Progress at TPM: Newsletter From CII TPM Club India

PROGRESS @ TPM
Newsletter from CII TPM Club India
For more details, Please contact:
A Wadood, Principal Counsellor & Technical Head, CII TPM Club India
Jayashree Das, Deputy Director
Confederation of Indian Industry, Institute of Quality - KNS Centre,

Bharat Nagara 2nd Stage, Magadi Main Road, Vishwaneedam Post, Bangalore - 560 091.
Phone: 080 - 23286085 / 7690 / 9391 | Fax: 080 - 23289388 / 23580314

Email: [email protected] / [email protected]
Website: www.tpmclubindia.org, www.cii-iq.in, www.cii.in
June 2016
2015 JIPM TPM AWARD WINNERS
Special Award for TPM Achievement
CII Institute of Quality (CII-IQ)
Bajaj Auto Ltd. Chakan Plant, Pune 01 From the Chairmans Desk
CII Institute of Quality is the leading authority on quality in organisations and industries. For over 100 years, CII
Bajaj Auto Ltd. Motorcycle Division 02
has provided Indian industries with the support, systems and tools to make a mark in the competitive world. It
(MCD), Waluj Plant, Aurangabad
realised that the best way to enhance an organisation's competitiveness was through the quality route.
Mahindra & Mahindra Ltd. 03
Farm Division - India, Mumbai Plant, What started as the Total Quality Management Division (TQMD) in the mid-eighties has now evolved to CII-IQ.
Dear Members,
Nagpur Plant & Rudrapur Plant As a champion of the quality movement, CII-IQ is powered by the responsibility of enriching the lives of its
With the first Newsletter of the year from TPM Club India, I members, improving their workplaces and making the world a better place by applying quality tools, techniques
Award for Excellence in Consistent TPM Commitment extend my greetings to you and your families for a very happy, and systems. CII-IQ provides the best training and consulting services for organisations to help improve their
exciting and satisfying year ahead. Today TPM has become a performance and set a standard of excellence.
AQUA Group Aquapump Industries, 07
big movement in India and the credit for this goes to the
Aquasub Engineering, (Unit I, II, III, IV)
foundation laid down by a number of Japanese TPM gurus. I am CII-IQ has tied up with several international organisations to bring the best of practices to India. It has helped
Bajaj Auto Ltd. Pantnagar Plant, Uttarakhand 08 saddened to inform you that one such guru - Tokutaro Suzuki several organisations improve their Total Quality Management besides winning recognition for some of them
San passed away on 15th of January 2016 at the age of 89 years. through the Deming Prize and the Japan Quality Medal.
Exide Industries Limited SF Division, 09 His contribution to the growth of TPM has been immense and
Taloja Plant will be remembered forever. May his soul rest in peace.
Hero MotoCorp Ltd Haridwar Plant 10 This is also the quarter where the results of JIPM (Japan CII IQ Vision: Services delivery mechanisms
Institute of Plant Maintenance) TPM Excellence Awards are of these products and services include:
JK Tyre & Industries Ltd Vikrant Tyre Plant, 11 announced. This year, Indian Industry has reaped an excellent To be a Centre of Excellence of international repute
Mysuru
number of awards the highest ever with 26 awards! As you that provides role model products and services for the Training programs (Open and in-house)
Lumax DK Auto Industries Limited 12 may be aware, TPM was initiated in India in 1991. Over the last continuous betterment of organizations and society.
25 years, many companies have adopted TPM and have won Counselling Support
Mahindra & Mahindra Ltd. 13 laurels through the JIPM. The first company in India received CII IQ Mission:
Farm Equipment Sector, Swaraj Division Plant 1 the award in 1995 and it took 12 years for the first 100 Indian Competitiveness Clusters
Mahindra & Mahindra Ltd. 14
companies to receive this award. Today, after another 7 years To evolve and leverage a Quality Movement that
we are at the threshold of 200 companies (199 companies have Assessment Services
Farm Equipment Sector, Swaraj Division Plant 2 transforms India by offering standard solutions,
received the TPM Excellence Award so far). India continues to creating practical insights, driving tangible results, Awards and Recognitions
Tractors and Farm Equipment Limited 15 be the leader in the number of awards received in the World thereby enhancing competitiveness and inclusive
Engineering Plastics and Tool Room Division over the last 5 years. Seminars, Conferences and Events
growth.
- Maraimalai Nagar
The 2015 TPM awards ceremony was organized by JIPM on
23rd March 2016 at Kyoto, Japan where delegates and award What we do Best Practice Study Missions (domestic and
Award for TPM Excellence, Category A
winners from across the globe were present. Congratulations to international)
Harsha Engineers Limited Changodar 21 the Indian Industry on keeping the Indian Flag flying high. CII-IQ opens a world of opportunities to improve the
and Moraiya Plants quality of workplaces, communities and lives by Publications Research
TPM Club India has its own contribution in this wonderful
providing information, contacts and more. CII-IQ
Hindustan Coca Cola Beverages 22 journey with 90 companies & 119 Awards over the last 13 years. TPM
Private Limited - Goblej Plant Our counsellors have built a very high level of technical provides the best training and consulting services for
capability to guide all types of manufacturing companies in organisations to help improve their performance and Total Productive Maintenance (TPM) talks of better
Hindustan Coca Cola Beverages 23 their journey of TPM and competitiveness. This can be visibly set a standard of excellence. It realises the utilisation of maintenance and production resources.
Private Limited - Raninagar Plant seen in the above achievement. I also take this opportunity to importance of creative sustainable programs that are In order to promote TPM in India, CII has tied up with
Jindal Steel and Power Limited 24 recommend the Indian industry to utilize their services to critical to an organisation's quality management JIPM and JIPM Solutions Co. Ltd., Japan. The
- Barbil Pellet Plant become competitive at a global level. system. services provided by the TPM club are:
Tata Hitachi Construction Machinery 25 I look forward to your continued commitment and support to
make TPM a way of life in your organizations and thereby Services provided by CII Institute of Quality: Spreading TPM
Company Private Limited, Kharagpur Plant
contribute to the governments vision of Make in India. Let us Seminars and workshops
The portfolio of products offered by CII-IQ covers
Toyota Kirloskar Auto Parts Pvt Ltd. 26 all strive to make Indian products known all over the globe for
their high quality. I look forward to a great year in our TPM wide-ranging products and services on quality and
Tractors and Farm Equipment Limited 27 Plant visits to TPM practicing companies
journey. competitiveness. This includes
Doddaballapur plant
Best regards Spreading of information through books on
Business Excellence
Tractors and Farm Equipment Limited 28 Ashok Sharma, different aspects of TPM
Madurai Operations Chairman, CII TPM Club India and Total Quality Management
President and Chief Executive, Data dissemination through Newsletters and
Award for TPM Excellence, Category B Agri and Africa & South Asia Operations, Total Productive Maintenance website
AVTEC Limited Chennai 29
Member of the Group Executive Board,
Mahindra and Mahindra Limited Lean Management Handholding for TPM implementation
AVTEC Limited Hosur 30
Six Sigma Training through in-house programs
AVTEC Limited Pithampur 31
Quality Tools and Techniques Consultancy to Indian and overseas companies
HIL Limited Kondapalli unit 32
(Roong sheet Manufacturing plant) Industrial and Legal Metrology Conducting TPM facilitators course
Conformity Assessment & Standards TPM Awards
33
AWARD FOR TPM EXCELLENCE, CATEGORY B SPECIAL AWARD FOR TPM ACHIEVEMENT
Company : HIL Limited Company : Bajaj Auto Limited
Factory : Chakan Plant, Pune, Maharashtra
Factory : Unit Kondapalli , Roong sheet manufacturing plant
Product : Two Wheeler - Motorcycle
Product : Fiber cement corrugated roong sheets and accessories
TPM Kick off : 8 December 2004
TPM Kick off : 28 January, 2010
Award for TPM Excellence : 2006
Award for Excellence in Consistent TPM Commitment : 2012
Award for TPM Excellence Second Category : 2015 Mr. V. Jayachandran Mr. Ravindra Pise
COO Special Award for TPM Achievement : 2015 Vice President
(Chakan & Akurdi)
Company Prole Company Prole

Established in 1946, HIL Limited is part of the CK Birla Groups Home and Building cluster. Being the worlds largest The Bajaj group was founded in 1926 by Shri Jamnalal Bajaj. The Group is amongst the top 10 business houses in India.
manufacturer and seller of bre cement roong, HIL Limited offers comprehensive building solutions. The company has a Bajaj Auto Ltd. (BAL), is a Flagship company of Bajaj group and is amongst the FIVE Most Innovative Indian Companies
strong focus to achieve market leadership by developing and marketing advanced, high quality, innovative, and and the only automotive company featuring in the coveted list of Forbes Worlds Top 100 Most Innovative
sustainable products for the building materials industry. HIL has two major brands - Charminar and Aerocon. The company Companies of the year 2014. Bajaj Auto is India's 5th Most Valuable Brand with a value of $3 billion, according to the
has a pan India presence with 17 manufacturing facilities, reiterating its commitment to innovation through a dynamic R&D rst ever BrandZ TM Top 50 Most Valuable Indian Brands ranking. Bajaj Auto has a global footprint, with presence in
facility and offering products that are affordable, strong and durable. Given its strong emphasis on customer centricity, HIL 60 countries and market leadership positions in more than 10 countries. Bajaj Auto is Indias No. 1 exporter in terms of
Limited also ensures a widespread reach through an extensive sales and distribution network spread across the country the share of total production that is being sold abroad. BALs all 3 Manufacturing Plants in India Waluj
with representation in all the states. (Aurangabad), Chakan (Pune) & Pantnagar (Uttarakhand) are ISO14001 & OHSAS18001 certied.
Kondapalli Plant BALs Chakan plant was started in the year 1998 and it manufactures High Performance bikes in Pulsar & KTM Family
under Sports & Premium Sports category. Chakan Plant is treated as a Manufacturing Laboratory to invent/adopt new
HILs Kondapalli plant (Vijayawada, Andhra Pradesh) was commissioned in 1998. In 2008, TPM practices were initiated in
Production Technology & Techniques. The newly developed Technologies / Processes are perfected for manufacturing
the plant. Presently, the plant produces 0.3Million MT/Annum of Fibre Cement Sheet from 2 manufacturing lines which are
and practiced at Chakan rst. Once proven and established, these are deployed at Other Plants. Chakan Plant strength is
fully automated.
Flexible Production System and we produce 22 Models with 122 Variants. Green Coverage is 72% & our Plant is
Expectation from TPM Positive water balance Plant.
For a successful business it is essential to achieve excellence in all spheres and continuously look for opportunities to
Expectations from TPM Achievement area - Tangible Benets
upgrade and improve. The Manufacturing facilities are the backbone of the business and effectiveness here can provide
the much required edge to the business. These were some of the key reasons that led to the implementation of TPM. With By adopting TPM, Our aim is: PRODUCTIVITY:
TPM, the processes and procedures have become streamlined and systematic. Our major focus is on optimum utilization To achieve & sustain zero accident, zero OLE increased from 87% to 94.56%
of the machinery with the elimination of waste and to have proper protocols which increase the machine life. Some breakdown and zero defect in all areas. Output per man increased by 2.8 times
additional benets are that people have become more proactive, with a sense of ownership as well as the interpersonal To improve the reliability and reduce the Product QUALITY:
dynamic between production and other departments has been simpler. Roles are now clearly dened, with increased cost. Warranty claim reduced by 97%
awareness, knowledge and accountability at all levels. To produce globally accepted products. In-process defect reduced by 98.5%
Achievement area Tangible benets To minimize pollution & conserve natural

