i n s i d e From The Chairman s Desk 20th Kaizen Conference cum Competition February 2013, Gurgoan

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1 Newsletter Volume 32 March 2013 From The Chairman s Desk 2012 TPM Excellence awards function was organized by JIPM and e assessment agencies (like CII in India, SMMT in UK, CSD in Taiwan, TPA in Thailand, CETPM in Germany and KSA from Sou Korea) on 27 March 2013 at Kyoto in Japan. 19 Indian companies were e proud winners of e award for e year Totally 97 Companies from across e globe, except Japan, successfully challenged e JIPM TPM Award Assessment for e year The ceremony was organised in a grand manner in e Center where Kyoto Protocol was signed for e United Nations Framework Convention on Climate Change (UNFCCC). I congratulate ese companies for eir great achievement and leadership role in eir TPM journey. During e first quarter of 2013, TPM Club India organized 20 Kaizen Conference at Gurgaon on February Kaizens were presented for e 8 trophies to be presented to e winners; 3 in operator s category, 3 in e supervisors/managers category and 2 in e senior manager s category. This conference cum competition was also a place where e companies shared eir best kaizens for e benefit of 275 participants from 95 companies. Chairman, TPM Club India As e readers would be aware, TPM has taken deep rooted in e Indian Industry. Many companies have started eir TPM journey and have clear mile stones. In is newsletter, we also cover e details of e companies which have successfully crossed e first mile stone of Kick off and celebrated eir success. We congratulate em for eir success and compliment em for furer grow. i n s i d e 20 Kaizen Conference cum Competition 1-5 TPM Kick Off In is newsletter, we cover e above 3 major activities to share e events and to compliment e companies. I urge many more companies to practice TPM for becoming competitive globally and to keep e flag of TPM in India on a high platform. Ø Hindustan Coca-Cola Beverages Pvt Ltd., Pirangut Factory, Pune 5-6 Ø Indian Oil Corporation Ltd., Panipat-Jalandhar LPG Pipeline (PJPL), Kohand 6 Ø Varroc Polymers Pvt Ltd., Greater Noida Plant (VPPL-GN) & (VPPL-BN) 7-8 Ø Synite Industries Ltd., Kolenchery, Kerala 9 Ø Carborundum Universal Ltd., (CUMI) Ceramics Division, Hosur 10 Ø Federal Mogul Goetze (India) Ltd., Bahadurgarh, Patiala (Punjab) 11 Ø A G Industries Ltd., Manesar TPM Awards Ceremony, Kyoto, Japan Tentative Calendar (May - Dec) Kaizen Conference cum Competition February 2013, Gurgoan Paradigm of Phenomenal Savings The 20 Kaizen Conference cum Competition conducted by TPM Club India of e CII Institute of Quality held in Gurgaon during February 2013 successfully concluded wi e announcement of e 8 winners; 3 in e operator level, 3 in e supervisor/manager level and 2 in e senior manager level categories. Besides various process improvements presented, it was estimated at over Rs crores of savings had directly accrued from e successful implementation of various Kaizens!. All major companies from different sectors across e country like Oil & Gas, Steel Industries, Auto OEMs & Auto Component Manufacturing, Cement Industries, Wires & Cables, Infrastructure, Pharmaceuticals, Food & Beverages, Textiles, Metal, Paints, Plastic, Engineering, Precision Tools from PSUs, OEMs, Tier 1 & Tier 2 suppliers presented eir best Kaizens. Over 275 participants from 95 organisations attended e 20 Kaizen Conference. This decade long Kaizen Conference cum Competition, wi 100 award winners till date, has over e years emerged as a preferred platform for corporates to not only present eir improvement initiatives but also compete amongst emselves, rough delegate voting, to be declared winners. 13 TPM National Conference, September 2013, Chennai

