Progress @ TPM Newsletter from CII Tpm Club India Newsletter December 2015 Volume - 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 beer than 2015. Thank you for your support, trust and confidence put in CII TPM Club India. Parcipaon in the club's acvies is increasing year on year and each of you is contribung to the vision “Make In India” of our Honorable Prime Minister. Using good manufacturing pracces is at the core of this vision & TPM is one of the key pracces to be globally compeve. 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 Compeons and Naonal Conference. 4 Kaizen conferences, 2 Circle compeons and a Naonal 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 indicaon 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 locaons hosted a Kaizen Conference for the first me. The response was stupendous. We thank the members for their unring support to make these conferences a great success. This year, we introduced the Champions Compeon to recognize the best of the best from the winners of our Kaizen conference and Circle Compeon. 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 parcipants for making this a great success. New TPM cerficaon 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 adopng TPM methodologies. We hope that many more companies would check their level of Compeveness in their TPM journey by ulizing this assessment tool. The response to the poster compeon, which was re-launched this year, gathered good response. The winners were felicitated at the TPM Naonal Conference. Apart from this, we also organised the first Internaonal Mission on Manufacturing to Germany to expose the members of the mission to the best German manufacturing pracces. 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 Compeon Aurangabad Kaizen Conference & Compeon Reliability Centered Maintenance Workshop on Why-Why Analysis 25th Kaizen Conference cum Compeon Pantnagar Kaizen Conference 15th TPM Naonal Conference CII IQ Manufacturing Mission to Germany The Champion's Compeon 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 Sharma Chairman, CII TPM Club India Chief Execuve, Agri and Allied Businesses, Members of the Group Execuve Board, Mahindra and Mahindra Ltd
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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-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
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
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
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: