Manufacturing Site for PPE Manufacturer Set up by LTTS

Background and Client: Personal protective equipment (PPE) is worn to minimize exposure to hazards that cause serious workplace injuries and illnesses. These injuries and illnesses may result from contact with chemical, radiological, physical, electrical, mechanical, or other workplace hazards. Legacy products have been labor-intensive, with unstructured documentation that relies highly on manual tracking. The client is a multinational, Fortune 100 company that had been facing challenges with its legacy products, resulting in heavy revenue losses and high-cost materials for production. As a result, they were seeking a solution to replace the existing product with an effective alternative.

LTTS (L&T Technology Services) draws on eight decades of worker safety experience and expertise from its parent company, Larsen & Toubro. Safety is one of its core values, and LTTS stands committed to ensuring 100 percent safety and zero harm to all stakeholders. With an approach that factors a thorough assessment of constructability, sustainability, feasibility, and plant safety, LTTS has led engineering projects in 200+ sites worldwide and has the necessary certifications. After assessing all the above strengths, the client selected LTTS to execute this project.

Challenges & Requirements: The client required guidance and assistance on multiple fronts.

• Operational Planning: Setting up a new manufacturing site with a high production rate is not possible without understanding the production layout and planning.
• Alternate Supplier: Identifying new alternate suppliers to improve the quality while reducing the cost.
• Design Protocol Compliance: PPE gear is manufactured in compliance with various design protocols and standards, such as CSA, ANSI, EU, AS/NZ & EAC.
• Notification: Push notification to the managers on zonal violations and entry-to-exit of hazardous zones. 
• Documentation Platform: Creating a single documentation platform to track the progress from sourcing to sales.

Solution Deployed: After assessing the situation and gauging the challenges, LTTS adopted the following approach: 

• Manufacturing Site: The LTTS team analyzed the market to identify the best manufacturing processes available. The manufacturing and assembly process reduced costs as well as the time to build the safety gear, reducing the overall expenses by $311K.
• Alternate Suppliers: With unique capability and understanding of market suppliers, the team identified new suppliers, which helped in saving $125K on production.
• Design Protocol: LTTS had the necessary certifications and expertise to follow the standard protocols of maintaining design and safety measures.
• Alert: Push notification images were inbuilt in the safety gear to monitor and track the workers in hazardous zones.
• Documentation: Reviewing the latest product specifications, drawings, BOMs, material information, and creating a central platform to review all the documentation by working with a cross-functional team and providing training.

Business Outcome: In a span of one year, the client realized overall savings of $1.5 million.

Other tangible benefits include:

• Training and coordinating with the client for Global Certification and meeting safety standards
• Push notification for workers safety
• Single documentation platform for ease of tracking status and progress