Progress @ TPM - CII-IQ · 2017-03-06 · Progress @ TPM Newsletter from CII Tpm Club India ......

Progress @ TPMNewsletter from CII Tpm Club India

Newsletter December 2015Volume - 35

FROM THE CHAIRMAN’S DESK

As the New Year is just around the corner, I would like to

start this message wishing all the members of TPM Club

India and the readers a very “Warm and Happy New Year

2016”. May this year be be�er than 2015. Thank you for

your support, trust and confidence put in CII TPM Club

India. Par�cipa�on in the club's ac�vi�es is increasing

year on year and each of you is contribu�ng to the vision

“Make In India” of our Honorable Prime Minister. Using

good manufacturing prac�ces is at the core of this vision &

TPM is one of the key prac�ces to be globally compe��ve. 2015 was a very good year for TPM Club India. On the JIPM

TPM Excellence Awards front, we have crossed 250 awards

(266 presently) from 186 companies with some of them

challenging higher levels. TPM Club members welcomed

our major conferences such as Kaizen Conferences, Circle

Compe��ons and Na�onal Conference. 4 Kaizen

conferences, 2 Circle compe��ons and a Na�onal

conference were organised this year. This is apart from the

40 open programmes and 2 TPM Facilitators Courses. 1400

plant personnel were trained through these programmes

on TPM and its elements. This is a clear indica�on that the

Indian Industry has adopted TPM wholeheartedly. We had

organised Kaizen Conferences in Delhi, Bangalore,

Aurangabad and Pant Nagar. Apart from Delhi all the other

3 loca�ons hosted a Kaizen Conference for the first �me.

The response was stupendous. We thank the members for

their un�ring support to make these conferences a great

success. This year, we introduced the Champions Compe��on to

recognize the best of the best from the winners of our

Kaizen conference and Circle Compe��on. The response

has been very good and the best in each category took the

Kaizen Championship Trophy and the Circle Championship

Trophy. I would like to congratulate the winners and thank

all the par�cipants for making this a great success. New TPM cer�fica�on programme, an assessment model,

was experimented this year at 2 of our member companies

namely Sona Koyo Steering Systems Ltd, Daruhera and SKF

Limited, Haridwar. The experiment was successful at both

these plants with good work done in adop�ng TPM

methodologies. We hope that many more companies

would check their level of Compe��veness in their TPM

journey by u�lizing this assessment tool. The response to

the poster compe��on, which was re-launched this year,

gathered good response. The winners were felicitated at

the TPM Na�onal Conference. Apart from this, we also

organised the first Interna�onal Mission on Manufacturing

to Germany to expose the members of the mission to the

best German manufacturing prac�ces. Presently, JIPM TPM Excellence Awards assessment for the

second stage is approaching the final stretch. Many Indian

companies are challenging the assessment this year. We

wish all the companies a very good success at the

assessments and a happy learning! Once again I thank you

for all the good work that has been done in 2015 and look

forward to scaling greater heights in 2016.

Progress @ TPM | December 2015 1

INSIDE

3rd TPM Circle Compe��on

Aurangabad Kaizen Conference & Compe��on

Reliability Centered Maintenance

Workshop on Why-Why Analysis

25th Kaizen Conference cum Compe��on

Pantnagar Kaizen Conference

15th TPM Na�onal Conference

CII IQ Manufacturing Mission to Germany

The Champion's Compe��on 2015

TPM Kick off: Harita Ferher Ltd

TPM Kick off: Numaligarh Refinary Ltd

Training Calender of TPM Club India

for the year 2016

2

3

5

4

4

6

7

9

11

12

13

16

Mr Ashok SharmaChairman, CII TPM Club IndiaChief Execu�ve, Agri and Allied Businesses,Members of the Group Execu�ve Board,Mahindra and Mahindra Ltd


Progress @ TPM | December 20152

3rd TPM Circle Compe��on 24 April 2015: Chennai

To con�nue the journey of further penetra�ng TPM amongst TPM prac�cing companies and companies planning to embark in

their journey of TPM, CII – TPM Club India successfully conducted the 3rd TPM Circle Compe��on on 24 April 2015 at Chennai.

22 TPM Circles competed in four categories for 1st Prize & 2nd Prize in each category.

The following were the Key Takeaways from the compe��on

Ÿ Kaizen presented at the compe��on

Ÿ Some of these best prac�ces that can be implemented in par�cipa�ng companies own circles.

Ÿ Learning the ' Percola�on of the Management Objec�ves` into the Circle level

Ÿ Networking

Ÿ with colleagues from the same company – different loca�on

Ÿ With other companies who are prac�cing TPM

Ÿ Each par�cipant returning with “ENHANCED KNOWLEDGE”

Mr.V Ramesh, Managing Director, E.I.D Parry (India) Ltd, in his valedictory speech congratulated all the circles who presented

their case studies. He informed that only decision are taken at the board mee�ngs & ac�ons for achieving the discussion,

happen in the shop floor. Hence it was very important that the circles become more ac�ve and vibrant to support the company

in becoming compe��ve.

Mr. Rajesh Parim, Principal Counsellor & Head, CII-IQ TPM Club India announced the winners of the compe��on. Mr. Ramesh,

Mr. Mayilvahan, Mr. P Masilamani, & Mr. R Anantharaman presented the prizes to the winners.

Winners of 3rd TPM Circle Compe��on

KK Circle JH Circle QM Circle PM Circle

1st Prize-Bajaj Auto Ltd., Chakan 2nd Prize-Badve Engineering Ltd(II).