2 In his valedictory address, Mr Yogesh Munjal, Chairman, CII-TPM Club India recounted e steady grow and implementation of TPM in e country. In 1991, Vikram Cement started TPM implementation in e country and won e TPM Excellence Award in Sundram Fasteners started in 1995 to win e award in In e same year, CII and JIPM (Japan Institute of Plant Management) signed an agreement for e promotion of TPM in India and e TPM Club India was born. Since 1995, 156 Indian companies have received 220 JIPM TPM awards; e largest award winning country outside Japan! Hindustan Unilever wi 41 awards, Tata's wi 13, IOCL wi 11 and Mahindra's wi 9 awards top e list of award winners in India. Allaying a common perception at TPM was only relevant to e Engineering Industry and at too specifically for auto industry, Mr Munjal clarified at e results so far indicates at 89 engineering companies; 65 process companies and 2 companies in e service sector have received e awards. He also complimented e 19 Indian 2012 JIPM TPM award winning companies who would be receiving e awards in Kyoto, Japan on 27 March Applauding e 81 kaizens presented during e 20 Kaizen Conference cum Competition, he noted at it indicates at ere has been lots of learning's and takeaways for e participants as companies practicing TPM have been rigorously pursuing e concept of cost reduction utilizing its proven meodology. Such Kaizen Conference cum Competitions of TPM Club India has always been designed considering e industrial scenario and e urgent need of Indian Industry. This year too, e focus has been given on cost reduction, activity reduction and productivity improvement grouped under 18 topics of importance considering 3 levels of engagement in a company like e Operator Level, Supervisor/Manager Level and Senior Management Level. The winners of each Kaizen Conference subsequently go on to contest e 'Kaizen Championship Award-2013', a high level Kaizen Competition wi a unique process of selecting e best out of e best to be held during e TPM National Conference in Chennai is September. 30 Kaizens on 5 subjects contested in e Operator's category for 3 trophies which were mainly relating to shop floor improvements. There were 41 Kaizen presentations on 10 subjects in e Supervisor's/Manager's categories for 3 trophies. These improvements related to elimination/ reduction of various loses to increase e Production efficiency of e manufacturing processes or to reduce e cost by reducing consumption of energy, consumables & raw materials. These improvements represented good examples of e maturity of Indian industries striving to excel rough creativity, innovation and technical knowledge. There were 10 companies in e Senior Manager's category vying for 2 trophies who presented eir improvements on subjects covering new technologies, process innovation, capital cost reduction and lead time reduction to meet customer demand. The 6 Nominations in e Operator's category were Auro Spinning Mills, Baddi; Hindustan Coca-Cola Beverages Pvt Ltd, Ameenpur; Hindustan Coca-Cola Beverages Pvt Ltd, Goblej; Mahindra & Mahindra Ltd, Igatpuri; Varroc Engineering Pvt Ltd, Plant IV, Aurangabad and Varroc Lighting Systems Pvt Ltd, Pune. The winners in is category were: Name of e Company (Operator s Category) Subject of Kaizen Position Achieved Auro Spinning Mills, Baddi Easy to Adjust 1st Position Mahindra & Mahindra Ltd, Igatpuri Easy to Clean, Lubricate, Inspect & Tighten 2nd Position Varroc Engineering Pvt Ltd, Plant IV, Aurangabad Poka Yoke 3rd Position The 6 Nominations of highest scoring companies in e Supervisor/Manager's category were Hero MotoCorp Ltd, Haridwar Plant; Hindustan Coca-Cola Beverages Pvt Ltd, Khurda; Light Alloy Products Ltd, Vellore; Mahindra & Mahindra Ltd, Kandivili; Turbo Energy Ltd, Pulivalam and Trident Ltd, Barnala. The winners in is category were: Name of Company (Supervisor/Manager s Category) Subject of Kaizen Position Achieved Trident Ltd, Barnala Reduction in Setup/Adjustment Time 1st Position Light Alloy Products Ltd, Vellore Breakdown Elimination or Increasing MTBF 2nd Position Hindustan Coca-Cola Beverages Pvt Ltd, Khurda Breakdown Elimination or Increasing MTBF 3rd Position The 4 Nominations for e Senior Manager's Category were Bajaj Auto Ltd., Chakan; IOCL, Barauni Refinery; M & M Ltd., Nagpur and Titan Industries Ltd., Hosur. The winners in is category were: Name of Company (Senior s Manager s Category) Subject of Kaizen Position Achieved IOCL, Barauni Refinery Equipment Related Design Changes/Lean m/c 1st Position Bajaj Auto Ltd, Chakan New Technology Introduction/Process Modification 2nd Position 2

