visual representation has
been given to the watch boxes for
easy replenishment

54. TOTAL NUMBER OF KAIZENS DONE &
RECORDED: 45

55. BEST KAIZENS

56. KAIZEN 1 : LEAN BILLING

57. CUSTOMER FINALIZES THE
WATCH TO BE BILLED
CUSTOMER GIVES HIS
FEEDBACK AND DETAILS IN
THE FEEDBACK BOOK
CRO STARTS BILLING ON ETP
ONCE HE RECEIVES DATA
FROM THE FEED BACK BOOK
OR HE ASKS FOR DATA AGAIN
CRO SETS THE WATCH AND
WILL SHOW IT TO THE
CUSTOMER
CRO PACKS THE WATCH AND
WILL HAND IT OVER TO THE
CUSTOMER IN HELIOS CARRY
BAG
(GIFT WRAP IT IF REQUIRED)
CRO 2 (HANLDING THE
CUSTOMER) WILL HANDOVER
CUSTOMER FEED BACK BOOK
TO THE CUSTOMER
CRO 1 WILL START BILLING ON
ETP
CRO 2 SETS THE WATCH AND
WILL SHOW IT TO THE
CUSTOMER (WHILE CRO1 IS
DOING BILLNG)
CRO 2 PACKS THE WATCH AND
WILL HAND IT OVER TO THE
CUSTOMER IN HELIOS CARRY
BAG
(GIFT WRAP IT IF REQUIRED)
SCENARIO 1:
ONE CRO, FOR BILLING
AND PACKING OF WATCH
SCENARIO 2:
TWO CROs, ONE FOR
BILLING AND ONE FOR
PACKING OF WATCH
ALL STEPS ARE BEING FOLLOWED PARALLELLY
OLD BILLING PROCESS FLOW - SNAPSHOT
AFTER GENERATING
BILL (HARD COPY)
AFTER CLEARING DOUBTS OF THE
CUSTOMER (IF HE/SHE HAS ANY)
Time taken:
870s = 14.5 m
Time taken:
550s = 9.2 m

58. Duplicate
data
• Customer’s
name
• Mob. No.
• Email ID
Customer fills feed back form
CRO asks for customer’s name/ mobile no./ email id
for billing (duplicity in taking customer’s data)
CRO will do the system billing (including UPL enrolment)
Bill gets printed
CRO sets watch and
shows it to the customer
CRO bring the watch box, takes
out the warranty card and puts stamp on it
CRO Gift wraps the watch
(if customer asks for it)
Handover the watch to the customer in a carry bag
CUSTOMER IS READY FOR BILLING
180 s
120s
90 s
10 s 30 s 180 s
240 s
20 s
Total time taken just for handing over the
watch to the customer
870 sec = 14.5 min

59. HOW FAST BILLING SHOULD
HAPPEN!!!

60. 14.5 mins !!!!!!!!!!!
Just for a billing!!!!!!!!!!
How to reduce it ?
Only the following things which are required for customers and billing should be in/on the cash
counter:
 visitor’s book, customer complaint toll-free tent card, gift card acrylic stand, tab
 all stationeries (pen, pencil, stapler, stamps, scale, glue stick, punching machine, calculator,
manual bill books, printer billing stationary, customer exit books) in a defined place, easy to
reach while billing
 monitor, printer, EDC machines, telephones in an organized fashion

61.  Pre-stamped and folded thank you cards
 20 carry bags at cash counter  Pre stamped invoices
 Pre stamped encircle cards

62.  3 watch boxes of all brands to be kept near the cash counter
 Warranty cards in these boxes are pre stamped
 Tab for recording customer data
and feed back

63. CUSTOMER FINALIZES THE
WATCH TO BE BILLED
CRO WILL ENTER HIS NAME IN
THE TABLET AND HANDS IT
OVER TO THE CUSTOMER FOR
FEEDBACK
CRO WILL START BILLING ON
ETP WHILE CUSTOMER FILLS
IN THE TABLET
CRO SETS THE WATCH AND
WILL SHOW IT TO THE
CUSTOMER
CRO PACKS THE WATCH AND
WILL HAND IT OVER TO THE
CUSTOMER IN HELIOS CARRY
BAG
(GIFT WRAP IT IF REQUIRED)
CRO 2 (HANLDING THE
CUSTOMER) WILL ENTER HIS
NAME IN THE TABLET AND
PASS IT TO THE CUSTOMER
FOR FEEDBACK
CRO 1 WILL START BILLING ON
ETP WHILE CUSTOMER FILLS
IN THE TABLET
CRO 2 SETS THE WATCH AND
WILL SHOW IT TO THE
CUSTOMER (WHILE CRO1 IS
DOING BILLNG AND
CUSTOMER IS GIVING DETAILS
IN THE TABLET)
CRO 2 PACKS THE WATCH AND
WILL HAND IT OVER TO THE
CUSTOMER IN HELIOS CARRY
BAG
(GIFT WRAP IT IF REQUIRED)
SCENARIO 1:
ONE CRO, FOR BILLING
AND PACKING OF WATCH
SCENARIO 2:
TWO CROs, ONE FOR
BILLING AND ONE FOR
PACKING OF WATCH
ALL STEPS ARE TO BE FOLLOWED PARALLELLY
ABOVE MENTIONED ARE TO BE DONE PARALLELLY
LEAN BILLING PROCESS FLOW WITH TABLET - SNAPSHOT
AFTER GENERATING
BILL (HARD COPY)
AFTER CLEARING DOUBTS OF THE
CUSTOMER (IF HE/SHE HAS ANY)
Time taken:
550s = 9.2 m
Time taken:
270s = 4.5 m