1st Prize-Mahindra & Mahindra Ltd., Igatpuri Engine Plant 2nd Prize-Lumax Auto Technologies Ltd., Chakan

1st Prize-Lumax Auto Technologies Ltd., Waluj 2nd Prize-Godrej Precision Engineering

1st Prize-Bajaj Auto Ltd., Chakan 2nd Prize-Eimco Elecon(I) Ltd.



Aurangabad Kaizen Conference & Compe��on 18-19 May 2015, Aurangabad

TPM Kaizen Conferences have come a very long way over the last 15 Years. Though these compe��ons are generally organized

in the major ci�es to spread the message of kaizen in the �er-1 & 2 ci�es, for the first �me, a Kaizen Conference & Compe��on

was organized in Aurangabad. This gave more opportunity to the companies in this region for par�cipa�ng / compe�ng in the

conference as well as to learn how organiza�ons are using kaizen as a core strategy to improve opera�onal excellence and

be�er serve the customer.

The following were the key takeaways Ÿ Kaizen presented at the compe��onŸ Some of these best prac�ces that can be implemented in par�cipa�ng companiesŸ Networking

Ÿ with colleagues from the same company – different loca�onŸ With other companies who are prac�cing TPMŸ Each par�cipant returning with “ENHANCED KNOWLEDGE”

A total of 57 Kaizens competed in four categories. While Mr. Yuvaraj S, Senior Counsellor , TPM Club India, CII IQ announced

the winners of the compe��on, Mr. Rajesh Parim, Principal Counsellor & Head, TPM Club India , CII IQ , Mr Sethuraman P,

Consultant, TPM Club India, CII IQ , Mr. A A Shelke, Manager, Bajaj Auto Ltd. & Mr. A S Raodeo ,General Manager, Garware

Polyester Ltd presented the prizes to the winners.

Winners of Aurangabad Kaizen Conference & Compe��on

Winners List

Restorative Kaizen Renovative Kaizen Innovative Kaizen Breakthrough Kaizen

1st Winner – Varroc Engineering Pvt. Ltd., Plant IV

1st Winner - Godrej & Boyce Mfg Co. Ltd., PED

1st Winner - Badve Auto Comps Pvt. Ltd., Plant 3

1st Winner - Mahindra & Mahindra Ltd., Nashik Plant 1

2nd Winner - SKF India Ltd., Pune

2nd Winner - Endurance Technologies Pvt. Ltd., Transmission Division

2nd Winner - Tirth Agro Technology Pvt. Ltd.

2nd Winner - Badve Engineering Ltd., Unit - V

3rd Winner - Endress + Hauser Flowtec (India) Pvt. Ltd., 3rd Winner - Aurangabad

Electricals Ltd.

4th Winner - Mahindra Vehicle Mfg. Ltd.



Workshop on Why-Why Analysis 21st July, 2015 at Pune

Present worldwide compe��on among industries has made their management to pursue proven tools, techniques and

methodologies to keep them ahead in this race.

In this backdrop, TPM Club India organized the programme on “Why - Why Analysis: TPM Way” which could be considered as

the best tool for the industries to iden�fy the REAL ROOT CAUSE of the problems. The Workshop provided detailed instruc�ons

on problem solving techniques and how to develop correc�ve ac�on plans which could be immediately applied on the shop

floor. The two days workshop was designed to cater to each TPM prac�cing par�cipant from beginner to expert. 26

par�cipants from various industries came across to learn the concept along with tools to find and fix the root causes of

incidents, accidents, quality problems, breakdowns, errors in processes and other problems on the shop floor.

Reliability Centered Maintenance 27,28-29 May 2015, at Badve Engineering Ltd, Aurangabad.

Planned Maintenance ( A salient Pillar of TPM ), could be explained as a specialized ac�vity performed by the Plant

Maintenance team members, which principally focuses on the improvement of equipment reliability and

maintainability by restora�on and sustenance of the Op�mal condi�ons, at the most economic cost. With the rapid

improvement of Equipment technologies, varie�es and the number of physical assets , higher expecta�ons of the

management for increased asset u�liza�on combined with several internal and external challenges, Plant

maintenance as a niche discipline has evolved with great exper�se in the past twenty years.

In this opera�ng scenario, the demands placed on the maintenance team has also increased manifold for ensuring

smooth func�oning of the Equipment / Machineries. Newer techniques, tools and methodologies need to be

integrated along with the daily maintenance prac�ces. In today's scenario of func�oning macro economic factors,

compiled with increasing customer expecta�ons for lead �me reduc�on, such high end tools are playing an increasing role for

asset reliability and cost reduc�on.

To cater to these requirements, a 3 day intensive workshop on RCM Methodologies and applica�ons, was conducted. The

venue for the workshop conducted by Mr S Venkateswaran , Senior Counsellor ,CII TPM Club India was at Badve Engineering

which was a�ended by members from both Engineering and Process Industries.

CII TPM Club India takes this opportunity to thank the Sponsors of 15th TPM Na�onal Conference held during 29-30 September

2015 at Chennai.

Sponsors of 15th TPM Na�onal Conference



25th Kaizen Conference cum Compe��on 30-31 July, 2015: Bangalore

25th Kaizen Conference was organized at Bangalore on 30-

31 July 2015. The Silver Jubilee celebra�on was marked

with a good par�cipa�on from more than 75 companies

and a total of 230 par�cipants a�ending the Conference. It

was very well represented by the leading

manufacturing behemoths of the Indian Industry, with

players from the Light, Medium and Heavy Engineering,

Petro chemical Plants, Automo�ve sectors etc. The best

of the Kaizens implemented in Plants were showcased

as various Plants vied for a slot in the selec�on list to

make it up to the Na�onal level compe��on.