3 The Trophies were given away by Mr Yogesh Munjal, Chairman, CII-TPM Club India to e proud winners. Benefits Reported by Various Participants Easy to Clean, Lubricate, Inspect & Tightening Hindustan Coca-Cola Beverages Pvt Ltd, Ammenpur; Lap Ross Engineering Ltd, Pulivalam; Mahindra & Mahindra Ltd, Igatpuri; Spicer India Ltd, Satara and Varroc Lighting Systems (I) Pvt Ltd, Pune made presentations in is category. Besides a direct cost saving of Rs.20 lakhs some of e oer benefits at accrued included MTBF improvement from 2 to 360 hours; Vessel cleaning time reduced from 37 sec/vessel to 10 sec/vessel; Waste water generation reduced from 2,160 liters to 432 liters; Preventive maintenance reduced from 2.5 hours to zero; Break down time reduced from 3 hours to zero. Easy to Adjust Amtek India Ltd, Bhiwadi; Auro Spinning Mills, Baddi; Hero MotoCorp Ltd, Dharuhera; Mahindra & Mahindra Ltd, FES Swaraj Division, Mohali; Sundram Fasteners Ltd, Chennai made presentations in is category. Some of e benefits at were presented included Less operator fatigue reduced accident chances; Crate life improvement from 3 to 5 years wi reduced stress & risk level of operators; Production increased by 20 pieces per mon wi time saving; Set up time reduction resulted in increased production of 78 components per mon; changeover time reduced from 30 minutes to 5 minutes. Easy to Operate or Monitor A G Industries Pvt Ltd, Manesar Plant; Carborundum Universal Ltd, IC Hosur; Carborundum Universal Ltd, Thiruvottiyur; Indian Oil Corporation Ltd, Digboi Refinery; Indian Oil Corporation Ltd, Haldia Refinery; The Supreme Industries Ltd, Pondicherry and Vardhman Acrylics Ltd, Bharuch made presentations in is category. Besides a direct cost saving of Rs.8.50 lakhs some of e oer benefits at accrued included Production increased from 55 pieces to 60 pieces per hour wiin 7 mons; Consistency in product weight achieved and stoppage eliminated; Grain coating improved wi dust level reduction from 70 micro gram to 50 micro gram/m3; Achieved zero failures from 4 failures per annum; Reduction of inspection time and stabilising vessel and actual suction pressure; Quality leak eliminated doubling inspection product output; Improvement in operations and safety levels. Implementation of Poka Yoke Hindustan Coca-Cola Beverages Pvt Ltd, Goblej; Mahindra & Mahindra Ltd, Nasik; Mahindra & Mahindra Ltd, FES- Rudrapur Plant; Tata Motors Ltd, Sanand (in absentia); Tata Motors Ltd, PVBU, Pune; Varroc Engineering Pvt Ltd, Plant- IV, Aurangabad made presentations in is category. Besides a direct cost saving of Rs.4.12 lakhs some of e oer benefits at accrued included SLE improvement by 0.5% wi yield improvement by 0.2% wi Zero defects; Zero level of wrong brush orientation per mon achieved; Line stoppage frequency reduced from 450 to 10 & elimination of defects; Elimination of wheel rejections; Potential defect of grease missing prevented. Elimination of Minor Stoppages A G Industries Pvt Ltd, Haridwar; Carborundum Universal Ltd, Sriperumbudur; Hindustan Coca-Cola Beverages Pvt Ltd, Chittor; Indian Oil Corporation Ltd, Maura Refinery; Marico Ltd, Dehradun; Sterlite Industries India Ltd, Tuticorin; TAFE Motors & Tractors Ltd, Bhopal; Tata Hitachi Ltd, Kharagpur made presentations in is category. Besides a direct cost saving of Rs.9.10 lakhs some of e oer benefits at accrued included Elimination of stoppage loss; Improvement of performance rate by 25%; elimination of rework; reduction in WIP; System Line Efficiency (OEE) improved by 0.5%; Reduced MTBF & increased seal life; Minor stoppages reduced from 93 minutes to 4 minutes & 3

4 EGA reduced from 0.78% to 0.27%; 6 hours breakdown improved machine availability by 1.2%; Line stoppage frequency reduced from 605 minutes/mon to zero wi 5S improvements; Zero minor stoppages wi savings of 13 minutes per pallet recovery time. Tool Change Time Reduction Marico Ltd, Pondicherry and Tata Motors Ltd, Sanand (in absentia) made presentations in is category. Besides a direct cost saving of Rs.2.70 lakhs some of e oer benefits at accrued included Production loss decrease from 312 minutes to 75 minutes wi consistency in quality and Improved quality wi reduction in minor stoppages. Energy Loss Reduction Badve Engineering Ltd, Unit V-Aurangabad; Grasim Bhiwani Textiles Ltd, Bhiwani; HIL Ltd, Hyderabad; Hindustan Coca-Cola Beverages Pvt Ltd, Siliguri; Indian Oil Corporation Ltd, Panipat Refinery made presentations in is category. Besides a direct cost saving of Rs lakhs some of e oer benefits at accrued included Reduction in LPG consumption by 27%; Increase in combustion efficiency of boiler; Energy savings. Customer Complaint Elimination or In-house Rejection/Rework Elimination Badve Engineering Ltd - II (Silencer Divison) Khandewadi; Hero MotoCorp Ltd, Haridwar Plant; Hero Motocorp Ltd, Gurgoan Plant; Kansai Nerolac Paints Ltd, Bawal; TVS Sundram Fasteners Ltd, Pant Nagar; Varroc Engineering Pvt Ltd, VEPL-III and Varroc Polymers Pvt Ltd, R&D Center, Aurangabad made presentations in is category. Besides a direct cost saving of Rs lakhs some of e oer benefits at accrued included Productivity improvement by 5% wi elimination of fitment difficulty; Total elimination of customer complaints; Zero customer rejections; improved machining efficiency & improved delivery adherence; Zero warranty PPM wi improved customer satisfaction; Zero in house rejection achieved. Logistic Cost Reduction Godrej & Boyce Mfg Co Ltd, Mumbai and Varroc Engineering Pvt Ltd-Corporate, Aurangabad made presentations in is category. Besides a direct cost saving of Rs lakhs some of e oer benefits at accrued included Improvement in production wi zero inventory and Reduction in transportation lead time & inventory reduction. Operator's Productivity Improvement rough Layout Changes (Man-hour Loss Reduction/Elimination) Chennai Petroleum Corporation Ltd, Manali; Hindustan Coca-Cola Beverages Pvt Ltd, Vijaywada; Spicer India Ltd, Pantnagar; Sundram Fasteners Ltd, Autolec Division, Bearing Plant; TAFE Ltd, Doddaballapur and Varroc Engineering Pvt Ltd, US Nagar, Rudrapur made presentations in is category. Besides a direct cost saving of Rs lakhs some of e oer benefits at accrued included Floor space reduction by 16% wi improvements in safety & time savings and reduction in WIP & savings in space. Low Cost Automation Amtek India Ltd, Bhiwadi; Marico Ltd, Dhaula-Kuan; Tata Motors Ltd, Jamshedpur, Kaizen Plant and Turbo Energy Ltd, Pullivalam made presentations in is category. Besides a direct cost saving of Rs lakhs some of e oer benefits at accrued included Improvement of productivity by ree times wi set up time reducing from 20 minutes to zero and a Capex saving of Rs.145 lacs. Tools, Jigs & Consumables Cost Loss ABI Showatech (India) Ltd, Vellore; Hindustan Coca-Cola Beverages Pvt Ltd, Moula-Ali; Sona Koyo Steering Systems Ltd, Dharuhera and YKK India Pvt Ltd, Rewari made presentations in is category. Besides a direct cost saving of Rs lakhs ere was a Tooling cost reduction from Rs.45 lakhs to Rs.8 lakhs during 9 mons. Breakdown Elimination or Increasing MTBF A G Industries Pvt Ltd, Haridwar; Axles India Ltd; Carborundum Universal Ltd, Thiruvottiyur; Hindustan Coca-Cola Beverages Pvt Ltd, Khurda; Indian Oil Corporation Ltd, Bongaigaon Refinery; Light Alloy Products Ltd, Vellore; Marico Ltd, Goa; Piaggio Vehicles Pvt Ltd, Baramati and TTK Prestige Ltd, Coimbatore made presentations in is category. Besides a direct cost saving of Rs lakhs some of e oer benefits at accrued included Improved production and reduced breakdown; SLE improvement of 3%; MTTR reduced from 190 minutes to 25 minutes wi reduction in manpower; 416 man hours savings annually wi improved equipment availability of 99.6%; Motor winding heating phenomenon eliminated completely wi savings in energy and MTBF increase. Reduction in Set/Adjustment Time Hindustan Coca-Cola Beverages Pvt Ltd, Dasna; Mahindra & Mahindra Ltd, Kandivali (E) Mumbai; Trident Ltd, Barnala made presentations in is category. Besides a direct cost saving of Rs lakhs some of e oer benefits at accrued included Increase in production time availability and reduction in set up time and Production increase from 450/day to 560/day wi machine OEE increasing to 91%. Start up Time Reduction or Normal Production Loss Reduction in Process Plant 4