COST
resources to protect the environment. Manufacturing Cost reduced by 47%
Benchmark Actual Target
Cate- -gory Index UOM To achieve high level of excellence in our work in
2009-10 2015-16 2016
terms of Change in Attitude, System Orientation, DELIVERY:
S No of Work related accidents Nos / annum 6 0 0 Analytical Approach & Flexibility. Customer delivery adherence achieved 100%
Lead time reduced by 59.5%
Production rate Qty in MT/Hr 9.75 1.7 times 1.8 times TPM provides a holistic, structured and quantiable
methodology for Deeper and Wider continuous SAFETY, HEALTH & ENVIRONMENT:
P OLE (Overall Line Effectiveness) % 63.62 1.38 times 1.4 times
improvement in an integrated way. No major accident since inception of Plant
Health & Environment parameters well within BAL
No. of Breakdowns Nos. / annum 528 80% 82% After successfully challenging Award for Standards, which are more stringent than Legal Norms
No of Customer complaints Excellence in Consistent TPM Commitment,
(Manufacturing related)
Nos. / annum 163 91% 0
we continued our TPM Journey with same MORALE:
momentum and passion. While doing so we 9.4 Kaizens / man / year
Q Scrap % 1.83 63% 67%
extended loss reduction & improvement activity
Rejection (Scrap & Rework) % 7.27 69% 79% through interface to our Business & Management
functions. Widely, Deeply & Interface Loss
D Delivery performance % 99 100 100 become key features of our TPM activities. For
Safety index
sustenance of the improvement, we have initiated
S Nos / 100000 0.88 0 0
standardization of the activates through systems &
M No of employee suggestions Nos/emp/ annum 0.90 3.70 times 4 times documentations.
32 01
SPECIAL AWARD FOR TPM ACHIEVEMENT AWARD FOR TPM EXCELLENCE, CATEGORY B
Company : Bajaj Auto Limited. Company : AVTEC LIMITED-C K BIRLA GROUP
Factory : Motorcycle Division, Waluj, Aurangabad Factory : AVTEC LIMITED, PITHAMPUR
Product : POWERTRAIN & PRECISION ENGINEERED PRODUCTS
TPM Kick off : 21 October, 2002
TPM Kick off : 09 / MAY / 2012
Award for Excellence in Consistent TPM Commitment : 2012 Award for TPM Excellence - Second Category : 2015
Mr. Naveen Nijhawan Dr Vikas Manjrekar
Special Award for TPM Achievement : 2015 Vice President Executive Vice President
(MCD-Waluj)

The Bajaj group was founded in 1926 by Shri Jamnalal Bajaj. The Group is amongst the top 10 business houses in India. AVTEC is a part of USD 1.6 billion diversied CK Birla Group. Leading Independent Manufacturer of Power-train and
Bajaj Auto Ltd. (BAL), is a Flagship company of Bajaj group and is amongst the FIVE Most Innovative Indian Companies Precision Engineered Products. Wide range of Engine & Transmission aggregates, and, Components for Automotive &
and the only automotive company featuring in the coveted list of Forbes Worlds Top 100 Most Innovative Companies Off-Highway Industry.
of the year 2014. Bajaj Auto is India's 5th Most Valuable Brand with a value of $3 billion, according to the rst ever BrandZ State of the art infrastructure with three manufacturing units in India at Pithampur, Hosur and Chennai, one Design & Batch
TM Top 50 Most Valuable Indian Brands ranking. Bajaj Auto has a global footprint, with presence in 60 countries and production facility in Switzerland and setting up a manufacturing unit in Russia. Corporate Headquarters is situated at New
market leadership positions in more than 10 countries. Bajaj Auto is Indias No. 1 exporter in terms of the share of total Delhi, India. AVTEC operates in three business segments (also called as Strategic Business Unit-SBU), viz. Automotive,
production that is being sold abroad. BALs all 3 Manufacturing Plants in India - Waluj (Aurangabad), Chakan (Pune) & Off Highway and Components.
Pantnagar (Uttarakhand) are ISO14001 & OHSAS18001 certied. Customer base including big manufacturers viz. Ford, General Motors, Caterpillar, Daimler, Eaton, Renault Nissan, Ashok
BAL Waluj plant started its operation in 1985 with manufacturing scooters. Motorcycle Plant was started in 1990 and Leyland Nissan, BEML, Allison Transmissions, Voltas, Godrej and many more. AVTECs manufacturing units are TS
caters to Economy, Value, Premium & Sports segment for both Domestic and Export market. 16949 certied for quality management systems and QS 14001 for environment managemen.
Following are the Key Features of MCD Waluj Plant: Achievement area - Tangible Benets
Export Hub - Plant caters major export needs of Bajaj Auto & contributes more than 85% of BALs total export. It is also Benchmark Actual
Gear Hub which caters to all gear requirements of all BAL Plants. Experienced, skilled, target oriented and self driven work S.No. PQCDSM Parameter UOM Good
(FY11-12) Actual FY15-16*
force manages production, quality and equipment maintenance. 1 P MOST - MOP (min) min. 229 275
Expectations from TPM Achievement area - Tangible Benets P Breakdown Nos. - Auto Nos./month 558 118
2
P Breakdown Nos. - Comp Nos./month 128 49
By adopting TPM, Our aim is: PRODUCTIVITY:
3 P Reduction in CLIT min. 52 15
To achieve & sustain zero accident, zero OLE increased from 81% to 95.75%
breakdown and zero defect in all areas. 4 P Workmen Skill Index Index No. 2.45 3.6
Output per man increased by 4.2 times
To improve the product durability and reduce the 6 P OEE (%) % 46 81
product cost. QUALITY: P MTBF - Auto hrs. 321 710
7
To minimize pollution & conserve natural Warranty claim reduced by 83% P MTBF - Comp hrs. 317 1041
resources to protect the Environment. In-process defect phenomenon reduced by 99% P MTTR - Auto hrs. 6.5 2.1
8
To minimize manufacturing Lead time. P MTTR - Comp hrs. 5 1
COST
To achieve high level of excellence in our work in Q Cost of Poor Quality (COPQ) - Auto % of Sales 0.72 0.37
Manufacturing cost reduced by 52% 9
terms of Change in Attitude, System Orientation, Q Cost of Poor Quality (COPQ) - Comp % of Sales 1.28 0.46
Analytical Approach & Flexibility. DELIVERY: Q Customer Rejection (PPM) - Auto ppm 337 222
Customer delivery adherence achieved 100% 10
TPM provides a holistic, structured and quantiable Q Customer Rejection (PPM) - Comp ppm 1240 66
methodology for Deeper and Wider continuous Component lead time reduced by 77%
Q Internal Rejection - Auto ppm 3879 3791
improvement in an integrated way. 11
SAFETY, HEALTH & ENVIRONMENT: Q Internal Rejection - Comp ppm 8332 1783
After successfully challenging Award for No major accident since inception of Plant Q SPR - Auto Engines % 95 98
12
Excellence in Consistent TPM Commitment, Health & Environment parameters well within BAL Q Warranty Cost % of sales 0.25 0
we continued our TPM Journey with same Standards (more stringent than Legal Norms) 13 C Cost Savings through Kaizen Rs. Lacs - 303
momentum and passion. While doing so we
14 C Oil and Consumables cost Rs. Lacs/month 16.75 9.30
extended loss reduction & improvement activity MORALE:
15 C Repair and Maintenance Cost Rs. Lacs/month 40.51 23.00
through interface to our Business & Management 9.50 Kaizens / man / year
functions. Widely, Deeply & Interface Loss 16 D Delivery Performance % adh 94 GMI-100 DICV-100
become key features of our TPM activities. For 17 S-S Accidents No./year 2 0
sustenance of the improvement, we have initiated 18 S-H Hygiene Index Index No. (out of 100) - 95
standardization of the activities through systems & 19 S-E Legal Compliance % compliance 100 100
documentations.
20 M Kaizens/ Employee Suggestion Nos./year <100 >1500
02 31
AWARD FOR TPM EXCELLENCE, CATEGORY B SPECIAL AWARD FOR TPM ACHIEVEMENT
Company : AVTEC Limited - C K Birla Group Company : Mahindra & Mahindra Ltd.
Division : Farm Division
Factory : AVTEC Limited, Hosur Product : Tractor
TPM Kick off : 11 November, 2006
Product : Power train & Precision Engineered Products
TPM Kick off : May 2012 Award for Excellence in Consistent
TPM Commitment : 2012
Mr. K G Shenoy Mr. R S Chatterjee
Award for TPM Excellence, Category B : 2015 Mr. Bhalchandra Wadekar Award for TPM Excellence in Special Category : 2015 Sr VP - Mfg, Sr GM & Head
Vice President Supply Chain Business Excellence
& Mfg Engg Automotive
Company Prole Farm Division & Farm Sector
Company Prole
AVTEC Limited, one of the largest independent manufacturers of Power trains & Precision Engineered Products in India, is a
Mahindra & Mahindra Group - A USD 16.9 billion Indian multinational group which employs more than 2,20,000 people in
part of C. K. Birla Group a leading global business house, with over 20,000 employees and a combined turnover of USD 1.6
over 100 countries. Mahindra operates in the key industries that drive economic growth, enjoying a leadership position in
billion. AVTEC,Hosur is Indias leading supplier of Transmission Aggregates and spares to the Off Highway market with an
estimated share of 16%. Supplies complete Hauling and Cycling Transmission Aggregates & spares. Serves a broad array of tractors, utility vehicles, information technology, nancial services and vacation ownership.
end-markets: mining, construction, material handling, railways and equipment: Dump trucks, forklifts, Railway OHE cars, Organization Farm Division
cranes, loaders. Major Customers include leading OEMs like BEML, Caterpillar, Eaton, Telcon, L&T Komatsu and Godrej
Hosur plant assembles transmissions to Ford Motor company plants in India. We also supply transmission to Nissan Ashok Mahindra & Mahindra is the only Indian company among the top tractor brands in the world & is leading Indian Tractor market
Leyland JV for one of their vehicles. The component business unit caters discrete component need for marquis customers like for last 32 years. FD has a presence in around 25 countries across six continents with more than 1000 dealers world-wide.
Caterpillar, Allison and Daimler to name a few. Manufacturing Locations are at Mumbai, Nagpur, Rudrapur, Jaipur and Zaheerabad.
FD has applied for TPM Special Award for Integrated award for organization, where in Mumbai, Nagpur and Rudrapur were
Expectations from TPM assessed. During this Phase of TPM Implementation, FD moved ahead in its journey by expanding the TPM Implementation
ZERO Rejections (Customer & In-plant) from Manufacturing to all the areas of Supply Chain i.e. Design, Suppliers and Dealers. Thus striving to achieve Supply Chain
ZERO Safety, Health and Environmental Issues
Excellence. Three new Pillars were added to conventional TPM Pillars - New Product Development, Supply Chain
Management and Sustainability. By Implementation of Breakthrough and Innovative TPM Activities. The organization has
High Productivity observed multifold benets in PQCDSM and has helped in overcoming the challenges of Business.
Delivery Performance - 100%
Increase in Employee Ownership Expectations from TPM
Reduce the losses by 30 % Improving supply chain efciency
Achievement Areas - Tangible Benets Reducing Product Cost