The compe��on was spread out in 4 sessions for 2 days.

The companies competed under Restora�ve, Renova�ve,

Innova�ve and Breakthrough Kaizen categories.

Restora�ve kaizens were presented, under the topic JH

ac�vi�es, Reduc�on of Minor Stoppages & Poka Yoke.

Restora�on being the star�ng point of all improvements, it

was quite evident from the benefits presented by the

companies, that there were improvements in produc�on

by 30-40% with substan�al reduc�on in cost.

In the Renova�ve Session, Setup Time Reduc�on , PM

Correc�ve Maintenance - Reliability & Maintainability,

Reduc�on of in Process Defects, PM - Correc�ve Maint –

Energy, Low Cost Automa�on, PM - Correc�ve Maint -

Safety & Karakuri Kaizens were presented.

In the Innova�ve Session, Process Razing Ac�vi�es,

Throughput Time Reduc�on Ac�vi�es, Innova�ve

Engineering Change, Input Op�misa�on were presented.

The benefits achieved by the companies presented in this

category totaled to about Rs.4.48 crores/annum.

In the Breakthrough Session, Product breakthrough

through Value Engineering Ac�vi�es, Lead �me reduc�on

across value chain were presented. The company

showcased 50% lead �me reduc�on. Value Engineering

ac�vity presented by companies, showed a cost saving of

Rs.70 crores/annum with a ROI of 3 days.

The results achieved by the companies in the

respec�ve categories were phenomenal in the

deliverables of Produc�vity , Quality , Cost , Delivery ,

Safety and morale. Also, many companies were able

to realize the improvement in the bo�omline, with

substan�al achievements in the Opera�ng Margins.

Such Kaizen Compe��ons amply bears tes�mony to

the fact that in today's VUCA environment, such

improvement ini�a�ves and Kaizen implementa�on

alone are the only means by which sustenance and

growth could be ensured, for the companies to remain

compe��ve.

Winners of 25th Kaizen Conference cum Compe��on



Category 1st

Winner 2nd

Winner 3rd

Winner 4th

Winner 5th

Winner

Restorative Hindustan Coca-Cola

Beverages Pvt Ltd, Bhopal

Indian Oil Corporation Ltd,

Pipeline Divn, WRPL, Rajkot

EID Parry (India) Ltd, Pudukottai

Renovative Toyota Kirloskar

Motor

Mahindra & Mahindra Ltd,

Igatpuri

SKF India Ltd, Pune

Triveni Turbine Ltd

Bajaj Auto Ltd, Waluj

Innovative TTK PRESTIGE Limited Real Talent

Engineering Ltd

Breakthrough Indian Oil Corporation Ltd -Barauni Refinery

Pantnagar Kaizen Conference 25-26 August 2015, Pantnagar

With the objec�ve to provide a unique pla�orm to Indian manufacturing industries to present their innova�ve & unique kaizen

ideas, a “Pantnagar Kaizen Conference” was organized by TPM Club India – IQ on 25-26 Aug, 2015 at Pantnagar, U�rakhand.

Kaizen Conferences have emerged as a great pla�orm to summarize & showcase the innova�ve Kaizens, Ideas, and Ac�vi�es

that are appealing to the manufacturing sector.

34 Kaizens from 20 companies in the presence of around 90 delegates reflected the momentousness of Indian industries

journey towards implementa�on and concep�on of new innova�ve ideas. Kaizen Conferences have become the fastest way

for the Indian manufacturing industries to a�end and learn the unique Kaizens and their methodology to improve their

business.

The conference programme featured the presenta�on on 34 kaizens ideas, 60 speakers from more than 20 companies & Q&A

session with Counselors and Speakers during the program. Bringing together TPM Club India counselors, speakers &

par�cipants from other industries, the Conference proved an excellent opportunity to share experiences and for networking.

Winners of Pantnagar Kaizen Conference

Winners List of 25th Kaizen Conference cum Compe��on



15th TPM Na�onal Conference 29-30 September 2015: Chennai

Winners of 15th TPM Na�onal Conference

TPM Club India of the CII Ins�tute of Quality organized the

15th TPM Na�onal Conference on 29-30 September in

Chennai. Mr J Srinivasan, Mentor TTK LIG Ltd delivering the

keynote address at the Inaugural session reiterated TPM

Club's support for Prime Minister's project ZED, the Zero

Defect Zero Effect through the various TPM pillars,

especially QM and SHE which would go a long way to

supplement the Make in India ini�a�ve. While

complimen�ng the programme structuring of the Na�onal

Conference he noted that the topics covered were very

relevant and unique though he did observe that more

ladies needed to par�cipate to make TPM stronger in the

shop floor. He complimented the launch of the prac�cal

guidance book on Planned Maintenance co-authored by

Mr Rajesh Parim, Principal Counsellor, CII-IQ and Mr

Namachivayam of TTK as an excellent example of academia

and industry collabora�on. Mr Rajesh Parim introduced Mr

J Srinivasan as a first genera�on TPM prac��oner since

1999 who had s ignificantly contributed to the

establishment of TPM prac�ces in India. TPM Club today

had well established itself with over 150 companies

suppor�ng it.

Mr Ken Otaguro, General Manager, TPM Awards Office,

Japan Ins�tute of Plant Maintenance, Japan speaking on

Next TPM and Global TPM Trends emphasized TPMs

importance in developing a human centric management

technology to use resources effec�vely and establish a

secure, safe and stable produc�on based on equipment,

material and informa�on. TPM, he said, had expanded its

horizon from total produc�ve maintenance to Total

Produc�on Management with assessments focusing on

whether TPM results were connected to business results.

Giving an interna�onal perspec�ve, he said that while Loss

Cost Matrix was important for iden�fying improvement

themes, kaizen themes within Japan were centered round

Karakuri and energy saving while globally it was on process

point analysis. TPM should support growth and

sustainability strategies of business and establish a

management structure for business profitability and

empower knowledge worker and promote their

contribu�on, he concluded.

The session on Advanced Maintenance Technologies for

Zero breakdown and Maintenance cost reduc�on was

conducted by Mr P Sunil Kumar, DGM –Manufacturing &

Mr A L Rajin, Manager Maintenance, Carborundum

Universal Ltd, Sriperumbudur who explained how

assembly of machines were broken down to component

level (eg. Packing gland) to understand the func�on of the

component and to know what can happen with

deteriora�on, thus improving the life through Kaizen or

design changes.

All the TPM Club counselors, Mr Rajesh Parim, Principal

Counsellor & Head, Mr Abdul Wadood, Principal

Counsellor, Mr S Narasimhan, Senior Consultant, Mr S

Venkateswaran, Senior Counsellor, Mr S Yuvaraj, Senior

Counsellor, Mr P M Janagiraman, Senior Counsellor, Mr

Ranjit Bhandari, Senior Counsellor and Mr A G Krishnan,



Consultant spoke in the session Business profits through

TPM pillars – A General understanding from CII – TPM Club

India emphasized the correla�on between each of the 8

pillar objec�ves and ac�vi�es to business bo�om line and

how the bo�om line gets improved through each pillar

ac�vity. For example, while the KK Pillar addresses

inventory turns, increased capacity without investment,

improvement in yield, the support of OTPM pillar in the

organiza�on moved from a high volume low profit zone to

high profit low volume zone handling more variety of parts.

The panel discussion on Government Policies and

Industrial Growth through TPM was conducted by Mr J

Srinivasan, Mentor, TTK LIG Ltd, Dr B D Yadav, Execu�ve

Director, Indian Oil, Mr Srikanth Sivaraman, Director,

SNAM Alloys Pvt Ltd and Mr H T Rajan, Chief Manufacturing

Officer, TTK Pres�ge Ltd. Mr. Srikanth highlighted the

Digital India policy and why industries needed to align to

this policy. He emphasized on the need for paperless

transac�on and paper-less internal communica�ons. For

factory applica�ons he indicated examples such as using

remote controls for switching on servers, furnaces,

compressors, office AC etc. Mr. Rajan focused on Swachha

Bharat policy and linked it to 5S. Mr Yadav talked about Skill

India (E&T and JH) and how TPM could support smart ci�es

projects. Mr Narasimhan opined that India was be�er

placed than China in terms of cost and quality.”TPM brings

consistency and stability in produc�on system which can

make us globally compe��ve”, he said. Mr.Srinivasan

summed up by saying that Govt. needed encourages R&D

investment.

The Panel discussion on Challenges in second journey of

TPM (Excellence to consistency) was conducted by Mr

Amer Hussain, Factory Manager, Hindustan Coca Cola

Beverages Pvt Ltd, Ameenpur, Mr Raj Deepak Cha�erjee,

Senior General Manager, ( Business Excellence), Mahindra

& Mahindra Ltd and Mr Chandrashekhar M Bhadane, AGM

– Maintenance, Project & EHS, Endurance Technologies

Pvt. Ltd. Then these ac�vi�es were made wider and

deeper. In first level the emphasis is on PQCDMS and in

consistency the focus is on reliability in equipment,

process, supply chain etc. As people development and

change management is the challenge, the TPM secretariat

was elevated to report to CEO. While Mr Cha�erjee related

how the challenge was to involve all func�ons and aligning

them to TPM goals, Mr Bhadane apprised the delegates of

the challenge they faced in mapping the flow and

shortening the produc�on lead �me. The session on Work

Standardiza�on and Reliability improvement was

addresses by Mr A Elavarasan, TPM Secretariat, Sona Koyo

Steering Systems Ltd who spoke on Assembly line

balancing and Mr BG Walture, Senior Manager ( Plant

Maintenance - MCD), Bajaj Auto Ltd, Waluj who spoke on

RCM Methodologies and its advantages. Sona Koyo

presented an interes�ng case study on material,

informa�on flow mapping through life size card board

simula�on technique and re-layout for minimum

movement . Re l iab i l i ty Centered Maintenance

methodology was presented by Bajaj through 7 step from

predic�ve (CBM) to RCM understanding part func�on and

increasing life of cri�cal parts. The session on TPM Cluster

for Supplier Compe��veness had a group of strategic

vendors presen�ng their case studies on TPM

achievements.

The session on Visual Management Solu�ons was

presented by Mr S Yuvaraj, Senior Counsellor, CII TPM Club

India. VMS which is applicable to informa�on, Raw

materials, Consumables, Tools, Machines and processes

achieves the purpose of surfacing the hidden issues and

make the resources communicate. The transparency index

is the measure of VMS system, he said. Mr Jun-ichi Uchida,

Execu�ve General Manager of TPM Development, JMAC-

TPM Company, Japan speaking on TPM Expansion to

Headquarters explained how the 8 pillars of TPM could be

adopted in corporate func�ons. In every func�on, work

flow has to be mapped and work breakdown standard

evolved.

The session on 5S & Safety was addressed by Mr S

Narasimhan, Senior Consultant, CII TPM Club India who

spoke on 5S for Middle & Senior Management in

compe��ve building and Mr Pramod Kumar Nayak, Team

Leader & Mr Chandra Sekhar Sethi, Execu�ve, Hindustan

Coca Cola Beverages Pvt Ltd, Siliguiri who spoke on

Ensuring Safety using LOTO Concept. KMI, KPI, KAI linkage

and review for 1S, 2S, 3S, 4S and 5S were explained. It was

explained that Manager were responsible for performance

and operators were responsible for ac�on. The success of

TPM hinged on 3 factors – Top management commitment,

Competent TPM coordinator and effec�ve consulta�on.

The session on Supply Chain and Marke�ng was conducted

by Mr Rajinder Singh, Country Manager and Chief Mentor,

Solving EFESO Consul�ng who men�oned 4 types of losses

happening in supply chains; Strategic, Tac�cal, Opera�onal

and People related. He explained how Service responses

were strategic, inventories were tac�cal, delays and

defects were opera�onal and rework due to lack of skill

was people and training related.


CII IQ Manufacturing Mission to Germany 12-15 October 2015

The Confedera�on of Indian Industry, CII Ins�tute of

Quality organized a Manufacturing Mission to Germany

from the 12-15 October 2015, which besides visi�ng the

Consulate General of India, Munich also visited BMW

Group, Sona Auto Comp, LAPP Group, Robert Bosch GmbH

Diesel Systems and Kramski GmbH plants in Munich and

Stu�gart.

The Mission members comprised of Mr S. Hari Ganesh,

Vice President Opera�ons, Snam Alloys Pvt. Ltd (Mission

Leader); Mr Iman Singh, OSD to MD, Frick India Limited ; Mr

Ajay Shah, Vice President - Opera�ons, KHS Machinery

Private Limited; Mr Falgun Desai, General Manager –

Engineering, KHS Machinery Private Limited; Mr

Ravichandran M A, Sr DGM - Manufacturing, L&T Valves

Limited; Mr Swapnil Vyas, Head Opera�ons, Mayur

Uniquoters Ltd and Ms Jayashree Das, Deputy Director, CII

IQ.

CONSULATE GENERAL OF INDIA, MUNICH

The Consulate General of India, Munich provides consular,

commercial and other services to the residents of Bavaria

and Baden Wür�emberg. In 2014, the share of Indo-

Bavarian bilateral trade was around 15 % of the total Indo-

German bilateral trade. Bavaria-based companies have

tradi�onally considered India as a reliable and promising

economic partner. At present, some 350 Bavarian

companies have their business ventures in India in

different fields. Some of the big names include Siemens,

BMW, Audi, MAN, Adidas, Allianz AG, Munich Re, Airbus,

Infineon, Wacker Chemie, Osram, Linde, etc.

According to official figures, as on 31 December 2014,

Bavaria is home to around 12,755 Indian na�onals and

about 6,500 PIOs. The NRI/PIO community in Bavaria

includes IT professionals; businessmen and traders;

restaurant operators; students and researchers.

India Week in Stu�gart: India Week in Stu�gart has been

annually organized since 2004. The event in July, 2008

marked the 40th Anniversary of Stu�gart-Mumbai

partnership. The 12th Indian Summer and the Indian Film

Fes�val & yoga and Ayurveda events took place at Stu�gart

in July 2015.

BMW

BMW, headquartered in Munich, is the world's leading

premium manufacturer of automobiles and motorcycles.

BMW Group owns three brands namely BMW, MINI and

Rolls-Royce. BMW Group operates 30 produc�on and

assembly facili�es in 14 countries and has a global sales

network in more than 140 countries with a workforce of

110,351 employees. BMW India produc�on plant is

located in Chennai and headquartered out of Gurgaon and

produces popular models such as: BMW 3, 5, 7 Series, X1,

X3 models and MINI exclusively for the India market. In

2013, BMW Motorrad, announced the partnering with TVS

Motors Co. to develop a series of bikes with engine sizes

below 500 cubic cen�metres.

LEARNING’S FROM THE VISIT:Ÿ Global centraliza�on from Munich to ensure global

standards.

Ÿ Purchasing strategy of BMW consists of 4 key elements ie- cost, quality, flexibility & innova�on to ensure lowest procurement price.

Ÿ Produc�on value added system of BMW consists of process supporters in every team who do not par�cipate in produc�on ac�vi�es but do observe produc�on issues in man, material and machine and take problem solving decisions.

Ÿ Quality is the pre-requisite for las�ng corporate success

Ÿ Value added system – employees from top to bo�om pass the knowledge to all team members

Ÿ Apprecia�on of suppliers at BMW's 8 category Supplier

Innova�on Award.Ÿ TWIS – Training within Industry is followed.

L-R: Mr Asheesh Gupta, Mr Iman Singh, Mr Ajay Shah, Mr Falgun Desai, Mr Sevala Naik, Mr Hari Ganesh, Mr Swapnil Vyas, Mr Ravichandran, Ms Jayashree Das, Mr Ramanathan at CGI office, Munich.