5 Sterlite Industries India Ltd, Tuticorin made a presentation in is category and Reported reduction in COP and breakdowns. New Technology Introduction/Process Modification/ Innovation Bajaj Auto Ltd, Chakan; Delphi-TVS Diesel Systems Ltd, Mannur; Mahindra & Mahindra Ltd, Nagpur; Spicer India Ltd, Dharwad and Tata Motors Ltd, Jamshedpur made presentations in is category. Besides a direct cost saving of Rs lakhs some of e oer benefits at accrued included Production improved by 75%,FTPR improved by 10% wi elimination of machine investment; Improvement in delivery, capacity increase from 90k to 150 k/mon wi Reduction in OEE to 2% from 6.6%; PDI complaint reduced by 20%. Equipment Related Design Changes or Lean Machine Building to Reduce Capital Cost Indian Oil Corporation Ltd, Barauni Refinery; Spicer India Ltd, Pune and Titan Industries Ltd, Hosur made presentations in is category. A direct cost saving of Rs lakhs was reported by e ree companies. Lead Time Reduction to fulfill Increased Demand by Customer Godrej & Boyce Mfg Co Ltd, Plant 13, Mumbai and Sona Koyo Steering Systems Ltd, Gurgaon made presentations in is category. Some of e benefits at accrued included Inventory reduction from 20 days to 12 days wi improved delivery from 81% to 92% and Production per day improved by 5% and LOL reduced by 13%. Hindustan Coca-Cola Beverages Pvt Ltd., Pirangut Factory, Pune TPM Kick Off: 05 October 2012 On 5 October 2012, Hindustan Coca-Cola Beverages Pvt Ltd, Pune Factory had TPM Kick-Off in factory on Manager Model Line. It has been a landmark journey of business excellence for which lots of hard work has been put in by entire Pune Factory team. The main pillar which took lead was e Jishu-Hozen (Autonomous Maintenance) followed by KK, PM, QM and SHE. Key mile-stones achieved before Kickoff were JH Step III completion on Manager Model Line (Can Filling line) & successful achievement set PQCDSM targets on Manager Model Line. The Kickoff ceremony was chaired by Mr Durgesh Telang - Zonal Vice President, (Maharashtra & Goa Zone), Senior Management & Associates from Hindustan Coca-Cola Beverages Pvt. Ltd. Mr Rajesh Parim, Mr S Srinivasan and Mr S Yuvraj from CII (TPM Club of India) graced e occasion. Guest of honor during e occasion was Mr Nitin Inamdar, Vice President & ED (Minda Group). The Kickoff event began wi lamp lightening by all guests of honors which was led by Mr Manish Kamat, HCCBPL Pune Factory Manager. Mr Manish Kamat spoke about how TPM journey started in Hindustan Coca-Cola Beverages Pvt. Ltd. Pune Factory & explained e Manager Model Line concept & process of selecting e Line. He briefly explained about e targets set against e benchmark & spoke about e benefits at have been achieved by factory using TPM tools of 5 Pillars to begin e journey. The TPM work done on Manager Model Line by each pillar till kick off was presented by respective pillar chairmen i.e. KK (Manish Kamat), JH (Parind Shirwaikar), PM (Prashant Nevrekar), QM (Ramachandra Kamat) & SHE (Vaishali Dangle). Post Pillar presentations Mr Durgesh TPM Kick Off 5

