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 @ TPMNewsletter from CII Tpm Club India
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.
Progress @ TPMNewsletter from CII Tpm Club India
Progress @ TPM | December 2015 3
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.
Progress @ TPMNewsletter from CII Tpm Club India
Progress @ TPM | December 20154
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
Progress @ TPMNewsletter from CII Tpm Club India
Progress @ TPM | December 2015 5
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
Progress @ TPMNewsletter from CII Tpm Club India
Progress @ TPM | December 20156
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
Progress @ TPMNewsletter from CII Tpm Club India
Progress @ TPM | December 2015 7
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,
Progress @ TPMNewsletter from CII Tpm Club India
Progress @ TPM | December 20158
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.
Progress @ TPMNewsletter from CII Tpm Club India
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.
Progress @ TPM | December 2015 9
Progress @ TPMNewsletter from CII Tpm Club India
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.
LEARNING’S FROM THE VISIT:
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.
Progress @ TPM | December 201510
Progress @ TPMNewsletter from CII Tpm Club India
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.
LEARNING’S FROM THE VISIT:
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
Progress @ TPM | December 2015 11
Progress @ TPMNewsletter from CII Tpm Club India
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
Progress @ TPM | December 201512
Progress @ TPMNewsletter from CII Tpm Club India
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.
Progress @ TPM | December 2015 13
Progress @ TPMNewsletter from CII Tpm Club India
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
Progress @ TPM | December 201514
Progress @ TPMNewsletter from CII Tpm Club India
Audit at MMP
Field Presenta�on on Kaizen
Audit at MMO – Warehouse
Progress @ TPM | December 2015 15
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
Progress @ TPMNewsletter from CII Tpm Club India
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
Progress @ TPM | December 201516
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