Address Customer needs by developing First Time Right New Products
Cate Off highway-SBU Component-SBU Automotive-SBU
KMI /KPIs UoM BM Achieved BM Achieved BM Achieved Improve Customer Satisfaction by ensuring Quality of Tractors at each node of supply chain
gory
2011-12 2015-16 2011-12 2015-16 2011-12 2015-16 Reduce end to end Lead time to ensure delivery of Tractors as per Customer requirements
OEE % 46 77 46 66 68 82.5 Progress towards Lean Supply Chainactivates through systems & documentations.
Breakdown Occurrences (Monthly) Nos 182 50 0 7 10 5

P Breakdown Hrs (Annually) Hrs 417 189 0 52 19 6 Tangible Business Results
32 % Reduction in Logistic Cost
MOST (Employee Contact Time) Mins 181 224 N/A N/A 289 305
22 % Reduction Manufacturing Conversion Cost
Customer PPM PPM 2243 205 231 167 124 10
90 % Availability of Tractors at Dealership
In-house PPM PPM 2270 749 839 638 180 44
45 % Reduction Supplier to Stock Yard Lead Time
Q Supplier PPM PPM 43386 2396 4026 1146 34 8
First Time Right Product Launch
Warranty Cost Lacs 105.63 38 N/A N/A 0 0
79% Improvement in Customer Quality
C Cost of Goods Manufactured % 76 77 101 95.06 85 95.66
90% Improvement in In-house Quality
D Delivery Performance % 94 100 95 100 95 100 Zero Reportable accident plant
S SHE (Accident, Hygiene TPM as an initiative has built in a culture of 'ZERO' Thinking across the organization and plants are now much closer to
& Environment) Issues Nos 2 0 0 0 0 0 achieve Zero Breakdowns, Zero Defects and many more zeroes which demonstrates world class operational efciencies
M Kaizens Nos 32 1176 27 250 10 210 across plants and functions.
Skill index Index 1.5 4.6 2 2.5 3.4 4.2
30 03
SPECIAL AWARD FOR TPM ACHIEVEMENT AWARD FOR TPM EXCELLENCE, CATEGORY B
Company : Mahindra & Mahindra Ltd. Company : AVTEC Limited - C K Birla Group
Plant : Mumbai
Factory : AVTEC Limited, Chennai
Product : Components of Tractor
TPM Kick off : 11 November, 2006 Product : Power train & Precision Engineered Products

TPM Kick off : May 2012
Mr. D V Khobrekar
Special Award for TPM Achievement : 2015 Sr GM & Plant Head Award for TPM Excellence, Category B : 2015 Mr. S Girish
Mumbai Plant Vice President
Farm Division - Mumbai Plant Company Prole

AVTEC Limited, one of the largest independent manufacturers of Power trains & Precision Engineered Products in India,
This is a component manufacturing plant which produces Engine & Transmission Components. Mumbai Plant
is a part of C. K. Birla Group a leading global business house, with over 20,000 employees and a combined turnover of
established in 1965, as an independent company called International Tractor Company of India Ltd. Thisan USD 1.6 billion. The AVTEC Limited, Chennai was commissioned with a specic aim of satisfying the huge Global demand
oldest plant in farm division. Mumbai Plant is the largest component manufacturing plant in Farm Division (FD). for AVTECs Transmission & Precision Engineered Components. Its Strategic location has helped the company
Components produced in Mumbai are supplied to Tractor manufacturing plants in a synchronized way. It signicantly shorten the response time.
manufactures major components like Trans case, Crankcase, Cylinder Head & also components like Gears, The First transmission was exported from the Plant in August 2006 & the number has continued to rise impressively ever
camshafts, crankshafts etc. Mumbai Plant is having 57% of machines having age more than 15 years, since. It deals with primarily components business segments. Spread over 3985 m2 of land area, AVTEC manufactures &
therefore it focuses on improving reliability of machines. exports Precision machined components including Housing Pistons, Housing Convertors, Rear Cover, Converter
Housing, Main Housing, Control valve body, Retailer Housings & Retarder Housings of Gear Box for Off Highway
Transmissions.
Expectations from TPM
AVTEC Chennai caters esteemed customers such as Allison Transmissions. AVTEC manufacturing units are certied with
Reducing Manufacturing Cost for Machining TS 16949 for quality management systems.
Supply the Components to other plants in a Synchronised Way Expectations from TPM
Improve Reliability of Machines for sustaining ZERO Breakdown ZERO Rejections (Customer & In-plant)
Reduce Manufacturing Lead Time ZERO Safety, Health and Environmental Issues
Improve Capability of Operators for Machining Operations High Productivity
Delivery Performance - 100%

Tangible Business Results
Increase in Employee Ownership
32 % Reduction in Logistic Cost
Reduce the losses by 30 %
20 % Reduction Manufacturing Conversion Cost
Achievement Areas - Tangible Benets
Zero Breakdown for A Category Machines
Category Index Unit Benchmark (FY 11-12) Current Status
97% Reduction in Total Breakdown Incidences
P OEE % 62 80
90% Improvement in In-house Quality Number of Breakdowns Numbers / yr 232 120
Zero Reportable accident plant Q Customer Complaint Numbers / yr 7 0
3 Times increase in Kaizen Rate C COGM (Cost of Goods Manufactured) % of sales 76.8 64.8
89 % Ergonomically Green Stations D Delivery Performance % 95 100
24% Reduction in Inventory S Major Accidents Annual Cases 0 0
Minor Accidents Annual Cases 0 0
M Employee Suggestions Numbers / yr 81 300
04 29
AWARD FOR TPM EXCELLENCE, CATEGORY A SPECIAL AWARD FOR TPM ACHIEVEMENT
Company : Tractors and Farm Equipment Limited Company : Mahindra & Mahindra Ltd.
Plant : Nagpur
Factory : Madurai Operations
Product : Tractors & Engines
Product : Tractors from 25 HP to 100 HP TPM Kick off : 11 November, 2006
TPM Kick off : October 2012
Award for TPM Excellence First Category : 2015 Mr. V. Srinivasan Mr. Ashutosh Tripathi
Special Award for TPM Achievement : 2015 Sr GM & Plant Head
Senior AVP - Operations
Madurai & Turkey Plants Nagpur Plant
Company Prole Farm Division - Nagpur Plant

TAFE is a part of the Amalgamations group, which is one of Indias largest light engineering groups and has equally varied
business interests that range from diesel engines, batteries, automobile components, engineering tools, tea gardens, book Nagpur Plant is one of the major manufacturing plants located in Central India. The Plant was established in
selling and publishing, vehicle and auto parts distribution among others. TAFEs tractor range currently spans the 25 to 100 HP August 1970 to manufacture Agricultural Implements. In 1996, the plant was transformed into tractor plant and
segment with product offerings in both air cooled and water cooled platforms to meet every customer need in India and overseas today it is the Integrated Tractor Plant which produces all types of Tractors and Aggregates, i.e. Engine, Tractor,
and for use at both on farm and off farm applications, under the Eicher, Massey Ferguson and TAFE brands. This range is
continuously being expanded to meet the requirements of overseas customers. TAFEs export footprint currently covers 80 Transmission & Hydraulics. Operations carried out are Assembly of Tractors, Engines, Transmission &
countries including South Asia, Eastern Europe, Africa and in the North American markets. Hydraulics, Sheet metal painting & machining. The Plant works in synchronized way with all its customers for
In June 2005, TAFE acquired Eichers tractor business from Bhopal along with its Engines plant at Alwar (Rajasthan) and its tractor & aggregates. Lean Manufacturing techniques were aggressively used to work in synchronization
transmissions plant at Parwanoo (HP) through a wholly owned subsidiary, TAFE Motors and Tractors Limited (TMTL). In keeping which helped to become exible to meet the Customer requirements. TPM has helped in Productionisation of
with its vision of increasing its presence in the global markets and to jointly leverage business opportunities with its collaborator
New Products, Reduction in Manufacturing Cost inspite of addition of activities year on year.
AGCO Corporation, USA (who own the MF Brand), TAFE has established a plant at Manisa, Turkey to manufacture tractors for
European Market. Expectations from TPM
Plant Prole:
Nullifying the impact of Manufacturing cost increase.
TAFE Madurai Operations was inaugurated by our chairman in the year 1998. Its spread over 66.49 acres, built up area is 8.06
and rest covered with green belt. In this plant we are producing tractors in both MF and TAFE brand. 100% of Global
Utilizing the capacities.
requirements are produced from this plant & exporting tractors to more than 80 countries
Expectation from TPM Productionisation of New products.
TPM journey was started in TAFE Madurai during 2011 in a humble way with manager model machines at 5 different locations
Productionisation of aggregates for new customers.
under the guidance of Yoichi Kido san from JMAC, Japan. After successful completion, during 2012 it was kicked off across the
plant in presence of all workmen, senior management and key suppliers. The expectations out of TPM implementation were like
Synchronization of Production between aggregates and Tractor Line
improving productivity, reduce Mfg. Cost/ Tractor, enhance product Quality, create safe working culture and increase employee
competency level. Reduce lead time to ensure delivery of tractors as per the pull from the customer
Achievement Areas - Tangible Benets
Bench Mark Actual Tangible Business Results
Category Result Index Unit Status
2011-12 2015-16
Nullied the Impact of Manufacturing Cost Increase
No. of work related accidents
Cases / Annum 32 0 100% Pull based Production Schedule Adherence
requiring days off work
S
No. of work related accidents 45 % Reduction in Supplier to Stock Yard Lead Time
Cases / Annum 432 97
Not requiring days off work
Sustained Zero Breakdown for A Category Machines
Eqt. Tr /
Employee productivity Index 0.69 0.87
Employee / Day 97% Reduction in Total Breakdown Incidences
P Overall Line Efciency % 78.5 84 11 % Improvement in Manpower Productivity