6 Telang, unveiled e TPM Kickoff by opening e lid of coke can wi confetti blast. This was followed by releasing of TPM Newsletter by Factory Manager Mr Manish Kamat. The good work done by factory associates to achieve PQCDSM targets by doing kaizen & modifications on e line under each pillar were appreciated by distinguished guests. Mr Durgesh Telang, Zonal VP (Maharashtra & Goa Zone), applause for all round performance by unit & moving into star quadrant in bottling unit score card. He emphasized at TPM will not only help e factory but also help individuals to develop skill, make emselves more competitive,capable & perfect professionals. Guest of honor of e day from Minda group (Mr Nitin Inamdar, VP & ED) highlighted e success story of his plant like achievement of Zero breakdown & Zero customer complaints for 42 & 38 mons respectively by practicing TPM. He said TPM is religion of industry & we should have blind fai in our TPM gurus. He also emphasized at TPM is only tool which teaches us to work proactively.mr Raju Ingale, AVP (Zonal Supply Chain) appreciated e effective use of TPM tool by Pune Factory team. He appreciated & highlighted e fact of huge increase in productivity on Manager Model Line wiout any cost impact. Mr G S Raghu, National Capability Development Manager while appreciating e work done gave broader perspectives to Factory team on e vision of HCCBPL in coming years Mr Rajesh Parim, Principal Counselor, CII TPM Club India gave excellent perspective to our team on benefits of TPM for e industry. He said only success can change attitude & success comes from big number of small ings which can happen only wi team work. TPM Gurus Mr S Srinivasan & Mr S Yuvaraj addressed e team on e challenges in future & eir expectation post TPM kickoff. Indian Oil Corporation Ltd., Panipat-Jalandhar LPG Pipeline (PJPL), Kohand TPM Kick Off: 8 December 2012 Dr B D Yadav, ED (NRPL) kicked off e Total Productive Maintenance (TPM) activities at Panipat-Jalandhar Pipeline (PJPL), Kohand recently. The initiative taken by PJPL is impressive, said Dr Yadav and applauded e team for completing e activities in four mons, which usually requires six mons. Mr K D Banerjee, Chief Operations Manager (NRPL-Kohand) explained e details of TPM activities. The TPM activities are being implemented in PJPL to achieve Kohand as a model station as well as to obtain TPM award for e pipeline from Japan Institute of Plant Management (JIPM). TPM is implemented in consultancy wi CII, which has also appreciated e impressive progress made at PJPL. As part of TPM, e pipeline adopted practices such 5S philosophy as well as TPM activities in office and pump station. The Pipeline is working on PQCDSM (i.e. Productivity, Quality, Cost, Delivery, Safety and Moral) activities for zero accident, zero product failure, zero breakdown and zero defects in line wi TPM requirements for achieving award from JIPM. PJPL, Kohand has received e Best Station Award and also secured first position in HR index audit in Norern Region Pipelines in

7 Varroc Polymers Pvt Ltd., Greater Noida Plant (VPPL-GN) TPM Kick Off: 20 December 2012 Varroc Polymers Pvt Ltd., Binola Plant, (VPPL-BN) TPM Kick Off: 21 December 2012 We are pleased to inform you at VPPL-GN, Greater Noida and VPPL-BN, Binola Plants have successfully completed st TPM Kick off Ceremony on 20 and 21 Dec-12 respectively after achieving TPM Manager Model Machine PQCDSM results. During ese ceremony, Mr N Ramanaan (President Polymer), Mr S N Patil (Sr. VP - Production Systems), Mr A Y Darade (AVP - Operations Polymer), Mr P M Sheshadri (GM - CQA), Mr Sharad Singh (Plant Head, VPPL-GN), Mr Rishi Ahuja (Plant Head, VPPL-BN) and Mr K D Saravanan (CII TPM Consultant) were present and ey shared e importance of TPM during is event to bo plant employees. Bo GN & BN Plants restarted TPM implementation from Jan-12 by selecting Manager Model Machine and achieved Manager Model Machine (MMM) PQCDSM results as well as implemented various success stories by respective Pillar Heads under e guidance of Mr K D Saravanan (CII TPM Consultant). Best wishes to VPPL-GN & VPPL-BN Plant Heads & eir team members for company-wide TPM implementation after successful completion of TPM Kick off ceremony! TPM KICK OFF CEREMONY: Varroc Polymers Pvt Ltd., Greater Noida Plant (VPPL-GN) Manager Model Machine Targets Vs. Actual Results Injection Moulding 850T-F Machine 7