L-R: Mr Iman Singh, Mr Ajay Shah, Ms Jayashree Das, Mr Thiemo Schalk, Mr Nils Raube, Mr Thorsten Ahrens, Mr Swapnil Vyas, Mr Ravichandran, Mr Hari Ganesh at BMW, Munich.



SONA BLW GROUP

SONA BLW PRÄZISIONSSCHMIEDE GMBH, acquired by

Sona Group, India in 2008, is an innova�ve and expert

partner for the global automo�ve industry and has more

than 50 years of experience in precision forging. The main

product focus is differen�al bevel gears and synchroniser

rings, as well as speed gears with finish-forged and back-

tapered dog toothing, reverse gears and reverse idler

gears. This extensive product range is supplemented by

Hatebur-forgings, cold extruded parts, steering knuckles

and precision forged parts for the truck industry.

LEARNING’S FROM THE VISIT:

Ÿ Major automo�ve component manufacturing

processes of gears, axle and engine parts, chassis and

heavy duty truck components. Ÿ Produc�on process Flow components of Design, High

speed cu�ng, Hot/cold forging, Cold Sieving, Shot

blas�ng, Heat treatment, Automated SPM machine ,

Final inspec�on and Packaging & Shipping to major

customers like VW group, Germany. Daimler, US. MAN,

Germany. BMW, Germany.

LAPP GROUP

Based in Stu�gart, it is one of the world's leading providers

of cables and conductors for different industries and

markets mechanical and systems engineering for the

automo�ve industry, MSR technology, electrical and

installa�ons engineering, etc. Its Bangalore based Indian

subsidiary has a turnover of about Rs 300 Crores. Mr

Andreas Lapp, Chairman is also the Honorary Consul of

India in Stu�gart.


Ÿ Self Quality analysis; High voltage tes�ng before

despatchŸ JIT inventory , with an average turnover �me of 2 weeks

and customer delivery in 48 hours.Ÿ During changeover, to avoid loss of copper, dummy

wires are used and no wastage is recycled to maintain

premium quality.Ÿ 100% wire tested in intermi�ent stages and final

inspec�on is visual and torsion.

BOSCH GROUP

Stu�gart based Bosch is one of the World's leading

suppliers of engineering and services with around 350

subsidiaries across 60 countries and an employee base of

2,81000, specialises in automo�ve and industrial

technology, consumer goods and building technology.

India Opera�ons

Bosch India with 10 manufacturing sites in Ahmedabad,

Bangalore, Chakan, Chennai, Coimbatore, Jaipur, Manesar,

Naganathapura, Nashik and Verna and 7 development

centres and 26,000 employees, has the largest

development centre outside Germany for end to end

engineering and technology solu�ons.

LEARNING’S FROM THE VISIT:Ÿ The century old Bosch private founda�on, besides

suppor�ng German society, spends to support other

educa�onal and health founda�ons..Ÿ Business profits used in R&D is key to Bosch' success.Ÿ Bosch mobility solu�ons including its Diesel systems,

Car mul�media, Gasoline systems, Automo�ve starter

motor & generators, Electric drives and other

automo�ve systems Ÿ Bosch power train technology comprising Air system,

Waste heat recovery, Electric hybrid high power density

ba�ery, Engineering & calibra�on, Injec�on system and

Exhaust and treatment.

L-R: Mr Swapnil Vyas, Mr Iman Singh, Mr Ma�hias Reimann, Mr. Ralf Lipka, Mr Hari Ganesh, Mr Aja Shah, Mr Ravichandran, Mr Falgun Desai, Ms Jayashree Das at Sona BLW, Munich.

L-R: Ms Jayashree Das, Ms Parva� Vasanta, Mr Iman Singh, Mr Swapnil Vyas, Mr Hari Ganesh, Mr Ravichandran, Mr Ajay Shah, Mr Falgun Desai, Mr. Dieter Veenhuis at LAPP Group, Stu�gart.

Ms Jayashree Das, Mr Iman Singh, Mr Ravichandran, Mr Cyrus Amini, Mr Falgun Desai, Mr Mr. Klaus Bohler, Mr Ajay Shah, Mr Swapnil Vyas at Bosch, Stu�gart.



KRAMSKI

30 year old Kramski GmbH, working on projects across

mul�ple sectors and with mul�ple technologies, is a family

owned business. They have been working for over 30 years

on. It has transi�oned from a high-performance tool and

die making company to a manufacturer of sophis�cated

stamped and hybrid parts, who produces approximately

2.5 billion parts annually. KRAMSKI Stamping & Molding

India Private Ltd. was founded on March 11, 2008, in

Tamilnadu as its 100% subsidiary.


Ÿ High precision Stamping and Injec�on moulding tools with plants and R&D centre in India.

Ÿ They deal with deep drawing parts 6 micron thickness with mastery over quality planning, Measurement Technology, Thermal treatments with inhouse training facili�es.

Ÿ They have a fully automa�c ware house and man less processes.

L-R: Mr Swapnil Vyas, Mr Iman Singh, Mr Ma�hias Reimann, Mr. Ralf Lipka, Mr Hari Ganesh, Mr Aja Shah, Mr Ravichandran, Mr Falgun Desai, Ms Jayashree Das at Sona BLW, Munich.