Breakdowns / 92% First Time Right Tractor Roll Out
No. of Break downs 401 25
Annum
Zero Reportable accident plant
Q ZERO Customer Compliant (RFT) Loss In % 82% 38%
3 Times increase in Kaizen Rate
C Mfg. Cost / Tractor Cost / Eq. Tr 5097 4766
95 % Ergonomically Green Stations
D Delivery of Trs to all Markets In% 86.2 96%
32% reduction in Inventory
Suggestions /
M Employee Improvement / Year 19.62 21.8
Year
28 05
SPECIAL AWARD FOR TPM ACHIEVEMENT AWARD FOR TPM EXCELLENCE, CATEGORY A
Company : Mahindra & Mahindra Ltd. Company : Tractors and Farm Equipment Limited
Plant : Rudrapur
Factory : Tractor Division , Doddaballapur
Product : Tractor
TPM Kick off : 11 November, 2006 Product : Tractor
TPM Kick off : 5 September, 2012

Mr. S K Dubey Award for TPM Excellence A First Category : 2015 Mr. Palaniappan T
Special Award for TPM Achievement : 2015 Sr GM & Plant Head General Manager
Rudrapur Plant (Operations)
Farm Division - Rudrapur Plant Company Prole

Tractors and Farm Equipment Limited (TAFE), a US $1.6 billion tractor major incorporated in 1960 at Chennai, India, is the
The Rudrapur Plant came into existence in 2000 as a satellite plant with an objective of promoting and second largest in India and Third largest tractor manufacturer in the world , with a 25% market share of the Indian tractor
establishing Mahindra brand in northern market. The plant has been identied as a strategic location in terms industry and a sale of approximately 170,000 tractors (domestic and international) annually. TAFE has four manufacturing
of low cost manufacturing location and expected increase in market demand. TPM is used as a strategy to plants three in India and one in Turkey. TAFE belongs to the Amalgamations group, leading biggest light engineering
improve plant productivity & cost reduction. Highest Manpower Productivity has become one of the feature of conglomerate in India, born in the year 1940
this Plant. By implementing theme based high impact Kaizens, variable cost & personal cost has reduced Plant Prole:
which helped plant to absorb increased impact of end of Tax Benet by 60% & sustain the status of low cost Tractors and Farm Equipment Limited, Doddaballapur Plant, is a Tractor assembly plant, located in KIADB industrial area,
tractor manufacture plant of FD. Doddaballapur near the garden city of Bengaluru.
TAFE Doddaballapur plant, established in the year 1988 with a production capacity of 10 tractors per day, which has grown
Expectations from TPM to a current capacity of 240 tractors per day. It is spread over 74986.0 Sq. meters with a constructed area of close to 50%
and 35% greenery cover and 15% road and parking space.This plant is capable of producing Tractors in the range of 30 to
Nullifying the impact of end of Tax Benet. 75 HP, with seven models and 140 variants.
Reduce Manufacturing Cost Expectation from TPM
Sustain Zero Breakdown of Machines Increase OLE
To upgrade overall skill level of the employees
Synchronization of Production between aggregates and Tractor Line
Reduce cost with low cost manufacturing.
Reduce lead time to ensure delivery of tractors as per the pull from the customer To create eye for identify the loss and abnormality
Improve 5S to make visible shop oor
Tangible Business Results
Achievements
Nullied the Impact of End of Tax Benet Target Target /
KPI UOM (Bench Mark) 2012-13 2013-14 2014-15
Actual
100% Pull based Production Schedule Adherence
Target 27 24 22
33 % Reduction in Supplier to Stock Yard Lead Time P MTBF Hours/Month 95
Actual 95 295 376
Sustained Zero Breakdown for A Category Machines Minutes/Month 45

Target 50 40 33
MTTR
Actual 45 37 25
98% Reduction in Total Breakdown Incidences
Target 0.50 0.55 0.58
Productivity Trs/Man/Day 0.49
9 % Improvement in Manpower Productivity Actual 0.49 0.52 0.57
Target 90 90 95
90% First Time Right Tractor Roll Out Q Right First Time (Internal) % 88 88 ( New Method
Actual 88 93 of Measurement)
Zero Reportable accident plant
Target 40 60 60
C Inventory Turn Turns 43
3 Times increase in Kaizen Rate Actual 43 51 59
Target 100 100 100
92 % Ergonomically Green Stations D Delivery of Tractors % 87%
Actual 87 83 90
10% reduction in Inventory Target 0 0 0
S No of accidents Numbers/Year 9
Actual 9 10 4
Target 25 25 30
M Suggestion per Employee Numbers/Year 20
Actual 20 25 30
06 27
AWARD FOR TPM EXCELLENCE, CATEGORY A AWARD FOR EXCELLENCE IN CONSISTENT TPM COMMITMENT
Company : Toyota Kirloskar Auto Parts Pvt Ltd. Company : AQUA Group of Companies, Coimbatore, India.
Factory : Aquapump Industries, Aquasub Engineering Unit I, II,III,IV
Factory : Transmission, Axles & Engines Lines
Product : Pumps (Domestic, Agricultural, Sewage, Dewatering
Product : Transmission, Axles & Gasoline Engines & Building Services)
TPM Kick off : March 2010 TPM Kick-Off : 26 December, 2005
Award for TPM Excellence - Category A : 2009
Award for TPM Excellence Category A : 2015 Mr. Sadashiva Baligar Award for Excellence in Consistent TPM Commitment - Category A : 2015 Mr. R. Kumaravelu
VP - TKAP Managing Director

Toyota Kirloskar Auto Parts Pvt. Ltd is situated in Bidadi industrial area about 35 Kms from Bangalore in Karnataka state. It AQUA GROUP of Companies, located in Coimbatore, Tamilnadu, India, is one of the largest pump manufacturing
is a Joint Venture amongst Kirloskar System Limited, Toyota Motor Corporation (TMC) & Toyota Industries Corporation company since 1976 with 5 Business Units, 3 Captive Units and two Service Units. The Group manufactures more than
(TICO) Japan established in the year of 2002. 5860 models (Includes Variants) and caters to Domestic, Agricultural, Industrial, Building Services, Sewage and
With the support and technical expertise from TMC in world renowned Toyota Production system (TPS), TKAP today Dewatering applications with production capacity of 3000 pumps a day & sells over 900,000 pumps a year through a
demonstrates Global Quality levels in the processes and products. TKAP is an established manufacturer of automotive network of 20 Branches, 1 Distributor and over 1256 Dealers.
drive train parts like Axles, Propeller Shaft, Transmissions and Gasoline Engines with an installed production capacity of Aqua Group manufactures Bore well Submersible pumps, Domestic pumps & Jet pumps in the brand name TEXMO and
640K units/Year. TKAP customers are currently Toyota vehicle plants in India, South East Asia and South America. Agricultural Monoblocs, Openwell Submersibles & Electric Motors in the brand name AQUATEX. These products are
exported to 29 countries in the brand name atx. Aqua Group bagged Exports Excellence Award for 10 years from
Engineering Exports Promotion Council (EEPC) , India for exporting Cast Iron pumps, Stainless Steel Sheet Metal pumps
Safe and Lively workplace through Each Employees Contribution (Total Employee Involvement) & Pump parts, Non-ferrous castings & Machined parts to various countries in the world.
Global Quality Product at Locally Competitive cost to enhance Customer satisfaction Aqua Group bagged National Energy Conservation Award consecutively for 3 years issued by Bureau of Energy
Become Plant of Choice for Global Toyota Efciency, India for the year 2013, 2014 & 2015 for producing highest number of energy saving agricultural pump sets.
Human Resource Development to Maximize performance (Mutual Trust & Respect)
Increased ownership of equipments and other resources Cost reduction through loss elimination
Achievement Area Tangible Benets Productivity improvement through enhancement of OEE Delivery adherence of products, spares and service
Zero Accidents, Zero Breakdown, Zero Defects Lead time reduction of production and development
Before Present
Category Parameter UOM Zero Customer Complaints Enhancement of knowledge and skill
(FY 2010) (FY 2015)
Involvement of employees in Continuous Improvement Hygiene and Conducive environment
First Aid Cases 44 9
Safety No of Accidents Tangible Benets
Lost working days 4 0
Excellence Award Consistency Award
In Process Defect % 0.11 0.04 2015-16 2015 - 16
Result Area Objective Measures UOM 2006 2009-10
Quality 2014-15
Factory Claim/Year No of Concerns 6 3 (BM1) (BM2) Upto Dec Target
Productivity & Overall Equipment Effectiveness ( OEE ) % 61 85 87 88 90