8 TPM KICK OFF CEREMONY: Varroc Polymers Pvt Ltd., Binola Plant, (VPPL-BN) Manager Model Machine Targets Vs. Actual Results Injection Moulding 850T-A Machine 8

9 Synite Industries Ltd., Kolenchery, Kerala TPM Kick Off: 5 February 2013 TPM Kickoff ceremony in Bio Ingredients Division of Synite Industries Ltd was held on e 5 of February 2013 at Synite Valley in Kolenchery, Kerala. Synite Industries Ltd is e world leader in Spice Oleoresin business and has always set e pace writing & rewriting industry standards. Synite started its TPM journey wi e selection of 'Manager Model Plants' in May 2012 under e guidance of Mr S Narasimhan, Sr. Counselor, CII Institute of Quality. Three teams, two Jishu Hozen teams in Production area and one Office TPM team in Warehouse practiced TPM rough a step by step approach. On successful completion of Step-3, TPM Kickoff ceremony was organized on 5 February Mr V T Moory, Director, Ultratech Cement, and Mr S Narasimhan assessed e progress of e ree teams in e forenoon session. The assessors first interacted wi e Senior Management of e company including e Chairman and e Directors. Mr Ninan Philip, Director Quality & Process Improvement, welcomed e assessors and introduced Synite, its Vision & e envisaged role of TPM in achieving e Vision. This was followed by a presentation on Bio Ingredients Division b y M r P r a v e e n Venkataramanan, COO of Bio Ingredients. Mr Pramod J Simon, TPM Facilitator appraised e assessors on e TPM journey at Synite and e future plans. This was followed by presentations on TPM activities by e ree team leaders. Site visits followed, where in e assessors listened to step-wise presentation and kaizen p r e s e n t a t i o n b y t e a m members. TPM kickoff ceremony was held in e afternoon at Synite Valley, Kolenchery. Mr Ninan Philip, Director Quality & Process Improvement, welcomed e audience. Mr C V Jacob, e Chairman of Synite Industries Ltd, formally launched e initiative by releasing balloons. Mr George Paul and Mr Aju Jacob, Directors, addressed e audience and commended e MMP members on eir efforts. Mr V T Moory addressed e audience on e advantages of TPM implementation and shared his valuable TPM experience. The Eight Pillar Chairmen and Fifteen Circle Leaders took eir respective Pillar Chairman and Circle Leader oas. Mr Narasimhan, Senior Counselor, CII, in his speech underlined e crucial role e Pillar Chairmen and TPM Leaders has to play in e Organization-wide Change. TPM Hand Book and Pocket book were released in e function by e Chairman of Synite Industries Mr C V Jacob. Awards were also distributed by Dr Viju Jacob and Mr Mani Varghese, Directors of Synite Industries Ltd, for excellent performance in e MMP. The function concluded wi Vote of Thanks by Mr Praveen Venkataramanan, e COO of Bio Ingredients Division. 9

10 Carborundum Universal Limited (CUMI), Ceramics Division, Hosur TPM Kick Off: 6 February 2013 Carborundum Universal Ltd (CUMI), Hosur plant is one of e flagship companies of USD 4.2 Bn Murugappa group. Murugappa group is one of e largest family promoted, professionally managed, diversified business conglomerate dealing wi Agro Products, Automobiles, Cements, Ceramics, Investments & Infrastructure. CUMI, Ceramics division is situated in Hosur, Tamilnadu was founded in 1991 to manufacture Technical Ceramic products like Wear resistant liners, Engineered ceramics and Metallised ceramics. CUMI decided to adopt TPM approach in line wi its business strategy of being most cost competitive organisation. The TPM journey started on 6 July 2012 wi an initial assessment by Mr Rajesh Parim, Head TPM Club of India. CUMI selected 5 model machines and 26 model machine manager's undergone hands on training under e guidance of Mr P M Janagiraman, Sr. Counsellor, TPM Club India from August All e 26 model machine managers experienced TPM in e model machines and achieved Zero Accident, Zero Breakdown & Zero Defect in e model machines wiin a record time of 6 mons. CUMI decided to take up e plant wide TPM and formally announced e TPM Kick off function to be conducted on 6 Feb CUMI invited Shri M M Murugappan, Chairman, CUMI and Mr Rajesh Parim, Head, TPM Club India for TPM Kick-off function on 6 February The TPM teams presented e progress of TPM activities to e senior management. This was followed by Gemba visit wherein e teams presented e kaizens and e journey towards achieving Zero Breakdown, Zero Defects and Loss Reduction. Kick off ceremony was made memorable by e august presence of CUMI's Customers, Suppliers, Vendors, Peer companies & CUMI's Employees. CUMI Chairman Shri M M Murugappan launched TPM Song and shared his views on e importance of TPM and how it is going to benefit e organisation. Mr Rajesh Parim explained e simplistic approach of TPM and its greater relevance in e current scenario. Results - TPM Model Machines P Q C D S M 30% increase in productivity for e model machines Breakdown reduced from 108 to zero Defects reduced from 2424 to zero 27% cost saving in power & powder 100% adherence to delivery for model machines Zero accidents in e model machines Kaizens and OPL are generated 10