64. CRO will do the system billing (including UPL enrolment)
Bill gets printed
CRO sets watch and
shows it to the customer
CRO Gift wraps the watch
(if customer asks for it)
Handover the watch to the customer in a carry bag
CRO takes out the customer data from the
customer feedback portal without disturbing
the customer again
Customer fills feed back in the TAB
CRO takes out the watch box and puts
watch inside it, warrant card is already stamped
CUSTOMER IS READY FOR BILLING
140 s
20s
90 s
10 s 30 s 10 s
240 s
10 s
Total time taken for handing over the watch to
the customer
550 sec = 9.2 min

65. COMPARISON
Scenario Without
Lean/KAIZEN
With
Lean/KAIZEN
Time saved
Billing with 1 CRO 14.5 min 9.2 min 5.3min
Billing with 2 CROs 9.2 min 4.5 min 4.7 min
14.5
9.2
5.3
9.2
4.5 4.7
0
5
10
15
20
Without Lean/Kaizan (min) With Lean/Kaizan(min) Time saved(min)
Billing with 1 CRO Billing with 2 CROs

66. KAIZEN 2 : SHORTCUT KEYS FOR FASTER
BILLING

67. KAIZEN 3 : NEAREST ATMS AND DISTANCE
FROM HELIOS STORE (CUSTOMER FOCUSED)

68. KAIZEN 4 : LOCK FOR METER BOX AND HOOK
FOR HANGING SHUTTER LIFTER

69. KAIZEN 5 : WHITE TAGS FOR WATCHES MORE THAN 90 DAYS OLD
(SO THAT CRO CAN EASILY APPLY FIFO ON THE VARIANTS IN
EVERY BRAND )

70. KAIZEN 6 : MASTER PROCESS FILE
commercial
folder1
folder3
File 1
File2
File 1
File 2
File 1
File2
folder2
service
folder1
folder3
folder2
operations
folder1
folder3
folder2
ABC
folder1
folder3
folder2
Data needed to
be updated at
day end or once
in a month
Folders Sub-Folders FilesOLD
PROCESS

71. commercial
folder1
folder3
File 1
File2
File 1
File 2
File 1
File2
folder2
service
folder1
folder3
folder2
operations
folder1
folder3
folder2
ABC
folder1
folder3
folder2
Data needed to
be updated at
day end or once
in a month
Master process
file
Folders Sub-Folders FilesNEW
PROCESS

72. 1
2
3
4
5
1
2
3
4
5
1
2
3
4
5
1
2
3
4
5
1
2
3
4
5
TOMMY FOSSIL SKAGEN ARMANI TITAN
KAIZEN 8: VISUAL REPRESENTATION FOR
WATCH BOX REPLENISHMENT

73. KANBAN
A scheduling system for Lean process

74. Store: Sector 18 Helios (HNOI) Kanban: 1 (Kanban Cards)
Before: it was hard to keep a track of
reorder level and quantity each and
every Item present at the store
After: All stationary and pantry items
are covered under kanban cards to keep
a right check on the reorder level and
quantity
Before After

75. Store: Sector 18 Helios (HNOI) Kanban:2 (‘Please use other bin’ cards)
Before: staff didn’t know which bin to
use
After: applied ‘Please use other bin’ card
to designate the buffer stock
Before After

76. Store: Sector 18 Helios (HNOI) Kanban:3 (Reorder level and reorder quantity cards)
Before: for stationary items like
registers, manual bill books, A4 sheets
(where 2 different bins were not
required) there was zero visibility for
Reorder level and reorder quantity
After: Reorder level and reorder
quantity cards were applied
Before After

77. Store: Sector 18 Helios (HNOI) Kanban: 4 (Kanban Cards)
Before: it was hard to keep a track of
reorder level and quantity each and
every Item present at the store
After: All stationary and pantry items
are covered under kanban cards to keep
a right check on the reorder level and
quantity
Before After

78. Store: Sector 18 Helios (HNOI) Kanban:5
Before:
Before After

79. NUMBER OF ITEMS FOR WHICH KANBAN
IS APPLICABLE - 34

80. BENEFITS OF KANBAN
 Organized way of working
 Focus on continuous delivery
 Reduction of wasted work / wasted time
 Increased productivity
 Increased efficiency
 Team members’ ability to focus

81. THANK YOU…