OEE - Machining line % 79% 90%
Equipment Number of Break downs Nos 2153 1498 836 534 0
OEE - Assembly line % 97% 99% management Break down (Average / month) Hours 3290 1429 838 475 0
Productivity Production Man-hour Man-hour/Unit 2.6 2.1 Customer Complaints (Average / Month) Nos 50 22 2 3 0
Final product rework (Monoblocs) DPMO 1207 1076 686 484 330
MTBF (Mean Time Between Failure) Hours 301 580
Quality Final product rework (Submersibles) DPMO 583 431 307 137 170
MTTR (Mean Time to Repair ) Minutes 64 48 Inprocess machining rejections (Monoblocs) PPM 11268 4375 2434 1410 1180
Inprocess machining rejections (Submersibles) PPM 3762 1419 851 700 500
Delivery Delivery Performance on time % 100% 100%
Inventory Carrying Cost % of STO 1.26 0.94 0.57 0.62 0.60
Cost
Cost In House Cost Reduction Reduction % Per Year 100% 100% Tooling Cost % of STO 0.89 0.5 0.32 0.29 0.25
Delivery % 95 98 99.5 97.78 100
Delivery
Training Man days / Month 3.50 5.51 Lead Time for Delivery Days 45 15 7 4 4
Morale
Suggestion/Month Per Person / Month 0.34 1.1 Major Accidents Nos / year 2 0 0 0 0
Safety
Minor Accidents Nos / year 166 45 18 7 0
Morale Suggestions Nos / Labour 2.56 8.8 13.6 8.54 15
26 07
AWARD FOR EXCELLENCE IN CONSISTENT TPM COMMITMENT AWARD FOR TPM EXCELLENCE, CATEGORY A
Company : Bajaj Auto Limited Company : Tata Hitachi Construction Machinery Co. Pvt. Ltd.
Factory : Pantnagar Plant, Uttarakhand
Factory : Kharagpur
TPM Kick off : 9 April 2008 Product : Construction & Mining Machinery
TPM Kick off : 12 January, 2012

Award for TPM Excellence - First Category : 2011
Award for TPM Excellence - Category A : 2015 Mr. Sandeep Singh
Mr. Ashok R Pilankar Managing Director
GM (Pantnagar)

The Bajaj group was founded in 1926 by Shri Jamnalal Bajaj. The Group is amongst the top 10 business houses in India. TATA HIATCHI CONSTRUCTION MACHINERY CO. PVT. LTD. (THCM), the leader in Construction Equipment (CE)
Bajaj Auto Ltd. (BAL), is a Flagship company of Bajaj group and is amongst the FIVE Most Innovative Indian Companies industry in India with more than 33% market share in Hydraulic Excavator Segment, is a joint venture between Hitachi
and the only automotive company featuring in the coveted list of Forbes Worlds Top 100 Most Innovative Construction Machinery Co. Ltd., Japan (HCM) and Tata Motors Ltd. (TML). THCM is in the business of designing,
Companies of the year 2014. Bajaj Auto is India's 5th Most Valuable Brand with a value of $3 billion, according to the manufacturing, marketing, selling and servicing construction equipments like Hydraulic Excavators, Excavator Loaders
rst ever BrandZ TM Top 50 Most Valuable Indian Brands ranking. Bajaj Auto has a global footprint, with presence in (BHL), Wheel Loaders (WL), Cranes, Motor Grader, Dumper, Transit Mixers and Compactors.
60 countries and market leadership positions in more than 10 countries. Bajaj Auto is Indias No. 1 exporter in terms of THCM has its Corporate Ofce at Bangalore and manufacturing facilities at Jamshedpur, Dharwad, & Kharagpur. Spread
the share of total production that is being sold abroad. BALs all 3 Manufacturing Plants in India Waluj over an expanse of 250 acres, the manufacturing facility in Kharagpur - West Bengal, is the newest manufacturing facility
(Aurangabad), Chakan (Pune) & Pantnagar (Uttarakhand) are ISO14001 & OHSAS18001 certied. of THCM family operating since 2009, it has a UNIQUE MIX facility of both Mass Production (Excavator) and Batch
BAL Pantnagar plant, the youngest plant of BAL, started its operations in 2007 with manufacturing of Platina-100 Production (Wheel Loaders, Dumpers, Compactors & Motor Graders). The plant has a fully automated conveyor system,
motorcycles. At present Pantnagar plant manufactures motorcycles viz. Platina, Discover, CT & Pulsar for domestic which is designed to cater to 5 Ton to 47 Ton Hydraulic Excavator, Integrated Shot Blasting and Painting shops for frames
market of India. It is a unique plant of Bajaj auto Ltd. due to its Simple Structure & Extended Factory Concept. With the & Attachments, The entire production facility is supported by fully functioning Fabrication shop with Wielding Robots and
Extended factory concept, we have achieved Lowest Inventory, Lowest Transportation cost, Lowest Lead time and Heavy Machine Shop for machining of components and World Class R&D Facilities. It is the biggest plant among all HCM
some other signicant advantages as compared to other plants of BAL. group Worldwide. The plant is strategically located in proximity to Mining customers of Eastern Region and Infrastructure
Development customers of North Eastern and Northern Part of India.
Expectations from TPM Achievement area - Tangible Benets Expectations from TPM
By adopting TPM, Our aim is: PRODUCTIVITY: When THCM started operations in 1999 the biggest challenge faced was to create a niche for itself in the growing Indian
To improve the Operating Prot by reducing various CE industry which was characterized with high customer expectations, increasing competitive intensity and buoyant
OLE increased from 84% to 94.2%
cost elements like Variable Conversion Cost, Fixed market conditions.
Production per hour Improved by 83%
Conversion Cost, Fixed Cost, Material Cost etc. In 2009 THCM Kharagpur started its operation and in 2012, TPM was formally kicked off at Kharagpur plants. It aimed at
To enhance Capacity by improving OLE, Production Output Per man Improved by 53% ZERO Accidents, ZERO Defects and ZERO Breakdowns and Delivering World Class Services & Products of highest
/ hr improvement & Output / Man improvement. value to its customers.
QUALITY:
To establish a Quality Maintenance System to Achievement area - Tangible Benets
Warranty claim reduced by 76%
produce high quality products through defect free
manufacturing and design. In-process defect reduced by 98% Cate Index Better Unit Kick off/TPM Actual Status Result With Increased Market Shares,
gory 2011-12 Till Dec'15 Achieved Improved Productivity, Reduced
To create and preserve a cleaner, healthier and
COST S Non Reportable Accidents Nos. 0 0 Zero Breakdowns, Improved Quality,
safer work environment with Yutori at workplace. Reduced Manufacturing Cost,
Manufacturing cost reduced by 36% Accident
To achieve high level of excellence in our work Enhanced Customer
S Carbon Emission T CO2/Per 3.14 2.23 29%
along with our cluster vendors. DELIVERY: Eq. M/c. Reduction Satisfaction, improved Health &
Environmental Conditions and
TPM provides a holistic, structured and quantiable Customer delivery adherence achieved 100% Q 0-50 hrs (Excavators) Defects 0.2 0.03 85%
100% Employee Involvement in
methodology for Deeper and Wider continuous /Machine Reduction
Lead time reduced by 47% Improvement Initiatives, thus
improvement in an integrated way. Q 0-50 hrs (Wheel) Defects 0.9 0.05 94% TPM serving as a Major
SAFETY, HEALTH & ENVIRONMENT: /Machine Reduction Catalyst.
After successfully challenging TPM Excellence Award,
P OEE % 56 78 39%
we continued to adopt TPM methodology by No major accident since inception of plant
Improvment
establishing linkage between Company Vision &
MORALE: P Number of breakdowns Nos/Month 55 7.4 87%
Mission, TPM Policy with Plant Vision & Mission and Reduction
KMI, KEI, KPI & KAI. We continued our TPM journey, 6.1 Kaizens / man / year
C Conversion Cost Rs.(million) 0.092 0.083 10%
working Widely in areas (widened scope) which /Machine Reduction
were not covered during the initial phase and Deeply
D Adherence to Production % 88 97 10%
for further improvement in already worked areas. We Plan Improvement
also started working on Interface Loss elimination M Numbers of Idea "Ideas per 2.5 5 100%
with involvement of Interface Functions like R&D, generated Person Improvement
Machine Tool Division, Materials etc. (Annually)"
08 25
Company : Jindal Steeel & Power Limited (jspl) Company : Exide Industries Limited
Factory : Pellet Plant, Barbil (Odisha) Factory : SF Division, Taloja Plant

Product : Lead Acid Batteries for Automotive and Inverter
Product : Iron Ore Pellets application
TPM Kick off : 19 January, 2012 TPM Kick-Off : 13 December, 2004

Award for TPM Excellence - First Category : 2015 Mr. T. S. Shanbhogue Award for Excellence in Consistent TPM Commitment - Category A : 2015
Executive Vice President Mr. Ajit Tamhane
& Unit Head Chief Operating Manager
(General Manager
Company Prole - Auto Division)
Company Prole
As a part of the OP Jindal Group & led by Mr. Naveen Jindal, JSPL is a US $3.14 billion business conglomerate with a dominant Exide Industries Ltd. is Indias largest manufacturer of lead acid storage batteries and power storage solution provider.
presence in steel, power, mining and infrastructure sectors. JSPL produces economical and efcient steel and power through With nine international standard factories spread across the nation, the company offers one of the widest ranges of
backward and forward integration. From the widest at products to a whole range of long products, JSPL today supports a batteries i.e. 2.5 Ah to 20,400 Ah capacity for every conceivable application in Automotive as well as Industrial segments.
product portfolio that caters to markets across the steel value chain. The company produces the world's longest single piece rails
TALOJA PLANT is located 45 KMs from Mumbai, established in the year 1996 , which has oor space of 43902 Sq. meter
of 121 meter length and it is the rst in the country to manufacture large size parallel ange beams. JSPL-Pellet Plant is located in
area out of 82845 Sq. meter total plant area for manufacturing of Automotive and Inverter batteries ranging from 25 Ah to
Barbil and has two plant of capacity 4.5 Million Metric Ton (MMT) capacity each, thus totalling to 9.0 MMT. Both these plant
200 Ah with total plant capacity of manufacturing 2.5 million units per annum. Exide-Taloja plant is supplier to most of the
operate on principle of dry & wet palletisation process and hence catering wide spectrum of customer requirement. JSPL-Barbil
is ISO 9001, ISO 14001, OHSAS 18001 & ISO 50001 certied plant and holds the distinction of being the rst pellet plant in the Original equipment manufacturers including new generation vehicles like Jaguar Land Rover, Volkswagen, Mercedes
world to receive the prestigious JIPM TPM Excellence Category A award with the recent declaration of 2012 JIPM TPM Benz, General Motors and Skoda in India. Exide-Taloja is accredited with ISO/QS 9000, TS-16949, ISO 14001 and
assessment results. OHSAS 18001 Certications.
Expectations from TPM Expectations from TPM