11 Federal Mogul Goetze (India) Ltd., Bahadurgarh, Patiala (Punjab) TPM Kick Off: 16 February 2013 Federal Mogul Goetze (India) Ltd Erstwhile is a leading piston manufacturing facilities located at Bahadurgarh near Patiala (Punjab). The plant was started in 1958 by e Nanda Groups in collaboration wi Goetze (India) for piston rings & in 1960 wi Mahle Germany for pistons and market leader for piston assemblies, currently e facility is a part of e world renowned name in auto components, Federal Mogul Corp of USA. Total Productive Maintenance was kicked-off at Patiala facility by Mr Sunit Kapur, MD and Country Head India on February 16, The ceremony began wi e lighting of lamps by Mr Sunit Kapur and Directors - Mr Dan Brugger, Mr Vikrant Sinha, Mr Alok Manaktala, Mr Pritpal S Kular, Campus Head Mr Sanjeev Sharma and Trade Union President Mr Nazar Singh. The lighting of lamps signified development of synergy rough team works. The function was anchored by TPM facilitator Mr Arvind Ghai, who shared e glimpses touching success stories /Lessons learnt for e 2 year long TPM journey of e facility. The rewarding experiences and shine examples were shared by Mr Maheshinder Singh, Mr Jotbir Singh, Mr Rahul Bhandari, Mr Tajvinder Singh, Mr Sant Sharan Sharma. Mr Rohit Yadav, leaders of Manager Model Machines towards improvements done by em on Productivity, Quality, Cost, Delivery, Safety & Morale. They also shared e intangible benefits received out of e activity which can be jotted as teamwork and camaraderie, job satisfaction and opening up of newer horizons of ought. The TPM Policy & Logo for is pioneer plant in India were unveiled by Mr Sunit Kapur, who emphasized e needs of speedy TPM implementation, it being e sole tool for addressing all parameters required for remaining competitive in business. He opined at e purview of TPM is not limited to only PQCDSM but to e culture of `continuous improvement' in e organization. The TPM Policy defines e future roadmap wi e key words `Togeer, we excel' and states, We, at FMGIL Patiala strives to improve Operations to achieve high - efficiency wi total employee participation rough TPM (Total Productive Maintenance) in a safe working environment which makes us competitive in business by enhancing Productivity, Quality and reducing cost. The Trade Union President linked e progress of e employees wi at of e company and assured of everyone's active participation for bringing about e cultural turn around i.e. TPM. He emphasized on e need for religious propagation of TPM across e organization as in is competitive global trade scenario. There is a high market demand on squeezing e prices and e cushion for enhancement in employee remuneration lies in efficiency of operations and reduction of wastage for which TPM comes as a very effective tools. The TPM Principal Consultant from CII, Mr Abdul Wadood was all praise for e efforts done and conveyed his best wishes for future progress on TPM front. He stressed on e need of TPM implementation as fast as possible so at maximum benefits could be reaped by curtailing e wastage to a minimum. Mr Sanjeev Sharma Campus Head in his concluding address anked all present including visiting dignitaries from corporate and key business associates, CII Counsellors, Mr Abdul Wadood, Mr Ranjit Bhandari and assured speedy implementation of TPM across e facility towards achieving business excellence. 11

12 A G Industries Ltd., Manesar TPM Kick Off: 22 March 2013 A G Industries Pvt. Ltd. was founded in 1993 to manufacture Plastic Moulding Painting & Sub Assemblies Air Bag Manufacturing. The TPM Journey here was started in April 2012 by selection of 3 Manager Model Machines (Two Moulding Process & One Painting Process) and practicing e step by step approach focusing on mainly 2 pillars Jishu Hozen & PM under e guidance of Mr A G Krishnan, Counsellor, TPM Club of India, CII. TPM Kick-off starts wi HAVAN by MD Mrs Geeta Anand. nd On e auspicious day of 22 March 2013 Dr A P Das, CEO of A G Industries has initiated e TPM Kick - Off at Manesar Plant and explained e benefits of TPM. Mr A G Krishnan- TPM Counsellor spoke about e passion at has to be inculcated in every employee so at every activity is taken as TPM activity in order to make e plant achieve excellence in Productivity, Quality, Cost, Delivery, Safety & Morale. Mrs Geeta Anand (MD) opening e TPM Policy expressed her deep gratitude to all e members; A G team encouraged by e positive response her embraced e TPM Initiative at Manesar Operations. TPM Model machine members shared & presented rough Skit ere benefits enjoyed during model machine activity. This was followed by an official football Kick-Off by Mr Arjun Anand along wi TPM book unveiling by Chief Guest. At last all e A G members took e TPM Oa to emphasize eir total commitment to implement TPM activity roughout e plant and to achieve e targets as outline in e master plan. Progress on model machines is as follows: S. No Description Unit Results 1 Fuguai's Identified Nos Fuguai's Rectified Nos Activity time on M.M.M Hours One Point Lessions Nos Why-Why Analysis Nos Kaizen Nos

