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Lean Management Coach


Lean Management Coach

Dhirendra Kumar Dubey

Mr. Dubey is a mechanical engineer from IIT (BHU) Varanasi, 1985 batch. He has thirty-seven years of total experience; twenty-seven years of coaching experience in Lean Transformation, NPD, TQM, TPM and Six Sigma and ten years of hands-on implementation of Total Organizational Quality Enhancement (TORQUE) at Bharat Electronics (BEL). He himself has been coached by great TQM sensei Dr. Noriaki Kano and Hitoshi Kume and had worked with Lean sensei James P Womack and John Y Shook.

He had chaired sessions at “First Congress of Asian Network of Quality” in 2003 at Beijing, China, where he presented an international paper on “Customer Value Management.”  He had hosted Lean Summit 2014, in Bangalore, to promote lean thinking across the country. As a Master Black Belt, he was instrumental to customize Motorola University Six Sigma Program to adapt to Indian environment. Through Gemba based research at Toyota Plants, in Japan & India, he had developed “Lean Transformation Model” that can be customized to suit any company in any sector. His Lean Model had helped companies like L&T Construction, Tata Reality & Infrastructure Limited, and Group Projects of Aditya Birla Management Corporation to complete projects within budget and schedule, keeping them into leadership position in project execution.

He had helped large number of organizations to achieve their targets for cost reduction, productivity improvement and quality improvements. Through his cluster-based model he had helped large number of suppliers of Maruti Suzuki, Tata Motors, Endurance Technologies and Voltas Limited to collectively learn and transform together, achieving desired quality, service, reliability and cost.

He had helped Mahindra Research Valley, M&M, Punjab Tractors, Apollo Tyres and JK Tyres, in a conscious attempt to define meaningful customer requirements using QFD (Quality Function Deployment), initiating dialogue with specific customers in terms of specific products with specified capabilities and identifying attractive quality elements through KANO Analysis. His capability to create an end-to-end learning design environment to provide better customer value with less resources expended is unique. He does it through synthesis of proven concepts like; Set Based Concurrent Engineering, Design Failure Mode and Effect Analysis, Fault Tree Analysis, Process Failure Mode & Effect Analysis, Design for Manufacturing & Assembly, Production Preparation Process, and Target Costing. He had helped critical component suppliers for Tata Nano Car to meet target cost with desired quality, reliability and durability.

He had done some unique interventions in food businesses of ITC - Atta, Biscuit, Snack food, Ready to eat, Confectionery; providing value to the customers at competitive price while preventing any possibility of product liability. Had coached bottle, crates and crown suppliers of Coco Cola for improving their process capability, coached Bangalore Dairy for quality improvement and cost reduction, coached Madura Garments to prepare for World Class Manufacturing for premium lifestyle garments, helped Arvind Ltd for their TQM initiatives across their business verticals, helped FCI (BD) Ltd Bangladesh to become brand for brands. 

At BEL (1985 -95), he was entrusted with the quality management of mobile RADAR and Satellite Communication systems with exceptional mobility in border areas. Low transfer of vibrations to the mounted electronic, electrical and mechanical equipment at the same time providing high ride comfort to the crew were some of the unique achievements at BEL. He had been instrumental in meeting quality and reliability of products in line with MIL-Standards and JSS 55555 Standards.

Since 1995 he had been into active consulting in TQM, TPM, TPS, WCM, Lean Transformation, and NPD.

He is a “think-tank” as well as “do-tank” and believes strongly in result-oriented coaching.

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