By moving forward in TPM journey, our aim is to: In today's competitive world, TPM is one of the best manufacturing practice followed by many successful companies to
achieve manufacturing excellence.
Achieve the increased production with minimum manpower and bare minimum investment
Ensure Safe, hygienic and environment friendly plant Maximize plant capacity utilization by reducing all losses. Bring Systematic approach in problem solving among all
Improve reliability of the equipment and machines and ensure supply of quality products to the customers Achieve and sustain zero breakdowns, zero accidents, and foster team work.
zero defects in all areas of the factory. Change mindset of employees, develop owner ship
Proactively eliminate & prevent losses and reduction cost in New equipment
Improve equipment reliability for getting consistent good among operators, technicians about their machine and
Increase employee productivity and develop High Performance Process Team and Expert Group to support the new initiative
quality products and reduce manufacturing cost. process.
of Process Based Organization
Totally satised customers. 100 % delivery performance Total employees involvement in achieving manufacturing
Decrease the logistic costs, the level of parts inventory and raw material
and reduction in lead time. excellence.
Achievement area - Tangible Benets: Please specify with respect to P, Q, C, D, S & M Create safe and environmental friendly workplaces. Good house keeping and 5S in all areas.
Key Performance Indicators (KPIs) Unit of Good FY (12) FY FY FY FY Upgrade skill and knowledge and empowerment of
Measurement Bench -13 -14 -15* 16** employees and multi skilling of them.
Mark (Apr-Dec)
P Production (Pellets) Million Metric Ton 3.7 4.04 4.14 0.905 1.08 Achievement Area - Tangible Benets
Overall Plant Efciency (OPE) % 74.36 84.65 97.93 66.74 76.11 Parameter Improvement with Respect to Benchmark
A Class & B Class Equipment Breakdown Nos. 315 169 123 21 6
Mean Time Between Failure
Increase in Output per man shift 1.90 Times
of a Class Equipment Hours 26 43.3 67 133 202.06 Increase in Production 2.50 Times
Manpower Productivity MT/Man/Year 9946 12023 12105 3829 7198 P Improvement in OEE (Total factory) 1.37 Times
Q Customer Complaints No./Year 8 4 2 0 0 Reduction in Breakdowns (Minutes) 92%
In house Fe (Iron) % No. of Samples
Reduction in Breakdowns (Nos.) 87%
Quality Defects (Total No. of Samples = 330) with Fe% < 63.5 50 42 12 0 0
Production Cost /MT 3672 4144 3855 5576 4752
Reduction in Warranty 80%
Energy Consumption kWh/MT 58.48 57.88 57.91 79.3 73 Q Reduction in Customer complaints 95%
D Purchase Requisition to Purchase Order cycle Days 60 50 45 35 21 Reduction in Line rejection 89%
Processing of Payment Days 15 11 7 6 6 Reduction in Conversion Cost 12%
S Major Accidents No. 0 0 0 0 0 C Improvement in Metal yield 67%
Reportable Accidents No. 0 0 0 1 0
Reduction in Power consumption 34%
Minor Accidents No. 0 2 0 1 1
D Delayed Delivery to Customers Reduced to Zero
Kaizens/man/year No. 1.8 2.32 3.77 4.36 4
M One Point Lessons No. 112 130 317 714 1500 No. of accidents Reduced to Zero
S
Man-days Training Man days/Employee 1.97 4.5 6.19 10.88 11 No. of man days lost due to Accidents Reduced to Zero
No. of Kaizens Increase by 11.2 Times
M
Training hours Increased by 6.1 Times
24 09
Company : Hero MotoCorp Ltd Company : Hindustan Coca Cola Beverages Private Limited
Factory : Hero MotoCorp Ltd, Haridwar Plant
Factory : Raninagar, Jalpaiguri, West Bengal, India
Product : Two Wheelers
TPM Kick off : 13 April, 2009 Product : Coca Cola, Thums up, Limca, Sprite, Fanta, Kinley Soda.
TPM Kick off : 6 June, 2011

Award for TPM Excellence - First Category : 2012
Award for TPM Excellence - Category A : 2015 Mr. Biplab Ghosh
Mr. Mukesh Goyal Factory Manager
Plant Head

Hero MotoCorp Ltd was incorporated on 19th Jan 1984 as Hero Honda Motors Ltd. Hero, the largest Indian bicycle Hindustan Coca-Cola Beverages Pvt. Ltd. (HCCBPL) has 25 bottling plants at strategic locations in various states spread
producer in the world with Honda, Japan joined hands and created Hero Honda. The successful association of Hero and across India. Hindustan Coca-Cola Beverages Pvt. Ltd. Raninagar plant started its operation in 1999. It is spread over
Honda for 27 years created the worlds largest two wheeler manufacturing company. In 2001, the company achieved the 11.35 acres of land with 4.5 acres of Green Field and with a Capacity of approx. 100k physical cases per day.
coveted position of being the largest two-wheeler manufacturing company in the World in terms of unit volume sales in a
calendar year. During 2010-11, both the partners decided to part ways and evolve beyond this partnership. Under the new
agreement, Hero Honda embarked on a brand journey under new name Hero MotoCorp Ltd. Hero MotoCorp has 4 Service to sales by ensuring high asset utilization and best in class OEE.
manufacturing facilities at prime locations in India (Dharuhera, Gurgaon, Haridwar & Neemrana) and the company is Zero Accidents, Defects and Consumer Complaints.
planning to setup its 5th & 6th manufacturing facility in near future in Gujarat & Andhra Pradesh. Recently, Company has Deliver the goods to the customer at the best Cost, on time in full.
also started its rst overseas manufacturing facility at Columbia. Highly engaged and motivated employees , willing to contribute and ready to take on any new challenge.
The foundation stone of Haridwar plant was laid on 19th Oct 2006 by the then Prime Minister of India- Dr. Manmohan Develop capabilities of suppliers and employees to stay competitive.
Singh. The plant was inaugurated by our founder chairman Dr. Brijmohan Lall Munjal on 08th April 2008 as Shrine of Sustain all improvements.
Technology. Today, it is the largest Two-wheeler manufacturing plant in the world. Installed capacity of the plant as on
today is 9500 motorcycles per day and over 15.0 million have been produced till date.
Achievement Area Tangible Benets
Haridwar Plant has used TPM methodology to meet its vision of Future Ready Plant. TPM Slogan/Objectives TPM IN --- WE WIN
Key drivers of this vision are : Kick off/ Actual status
Category Index (Calculation Formula) unit Target 2016
Customer Delight TPM STARTED 2015
Operational Excellence
Number of work-related accidents
Happy Workplace S Number 5 0 0
requiring days off work
Supplier Upgradation
Environment Friendly Plant S Number 2 0 0
not requiring days off work
Achievement Area - Tangible Benets Cases/workman day

P Productivity for main product 47 100 150
( CPWD )
Category Parameter UOM Improvement w.r.t. Benchmark
(FY 2008-09) P OEE (Overall Plant Efciency) % 56 61 80
P Vehicle Production Avg. Nos. / day Improved by 138% P Number of tags raised Number 435 6855 10000
P Plant Productivity Vehicle / man / day Improved by 27% Breakdowns/
P Number of breakdowns annually 696 96 0
Q Customer Complaints (1-90 Days) PPM Reduced by 56%
Q Number of customer complaints Number 89 9 0
Q Vehicle Straight Pass % Improved by 10.3%
Q In-line defect rate | Scrap % 0.33 0.04 0.02
C Manufacturing Variable Cost Rs. / Vehicle Improved by 15%
D Production Schedule Adherence % Maintained 100% 101 % to 104 % to Net 95.1 % to
C Cost index Cost/unit
Net Revenue Revenue Net Revenue
S Safety Incidents (Loss Time Accidents) Nos. Maintained 'Zero Accident'
D Lead time in days Days 7 days 4 days 3 days
S NLTA (Injury) Rate Injury per 1000 Reduced by 80%
Mandays worked D Delivery performance % 76 77 100
M Kaizen Nos./ Man / Year Increased by 1868% S Safety index Accidents per 100000
operator hours 0.82 0.02 0
(19 times approx)
M Number of Employee Suggestions Number 62 930 1500
10 23
Company : Hindustan Coca Cola Beverages Private Limited Company : JK Tyre & Indutries Ltd
Factory : Goblej , Ahmedabad Plant Factory : Vikrant Tyre Plant, Mysuru
Product : Coca Cola , Thums up , Limca , Sprite , Fanta , Kinley Soda , Product : Mfg of Truck, Bus, Light Truck, Tractor & OTR Tyre
Coke Zero , Diet Coke , Maaza , Minute Maid , Nimbu Fresh TPM Kick-Off : 9 June, 2006
TPM Kick off : 27 February, 2011
Mr. Somen Adhikari Award for Excellence in Consistent TPM Commitment - Category A : 2015
Award for TPM Excellence First Category : 2015 Factory Manager Mr. Umesh Krishna Shenoy
Vice President
Works
Hindustan Coca-Cola Beverages Pvt. Ltd. (HCCBPL) - As part of the Bottling Investments Group (BIG) of The Coca-Cola
J.K. Organization (JKO) owes its name to its visionary founders Lala Juggilal Singhania and his illustrious son Lala
Company, HCCBPL has 25 bottling plants at strategic locations in various states spread across India.
Kamlapat Singhania who pioneered to set up an Indian enterprise, inspired by Swadeshi movement called by of Father of
Hindustan Coca-Cola Beverages Pvt. Lt. Goblej Unit belongs to Gujarat, Rajasthan, and Bhopal Zone. This is the rst our Nation-Mahatma Gandhi over a century ago. JKO played an important role in rapid industrialisation in India, post
plant Greeneld Plant set up in 1998 over approx. 52 acres of land with Capacity of approx. 200k physical cases per day. independence.
Expectations from TPM JK Tyre & Industries Limited - Is the ag ship of JK Orgn set up in later 1970s in Kankroli, Rajasthan. Over the last 4
Service to Sales by Ensuring high assert utilization and best in class OEE decades, JK Tyre has grown multi-fold (organically and inorganically) in 4 states of India and overseas and has 9
manufacturing plants: 6 plants in India and 3 plants in Mexico.
ZERO Accidents , Defects , and Consumer Complaints
Deliver the goods to the customer at best Cost on time JK Tyre enjoys market leadership in several products being acknowledged as pioneers of radialisation with its in-house
R&D, Technological edge, consistently high quality of products with manufacturing excellence driven by its highly
Highly Engaged and motivated Employees , willing to contribute and ready to take on any new challenge.
competent and motivated people.
Develop Capabilities of Suppliers and employees to stay competitive.
Sustain all Improvements. It exports to over 100 countries across 6 continents and enjoys patronage of loyal customers
JK Tyre Vikrant Tyre Plant (VTP) has 3 manufacturing facilities at Mysuru location, Bias plant , Radial Plant & OTR (Off the
TPM Slogan/Objectives TPM IN --- WE WIN Road) Tyre plant with wide range of products for Truck, Bus, LTR & OTR tyre. JK Tyre is the largest manufacturing
organisation in Mysuru, providing employment (direct and indirect) to over 10,000 families in the society apart from
Kick off/
Category Index(Calculation Formula) TPM STARTED
Actual status
Target 2016
performing its important role in growth of industry
unit (2015)
(2011)
Number of work-related accidents requiring Expectations from TPM