13 2012 TPM Award Ceremony, 27 March 2013, Kyoto, Japan. At e scenic beauty of e Kyoto International Convention Center, Kyoto, e award ceremony for e 2012 TPM award winners was organized on 27 March Wi e Sakura flowers blooming a little early is year, e participants could enjoy e beauty of e flowers and e place in a much appreciable manner. At e starting of e ceremony, e history of e TPM awards was communicated to e award winners rough a video. The organisers of e 2012 TPM award process and e award ceremony namely JIPM, CII, CETPM, CSD, KSA, IF (SMMT), TPA were introduced to e participants. The assessors, who criss crossed e Globe for assessing e applicant companies and spent ousands of hours carefully evaluating e activities and progress on TPM and en completing e assessment process were introduced to e winners. Mr Osamu Nakatani, Chairman, JIPM informed e award winners at TPM was well recognized by businesses around e world as a reliable means of assessing e level of manufacturing excellence achieved by e plants. In his opinion, if e manufacturing industry aim to achieve furer development in future, ey will need to work on an exhaustive elimination of lossess similar to e achievements made by e winners of Category A & B in TPM Awards and by e winners in Consistent. Future development will also need to be based on persistent improvement efforts made to create new values, such as ose made by e plants which have been given e Special Award. These persistent kaizen activities, which also contribute to e creation of better communities, are e essence of TPM. His speech was followed by e award distribution ceremony in a cheerful environment. At e end of e ceremony, e winners experienced e cultural activities of Japan rough a dance programme which was highly appreciated by all. The Award ceremony also turned out to be a place where e winners greeted each oer and exchanged notes on e activities and e problems solved in eir TPM journey. 13

14 2012 TPM Award Ceremony Glimpses of e award presentation!!! Unilever Mexico, HPC Cuernavaca Plant Unilever Turkey, Sanayi ve Ticaret Turk A.S., HPC Factory Arcelik A.S., Eskisehir Refrigerator Plant Unilever, Besan Besin Sanayi ve Ticaret A.S. Bajaj Auto Ltd, Motorcycle Division (MCD), Waluj Plant, Aurangabad Bajaj Auto Ltd., Chakan Plant Bajaj Auto Ltd., Commercial Vehicle Division (CVD), Waluj Plant, Aurangabad Bak Ambalaj San. ve Tic. A.S., Bak Ambalaj (Plant 1 - Plant 2 and Ekbak Sites) Borcelik Celik Sanayii ve Ticaret A. S. Eti Gida Sanayi ve Ticaret A.S., Eti Gida Cake Plant Indian Oil Corporation Ltd., Panipat Refinery Mahindra & Mahindra Ltd., Farm Division, Mumbai Plant Mahindra & Mahindra Ltd., Farm Division, Nagpur Plant 14 Mahindra & Mahindra Ltd., Farm Division, Rudrapur Plant

15 2012 TPM Award Ceremony Glimpses of e award presentation!!! Pepsico India Holdings Private Ltd., Kolkata Plant Demisas Dokum Emaye Mamulleri Sanayi A.S. Hero MotoCorp Ltd., Gurgaon Plant Hero MotoCorp Ltd., Haridwar Plant Indian Oil Corporation Ltd., Bongaigaon Refinery Ispak Izmit Sivi Paketleme A.S. Lumax DK Auto Industries Ltd., Pantnagar Mahindra & Mahindra Ltd., Farm Equipment Sector, Swaraj Division - Plant 1 Mahindra & Mahindra Ltd., Farm Equipment Sector, Swaraj Division - Plant 2 Orient Cement (Props Orient Paper & Industries Ltd), Clinker Grinding Unit (CGU) Uniproducts (India) Ltd. Vestel Elektronik San. ve Tic. A.S. TAFE, Engineering Plastics and Tool Room Div., Maraimalai Nagar - Chennai TAFE, Engineering Plastics and Tool Room Div., DBR, Bangalore 15

16 Tentative Calendar of TPM Club India (May - Dec) 2013 Programmes May-13 Jun-13 Jul-13 Aug-13 Sep-13 Oct-13 Nov-13 Dec-13 Deployment Seminar Tools, Techniques & Formats for TPM Chennai Delhi Gurgoan "Developing Equipment Competent OperatorStep 4 Jishu Hozen (Autonomous Maintenance)" JH 5 Bangalore Gurgoan Bottom Line Improvement rough Focussed Improvement Concept (KK) Cummi Chennai Pune PM Analysis Quality Maintenance Workshop Workshop for Setup Time Reduction Workshop for Improving e Machine Operating Conditions rough Jishu Hozen Coimbatore Pantnagar/ Madurai Gurgoan Mumbai Pune Breakrough Thinking in Achieving Zero Machine Breakdown rough PM Pune Increasing Administrative Productivity rough Office TPM Pune Eliminating Losses rough Makigami Analysis (Process Flow) Chennai Developing New Machines and Products wi Least Cost in Short Time (DM) Pune Delhi Productivity Improvement rough Skill Enhancement (E&T) Delhi Gurgoan Seminar on Key Performance Measurable Kaizen Conference TPM National Conference TPM Study Tour Circle Progaramme Aurangabad Pune Chennai Chennai Noren Region Bangalore TPM Facilitators Course Advanced Facilitators Course FC Bangalore