The Champion's Compe��on 2015 28 September 2015, Chennai

Kaizen Conference cum Compe��on is organised by CII-TPM Club India in conjunc�on with TPM Na�onal conference every

year. In 2015, TPM Club India organised 4 kaizen conferences and 2 circle compe��ons. To mo�vate the winners of these

conferences / compe��ons, “The Champion's Compe��on 2015” was organised on 28th September 2015 at Hotel Hilton,

Chennai. 23 kaizens and 15 Circles competed for the Kaizen Championship Trophy and Circle Championship Trophy

respec�vely. 3 trophies were given in the Kaizen category and 2 trophies in the Circle category for the year 2015.

CIRCLE CHAMPIONSHIP

Winner Company Topic

1st Winner Bajaj Auto Ltd.Chakan

Planned Maintenance

2nd Winner Eimco Elecon(I) Ltd. Planned

Maintenance

3rd Winner Raychem RPG Pvt.

Ltd, Vasai Kobetsu Kaizen

Runner up Company Topic

Runner up 1 Harita Fehrer Ltd. Kobetsu Kaizen

Runner up 2 Endress+Hauser

Flowtec India Pvt. Ltd Planned

Maintenance

Runner up 3 Raychem RPG Pvt.

Ltd, Halol Jishu Hozen

Runner up 4 Godrej & Boyce Mfg.

Co. Ltd. - PES Quality

Maintenance

Runner up 5 Badve Engineering

Ltd., Unit-16 Quality

Maintenance

KKAAIIZZEENN CCHHAAMMPPIIOONNSSHHIIPP

Category Winner Runner-up

Restorative Marico Ltd, Pondicherry

Varroc Engineering Pvt Ltd, Plant IV

Aurangabad

Renovative Godrej & Boyce Mfg Co.Ltd. PED

Mahindra & Mahindra Ltd, Kandivili

Innovative TTK PRESTIGE

Limited Badve Auto Comps

Pvt.Ltd, Plant 3

Break Through

Mahindra Vehicle Manufacturers

Ltd, Chakan

Indian Oil Corporation Limited, Barauni

Refinery



Harita Ferher announced TPM implementa�on in its Pune plant during September 2014.Manager Model Machine Ac�vity

started on PUA line (Foaming line) with the support from CII TPM Club of India under Mr. Biju K Raj - Counselor TPM Club . A�er

successful Manager Model machine phase, TPM was Kicked off companywide on 15th October 2015.During Kick off, Harita

Ferher Group President Mr. Giridharan unveiled the TPM policy and declared the results achieved on Manager Model

Machine. Immediately a�er Kick off Mr. Giridharan announced TPM implementa�on in their Chennai and Hosur plant under

the guidance of Mr. Biju K Raj.

The Harita Pune team under Mr. Chandra Mouli ( GM- Opera�ons) has achieved considerable results in the MMM shown as

below.

TPM Kick off Harita Ferher Ltd , Pune

N R L



TPM Kick off Numaligarh Refinary Ltd, Assam

Numaligarh Refinery Limited, a subsidiary of M/s. Bharat Petroleum Corpora�on Limited, is a Govt. of India Enterprise under

Oil & Gas Sector. Other share holders are Oil India Ltd. & Govt. of Assam. The Founda�on stone of Numaligarh Refinery Ltd was

laid in Numaligarh, Assam in 1992 as per the Assam Accord in 1985. Refinery and its marke�ng facili�es was commissioned in

2000.

Salient Highlights of the Company:

Ÿ Highest Dis�llate Yield amongst Oil refineries in the Country

Ÿ Energy Consump�on among lowest in Industry: 3 CHT awards in 2013

Ÿ Over 12.11 years of LTA free opera�ons: 23.2 million LTA free manhours on 12.02.15

Ÿ Zero discharge of effluents.

Ÿ Non-illumina�ng ground flaring system

Ÿ Sustained profitability since start of commercial opera�ons

Ÿ Gross Refining Margin (>$10/bbl), amongst highest in the Country.

Ÿ Over 3-fold increase in Net Worth (Rs 929 cr in 2001-02 to Rs 2,991 cr on 31.3.14)

Ÿ Since incep�on, all business processes driven by ERP

Ÿ Advance Process Control through DCS and Terminal Automa�on

Ÿ Extensive LAN / WAN u�liza�on

Ÿ Perks / Benefits / A�endance / Leave / Travel all online

Ÿ B2B transac�ons e-commerce with OIL, ONGC, BPCL, IOCL, & HPCL

Ÿ 100% e-procurement cycle for tenders above Rs 5 lakhs, e-auc�on under implementa�on too

Ÿ Payment made and received through NEFT / RTGS

Ÿ Online bill tracking and job applica�on processes

Recent Awards:

Ÿ Ramakrishna Bajaj Performance Excellence Award 2014 by IMC.

Ÿ Sarva-Shreshtha Suraksha Puraskar 2014 by Na�onal Safety Council.

Ÿ Genentech Environment award 2014 for Refinery - Gold Category

Numaligarh Refinery started its TPM journey on 13th March, 2014 under the guidance of Mr.S.Narasimhan, Sr. TPM Counselor

& Mr. Biju K. Raj, TPM Counselor, TPM Club of India, CII Ins�tute of Quality, Bangalore choosing en�re ground floor area of

Sulphur Recovery Block (SRB) as Manager Model Plant (MMP) where it undertook implementa�on of 3S and JH steps-0, 1, 2 &3

ac�vi�es. Management representa�ves from various departments took part in the ac�vi�es of MMP which was a Trainers

Training Program for implementa�on of TPM in en�re NRL in forthcoming days.