S Number 0 0 0
days off work To Achieve World Class Business Excellence in all spheres of our activity to achieve & sustain Zero Accident, Zero
Pollution, Zero Defect, Zero Breakdown, Zero Loss & Ultimately become most preferred & protable tyre brand across the
S Number 352 7 0 world
not requiring days off work
Cases/workman day
P Productivity for main product
( CPWD ) 352 7 0 Achievement Area - Tangible Benets
P OEE (Overall Plant Efciency) % 68 76 81 Area Performance Indicator UOM B.M - 0 B.M - 1 Actual
P Number of tags raised Number 234 25066 135000 S Accidents (Major) Numbers 5 0 0
A Rank - 360 0 0 OEE % 75.13 82.33 87.97
P
P Number of breakdowns Number B Rank - 504 72 0 Total Breakdowns Nos/Month 11,560 2,312 279
C Rank - 162 54 0
Overall process scrap % 1.89 1.173 0.705
Q Number of Customer Complaints Number 155 302 0 Q
Customer complaints (OEMs) Nos/Year 7 2 0
C Cost index Cost/unit Case 12 14.7 14
D Delivery to Customer (OEMS) % adherence 93 100 100
D Lead time in days days 7 Days 2 Days 2 Days
M Suggestion / Man Numbers 0 0.62 1.62
D Delivery performance % 90 95 100
E Treated Water Reuse % 65 90 100
Accidents per 100000
S Safety index 0.49 0.22 0 During last 10 years, TPM implementation at Vikrant Tyre Plant not only helped in improving our business results but in
operator hours
organisational transformation in its culture seen in the steep increase in employee involvement in teams, high level of
M Number of Employee Suggestions Number 10 5300 10000 commitments and high morale among motivated employees
22 11
Company : Lumax DK Auto Industries Limited Company : Harsha Engineers Limited
Factory : Pantnagar, Uttrakhand, India
Factory : Changodar & Moraiya Plant
Product : Automotive Lighting Products
TPM Kick off : 9 April, 2008 Product : Bearing Cage Manufacturing
Award for TPM Excellence - First Category : 2012 TPM Kick off : 17th September, 2011
Award for TPM Excellence First Category : 2015 Mr. Harish Rangwala
Mr. Anmol Jain Managing Director
Managing Director

Harsha Engineers Limited is a global solution provider of Bearing Cages of all types and all material as well as special
Lumax DK Auto Industries Limited: The Plant situated at Pantnagar industrial Area of Uttrakhand, belongs to DK Jain
purpose Stamped Components. Since its inception in 1972, Harsha has leveraged continuous customer engagement and
Group. Lumax has grown from success since its foundation in the year 1945. The company went Public in the year 1984
aspired to be the world class in manufacturing practices. Today, Harsha has become a preferred supplier of different types
and thus in the same year embarked on its highly successful joint venture with STANLEY, japan.Lumax have 30 years of
of Roller and Ball Bearing Cages and Cages for Bearing with special applications with various manufacturing technologies
highly rewarding partnership with STANLEY, japan one of the oldest live JV in India.
such as stamping, machining & injection molding. Harsha developed around 300 new products in a year.
Lumax has a vision with an experienced and customer focused management team. This is clearly evident from our In Harsha, the manufacturing excellence is driven by the philosophy of new technology and innovative practices to design,
nancial growth which has been a steady upward trend right since our inspection. manufacturing and deliver products with a competitive advantage of customer responsiveness, speed, exibility, reliability
Under the umbrella of DK Jain Group there are 8 (Eight) Companies named as Lumax Industries Ltd., Lumax Auto and sustainability and with an aim to be Global Leader and Preferred Supplier of Bearing Cages and Precision
Technologies Ltd., Lumax Gill-Austem, Lumax DK Auto Industries Ltd., Lumax Mannoh, Lumax Cornaglia Auto Tech Ltd., Components.
Lumax ancillaries Ltd., and Lumax Tour & Travel. Total Group sales turnover is $400 million.
Expectation from TPM
Expectations from TPM Improve Overall Equipment Efciency Faster Product Development
Yield Improvement in All Process Visual Management of Manufacturing Machines
Zero Customer Complaint Achieve On time Delivery
Zero Machine ( Accident, Break down & Defect-Zero) Create safe and participation working environment
Zero Breakdown Improve employee satisfaction score
Concept implemented Develop skills, capacities, Flexibility and reliability
Zero Accident Benchmarking for Manufacturing Excellence
Material movement online in all process Higher employee moral, greater organization protability
Cost Competitiveness
Achievement Area - Tangible Benets

TPM Tangible Benets
Category Index (Calculation Formula) Unit Kick off Actual Status Target B.M Year
/ TPM Started 2015 (Dec) 2015 Key Performance Indicators UOM
2010-11 2015-16
S Number of work-related accidents P Productivity Nos./Man/Hour 799.96 1113.37
requiring days off work Cases / Annually 0 0 0
P Overall Equipment Efciency % 54.9 69.72
S Number of work-related accidents Number of Tags raised
P (Cumulative from BM) Number 0 162167
not requiring days off work Cases / Annually 459 39 0
P Productivity for main products Parts/Opeartor hours 120 190 200 P Machine Breakdown Occurrence / Month 907 55
P OEE (or Overall Plan Efciency) % 51 95 95 Q Number of Customer Complaint Nos./ Month 8 4
P Number of tags raised Number 643 18349 18500 Q In process Rejection PPM / Month 42590 10648
P Number of breakdowns Breakdowns / Annually 105 0 0 C Conversion Cost Rs./Cage 50.78 35.99
Q Number of customer complaints Number 5 0 0 D On time Delivery % 86 98.26
C Cost index % to sale 6.1 6.3 6.0 D New Product Developed Days 154 77
D Lead time in days Days 45 4 2
S Accidents Nos./ Annually 28 4
M Number of Employees Suggestion Number 0 542
S Safety index Accidents per 100,000 0 0 0
operator hours
M Number of Employee Suggestions Number 0 9530 9500
12 21
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AWARD FOR EXCELLENCE IN CONSISTENT TPM COMMITMENT
AWARD FOR TPM EXCELLENCE, CATEGORY A
Company : Mahindra & Mahindra, FES- Swaraj Division
Factory : Swaraj Division-Plant-1, Mohali
Product : Tractors
Award for TPM Excellence, Category A : 2012

Award for Excellence in Consistent TPM Commitment : 2015 Mr. Jitender Gujral
Vice President
Manufacturing
Tractors and Farm Equipment Limited , Dodballapur Tractors and Farm Equipment Limited Madurai Company Prole
Mahindra embarked on its journey in 1945 by assembling the Willys Jeep in India and is now a US $16.9 billion Indian
multinational. Mahindra employs more than 2,00,000 people in over 100 countries. Mahindra operates in the key
industries that drive economic growth, enjoying a leadership position in tractors, utility vehicles, information technology
and vacation ownership. In addition, Mahindra enjoys a strong presence in the agribusiness, aerospace, components,
consulting services, defense, energy, nancial services, industrial equipment, logistics, real estate, retail, steel,
commercial vehicles and two wheeler industries.
In 2013, the Mahindra Group received the Financial Times Boldness in Business Award in the Emerging Markets
category.
M&M Board of Directors ranked as one of Indias Best Boards in the Economic Times-Hay Group survey 2014
Tata Hitachi Construction Machinery
Toyota Kirloskar Auto Parts Pvt Ltd. Company Pvt. Ltd Kharagpur In 2015, Mahindra & Mahindra was recognized as the Best Company for CSR in India in a study by the Economic Times
The Business of AFS has three business verticals - Automotive Division (AS), Farm Division (FD) & Swaraj Division
(SD). The Farm Division & Swaraj Division forms the part of Farm Equipment Sector(FES).
AWARD FOR TPM EXCELLENCE, CATEGORY B Swaraj Division, erstwhile Punjab Tractors Limited (PTL) was promoted by Government of Punjab, through Punjab
State Industrial Development Corporation Ltd. In February 2009, Punjab Tractors Limited was merged with Mahindra &
Mahindra Ltd. as Swaraj Division. Swaraj won Deming prize in 2012.
Plant Prole - Mahindra and Mahindra Ltd., Swaraj Division, Plant 1
Plant-1 of Swaraj Division was established in 1974 at Industrial area in Mohali (Punjab) near Chandigarh. At present, the
plant is manufacturing 8 tractor models, ranging from 20.0 H.P to 42 H.P, having more than 40 variants. Plant is
established in 97000 sq. meters area and having the exibility of producing all models of Swaraj product mix. There are a
total of 230 machines & equipment's in the plant with an average age of 22-25 years. Plant is certied for ISO 9001:2008,
ISO 14001:2004 and OHSAS 18001:2007.
Expectations from TPM Achievement area - Tangible Benets