Subsequently, it chose Warehouse-1 as Manager Model Office (MMO) on 25th September' 2014 and started implementa�on

of 1S, 2S & 3S. It was an auspicious day for NRL on 13th February, 2015 when it celebrated TPM Kick Off successfully.

Further to audits at MMP and Warehouse-1, Mr. V.T. Moorthy, Assessor, appointed by CII, formally announced successful

comple�on of MMP and eligibility of NRL for expanding TPM ac�vi�es to all its units and offices. Mr. P. Padmanabhan, MD, NRL

kicked off a football symbolizing spreading of TPM ac�vi�es amongst the en�re organiza�on.



TPM Kick Off TPM Kick Off

PERFORMANCE INDICATOR UOM

BMMar’14

Target / Actual

ACTUAL ACHIEVEMENT % Improvement on

BM

Apr’14

May’ 14

Jun’14

Jul’ 14

Aug’ 14

Sep’ 14

Oct’ 14

Nov’ 14

Dec’ 14

Jan’ 15

Feb’15 till

12th

PProductivity

Plant Availability % 98

T 100 100 100 100 100 100 100 100 100 100 1002

A 100 100 98.6 100 100 100 100 100 100 100 100

Q Quality

H2S Content in SG/ SW

PPM 10/10

T 6.5 6.5 6.5 6 6 6 6 6 6 6 635

A 6.5 6.5 6.5 6.5 6.5 6.45 6.45 6.45 6.44 6.43 6.43

T 9.5 9.5 9 9 9 9 9 9 9 9 910

A 9 9 9 9 9 9 9 9 9 9 9

C Cost

Defective Steam traps

Rs/Kg/hr

67200T 3 3 3 3 3 3 3 3 3 3 3

99A 31200 9600 8400 6000 4800 4800 4800 4800 1200 .600 600

DDelivery Processing

of Feed%

100 T 100 100 100 100 100 100 100 100 100 100 100100

A 100 100 100 100 100 100 100 100 100 100 100

S SHE

Injury N0 0T 0 0 0 0 0 0 0 0 0 0 0 No

injury maintai

ned

A 0 0 0 0 0 0 0 0 0 0 0

Minor FireNo 2/Yr

T 0 0 0 0 0 0 0 0 0 0 0

A 0 0 0 0 0 0 0 0 0 0 0 100

MMorale

Kaizen suggestionsCum.

No 0T 1ph 1ph 1ph 1ph 1ph 1ph 1ph 1ph 1ph 1ph 1ph

A 1 5 7 7 16 16 18 28 31 35 56 5.6 K

OPL Cum. No 0 A 0 0 3 8 9 9 12 12 21 38 46 4.6 K

TPM MANAGER MODEL PLANT – RESULT SUMMARY



Audit at MMP

Field Presenta�on on Kaizen

Audit at MMO – Warehouse


Mr. P. Padmanabhan, MD, NRL throwing off the Ball to mark TPM implementa�on in en�re Refinery

JH Circle Leaders taking Oath

Mr. P. Padmanabhan, MD,NRL releasing TPM Hand Book


For more details on TPM programmes of CII-IQ, please contact Jayashree Das, Deputy Director, CII Ins�tute of Quality, Near Bharat Nagara, 2nd Phase, Vishwaneedam Post, Magadi Main Road, Bangalore- 560091; M: + 91 99019 71214; E:

[email protected]; P: +91 80 23289391/7960; W: www.cii-iq.in, www.tpmclubindia.org


Programmes Jan Feb M Apr May Jun Jul Aug Sep Oct Nov Dec

TPM Kaizen Conference Gurgaong

aonChennai Pune

TPM Na�onal Conference Bangalore

TPM Champion Trophy

TPM Circle Compe��on HaridwarAurangab

ad TPM Facilitators Course

3M Conference Delhi

Workshop on Deployment of Jishu Hozen (28-29

Blr)Pune Chennai

How to improve Business Compe��veness through

KK Methodology

Workshop on Quality Maintenance to achieve Zero

Defect StatusPune Delhi Pantnagar

Semin on Developing Circle Leaders Chennai Delhi

Semin on Visual Management

Workshop on Work Breakdown Structure (North) Chennai Delhi

Workshop on Why-Why Analysis Bangalore Delhi Chennai

Workshop on Reliability Centered Maintenance

Workshop on Streamline the Manufacturing Process

for Be�er Produc�vity & Organisa�on Growth

(22-23

Chn)Pune

Workshop on 5S -Efficiency Through Basics 5 S

Prac�cesPune Hosur Delhi

PFMEA Chennai

Semin on Enhancing Profitability through HR

Interven�onGurgaon

Achieving Zero Break Down: Workshop on Planned

MaintenanceChennai Pune Bangalore

TPM Awareness Seminar (25-26

Blr) (Hyd) Delhi

Workshop on Jishu Hozen in Assembly Lines Pune North

TPM Study Tour Gurgaon Chennai (North) (South)

Workshop on Line Balancing in Assembly Line2-4

Bombay

Workshop on JH Step 4 Haridwar Chennai

Workshop on Elimina�ng Losses through Makigami

Analysis (Process Flow)Pune

Workshop on Produc�vity Improvement through

OFFICE TPMChennai Bangalore

Semin on Profitability Enhancement Program Gurgaon

Innova�on in Mfg Qlty Products to World Class

Standd

Coimbato

re

Tentative Calendar of TPM Club India for the Year 2016

Progress @ TPM - CII-IQ · 2017-03-06 · Progress @ TPM Newsletter from CII Tpm Club India ......

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