AVTEC, Chennai AVTEC, Hosur In today's competitive world, TPM is one of the best PRODUCTIVITY:
manufacturing practice followed by many Increased by 48.1 %
successful companies to achieve business Breakdown incidences/month reduced by 91%
excellence.
QUALITY:
To maximize plant capacity utilization by reducing Machine Shop Scrap & rework reduced by 43%
all losses.
To achieve and sustain zero breakdowns, zero
COST
Manufacturing Cost reduced by 53%.
accidents, zero defects in all areas of the factory
To t a l l y s a t i s e d c u s t o m e r s a n d r e d u c e DELIVERY:
manufacturing cost 100% schedule adherence
To create safe and friendly workplaces Equipment development lead time reduced by 30%
AVTEC, Pithampur HIL, Kondapally To u p g r a d e s k i l l a n d k n o w l e d g e a n d SAFETY:
empowerment of employees First Aid incidents Reduced by 90%
To bring systematic approach in problem solving
MORALE:
among all employees
Kaizens/Employee/Year increased by 4.7 times.
Total employees involvement in achieving
manufacturing excellence
20 13
Photo Gallery
Company : Mahindra & Mahindra, FES- Swaraj Division
Factory : Swaraj Division Plant-2, Chappercheri
Product : Tractors
Award for TPM Excellence, Category A : 2012

Award for Excellence in Consistent TPM Commitment : 2015 Mr. Yatinder Nath
Plant Head
Hero MotoCorp Ltd, Haridwar JK Tyre & Industries Ltd Vikrant Tyre Plant, Mysuru
Company Prole
The Mahindra Group focuses on enabling people to rise through solutions that power mobility, drive rural prosperity,
enhance urban lifestyles and increase business efciency.
A USD 16.9 billion multinational group based in Mumbai, India, Mahindra employs more than 2,00,000 people in over
100 countries. Mahindra operates in the key industries that drive economic growth, enjoying a leadership position
in tractors, utility vehicles, information technology and vacation ownership. In addition, Mahindra enjoys a strong
presence in the agribusiness, aerospace, components, consulting services, defense, energy, nancial services,
industrial equipment, logistics, real estate, retail, steel and two wheeler industries. Mahindra & Mahindra Ltd. Farm Equipment Sector,
Lumax DK Auto Industries Limited Swaraj Division Plant 1
The Business of AFS has three business verticals - Automotive Division (AS), Farm Division (FD) & Swaraj Division
(SD). The Farm Division & Swaraj Division forms the part of Farm Equipment Sector (FES). Swaraj Division, erstwhile
Punjab Tractors Limited (PTL) was promoted by Government of Punjab, through Punjab State Industrial Development
Corporation Ltd. In February 2009, Punjab Tractors Limited was merged with Mahindra & Mahindra Ltd. as Swaraj
Division. Swaraj won Deming prize in 2012.
Plant Prole
Plant 2 was set up in 1980 in village Chappercheri, Mohali (Punjab) .In 1995 the Tractor setup was set in Plant-2 with an
annual capacity of 12000 Tractors per year. Over the years the capacity was enhanced to meet customer demand. The
total plant area is 156000 sq. meters and has the exibility to producing various model mix of tractor. Plant is certied for Mahindra & Mahindra Ltd. Farm Equipment Sector, Tractors and Farm Equipment Limited Engineering
ISO 9001:2008, ISO 14001:2004 and OHSAS 18001:2007. Swaraj Division Plant 2 Plastics and Tool Room Division - Maraimalai Nagar
Expectations from TPM Achievement area - Tangible Benets AWARD FOR TPM EXCELLENCE, CATEGORY A
In today's competitive world, TPM is one of the best PRODUCTIVITY:
manufacturing practice followed by many Increased by 50 %
successful companies to achieve business Breakdown incidences/month reduced by 97%
excellence.
QUALITY:
To maximize plant capacity utilization by reducing Machine Shop Scrap & rework reduced by 79%
all losses.
To achieve and sustain zero breakdowns, zero
COST
Manufacturing Cost reduced by 18%.
accidents, zero defects in all areas of the factory
To t a l l y s a t i s e d c u s t o m e r s a n d r e d u c e DELIVERY:
manufacturing cost 100% schedule adherence
Harsha Engineers Limited Changodar and Moraiya Hindustan Coca Cola Beverages Pvt. Ltd. - Raninagar
To create safe and friendly workplaces SAFETY:
To u p g r a d e s k i l l a n d k n o w l e d g e a n d First Aid incidents reduced by 94%
empowerment of employees
MORALE:
To bring systematic approach in problem solving
Kaizens / Employee / Year increased by 5.6 times.
among all employees
Total employees involvement in achieving
manufacturing excellence
Good house keeping and 5S in all areas
Hindustan Coca Cola Beverages Pvt. Ltd. - Goblej

Jindal Steel and power Limited- Barbil Pellet
14 19
Photo Gallery
SPECIAL AWARD FOR TPM ACHIEVEMENT
Company : Tractors and Farm Equipment Limited
Engineering Plastics & Tool Room Division
Factory : MARAIMALAI NAGAR
Product : Injection Molded Plastic Parts
TPM Kick off : 23 May, 2009
Award for TPM Excellence, Category B : 2012
Award for Excellence in Consistent TPM Commitment : 2015 Mr. S Lakshminarayanan
General Manager
- Operations
Bajaj Auto Ltd. Chakan Plant, Pune Bajaj Auto Ltd. Motorcycle Division (MCD), Waluj Plant
Company Prole
The Engineering Plastics Division of TAFE (TAFE-EPD) manufactures high precision moulds and custom moulded engineering plastics
at its state-of-the-art facility in Bangalore, Karnataka, and Maraimalai Nagar near Chennai, Tamil Nadu. The imperatives of growth in the
engineering plastics and tool making industries demands continuous innovations in technology and business practices. We meet this
challenge by combining the most sophisticated technology with a skilled workforce, aggressive quality control systems and an
unwavering dedication to customer service. Engineering Plastics Division has a primary focus on manufacturability in injection moulded
engineering plastics.
This centre of Engineering Plastic and Tool Room Division having established a name in the Industry and in line with our vision and
mission established its second manufacturing plant at Maraimalainagar Chennai in the year 2002. The growth of this unit has been
exponential since it started commercial production. From a sale of Rupees 6 Crores in the year 2003, it has registered a phenomenal
growth, given the time frame since it commenced commercial production. It also added to its customer base auto majors such as Ford
India Private Ltd, Renault Nissan India Private Ltd. Ford accorded Q1 status within one year and appreciated the efforts taken to receive
Mahindra & Mahindra Ltd. Farm Division - India
Mumbai, Nagpur & Rudrapur Plant Q1, subsequent to start of production for India specic program. This is a record of sorts even amongst FORD supplier community.

Year on year - Enhanced level of Overall Equipment Efciency Embrace new ideas Draw parallel from various Applications
AWARD FOR EXCELLENCE IN CONSISTENT TPM COMMITMENT Raise the bar of Performance [Industries] and evaluate feasibility to apply the principles to
Safety Conscious and Self Directed Teams improve work practices
Self Regulated Work Groups Enjoy work and spread Peace and Happiness
Zero Accident to Zero Risk Great Company to work with
Understand, Appreciate prevailing work practice and make work
Simple and Easy
Category Index (Calculation Formula) Unit Kick off Actual Status Target
/ TPM Started 2015 (Dec) 2015
S Number of work-related accidents
requiring days off work Cases/ annually 0 1 0
S Number of work-related accidents
/ injuries not requiring days off work Cases/ annually 48 4 0
AQUA Group Aquapump Industries Bajaj Auto Ltd. Pantnagar
P Productivity for main products Parts/Operator hours 55 65 70
P OEE (or Overall Plant Efciency) % 66 83 85
P Number of tags raised Number 366 6538 7000
P Number of breakdowns Breakdowns/ annually 67 16 14
Q Number of customer complaints Number 24 16 14
Q In-line defect rate Scrap % 1.39 1.49 1.14 1.24 1 1.05
Scrap and rework %
C Cost index Cost/Unit 5.53 12.78 8.1 9.15 NA 9.0
Cost/Kilogram
D Lead time in days Days NA NA NA
Exide Industries Limited, Haldia Exide Industries Limited Sf Division, Taloja S Safety index Accidents per 100,000
operator hours 37 3 0
M Number of Employee Suggestions 242 343 375
Other <Specify achievements not expressible in numerical terms>

Do you have a program where all employees can participate in TPM? YES
Do you have a program allowing employees to be recognized their achievements? YES
Are top management involved in the audit/verication of completion of TPM pillar steps? YES
Are all pillar activity boards displayed and reviewed by top management? YES
18 15
Photo Gallery
16 17

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PROGRESS @ TPM

Newsletter from CII TPM Club India

For more details, Please contact:

Confederation of Indian Industry, Institute of Quality - KNS Centre,

Phone: 080 - 23286085 / 7690 / 9391 | Fax: 080 - 23289388 / 23580314

Conformity Assessment & Standards TPM Awards

Company Prole Company Prole

Achievement area Tangible benets To minimize pollution & conserve natural

Company Prole Company Prole

Achievement Areas - Tangible Benets Reducing Product Cost

Breakdown Occurrences (Monthly) Nos 182 50 0 7 10 5

Award for TPM Excellence : 2010

Farm Division - Mumbai Plant Company Prole

Improve Capability of Operators for Machining Operations High Productivity

Delivery Performance - 100%

89 % Ergonomically Green Stations D Delivery Performance % 95 100

24% Reduction in Inventory S Major Accidents Annual Cases 0 0

Minor Accidents Annual Cases 0 0

M Employee Suggestions Numbers / yr 81 300

Company Prole Farm Division - Nagpur Plant

P Overall Line Efciency % 78.5 84 11 % Improvement in Manpower Productivity

TPM Kick off : 5 September, 2012

Farm Division - Rudrapur Plant Company Prole

Sustained Zero Breakdown for A Category Machines Minutes/Month 45

Company Prole Company Prole

Productivity & Overall Equipment Effectiveness ( OEE ) % 61 85 87 88 90

TPM Kick off : 12 January, 2012

Company Prole Company Prole

Factory : Pellet Plant, Barbil (Odisha) Factory : SF Division, Taloja Plant

TPM Kick off : 19 January, 2012 TPM Kick-Off : 13 December, 2004

Expectations from TPM Expectations from TPM

TPM Kick off : 6 June, 2011

Company Prole Company Prole

Achievement Area - Tangible Benets Cases/workman day

Number of work-related accidents requiring Expectations from TPM

Company Prole Company Prole

Achievement Area - Tangible Benets

Award for TPM Excellence, Category A : 2012

Expectations from TPM Achievement area - Tangible Benets

Award for TPM Excellence, Category A : 2012

Hindustan Coca Cola Beverages Pvt. Ltd. - Goblej

Expectations from TPM

Other <Specify achievements not expressible in numerical terms>

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