act acma foundation cluster journey of 16 months april 2013 16 april 2013 17 o p kandwal dy....

April 2013 15www.acma-act.in

Nipman Fastener Industries Pvt. Ltd.HARIDWAR

Nipun Malhotra, Executive Director

Our journey with ACT/ACMA started in year 2004 since all our three locations at Ghaziabad, Manesar and Haridwar have been part of ACMA Foundation Cluster/Advanced Cluster programs. The ACT/ACMA Cluster programs have helped foster company wide awareness and training through building world-class capabilities and practices within the team. This is important to “Give Our Customers The Best” on continual basis for long term success of our organization in the changing global market scenario.

Amit Shriwastav, CEO, ACT Foundation Cluster 7

We started our journey with ACT/ACMA Foundation Cluster in Oct-2011, under the guidance of Senior Counselor Mr. K R Bhoopalan and Mentor Mr. Rakesh Gupta who provided us training on sustenance of KPI's i.e. 5S, TEI, Safety, Quality Performance etc. Monthly Review Meetings (MRMs) and Model Plant visits have strengthened our belief that learning never comes alone, it’s always learning by sharing. We have observed a remarkable difference in our day to day management. Thanks to the cluster program.

ACT ACMA Foundation Cluster Journey of 16 Months

Achievements of ACT ACMA Foundation Cluster 7The impact of the program can be seen in the continuous improvement of the 5S score through the journey of the cluster program. At the start of cluster program we had our Plant 5S score of 68 - 56. Thanks to the ACT ACMA ROAD MAP and Our Senior Counselor Mr. K R Bhoopalan’s guidance and valuable inputs through Class Room Training and GEMBA visit that we today have a Plant 5S score of 75, in addition to Increasing Employee Involvement Trend, Declining SIN score & Internal PPM Trend.

It’s not only through the Training but we have also learnt a lot from Monthly Review Meetings (MRM), conducted regularly, giving us the opportunity to visit world class manufacturing facilities. The Distinctive Inputs on Various Topics by our Mentor Mr. Rakesh Gupta have also helped us go a long way.

We hope this Journey of Learning by Sharing continues day after day for Nipman and all the other organizations that have been part of this cluster.

Shining Examples:

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April 2013 April 201316 17www.acma-act.in www.acma-act.in

O P KandwalDy. CoordinatorACT Foundation Cluster 7 Nipman Fastener Ind. Pvt. Ltd.Haridwar, Uttrakhand

Awarded Best Supplier by A G Industries Haridwar 2010 – 2011 ACMA Awards: Winner, Quality & Productivity 2011-2012, Bronze Trophy.

Visual Factory Shining

Examples:

Front View Security Gate

Front View Information Center Green Area

Raw Material Receipt Area Material Despatch Area

Rojee Tasha Stamping Pvt. Ltd.Pantnagar, Uttrakhand

S. D. Ganage, Chairman, Ganage Group of Industries

We decided to join the ACMA/ACT Foundation Cluster VII program in Sep-11 to continuously improve in terms of manufacturing and process engineering, aimed at establishing world-class shop floor practices.

After 16 months into this program, I am pleased to witness tremendous changes in the plant. These changes have been possible mainly by changing the mindset of our people across all levels. This cluster has given us the ability to see the invisible and enhance abilities of engineers.

Thanks to our mentor ‘Mr. Rakesh Gupta sir’ & Senior Counselor- ‘Mr. V. K. Sharma’ for their valuable guidance and support for the changes in our organisation and for giving such wonderful concepts to Indian auto component manufacturers.

Prashant Panigrahi, CEO, ACT Foundation Cluster VII

In September 2011, key decision of joining ACT foundation cluster VII program was taken by our Chairman, Mr. S.D. Ganage. Under his dynamic leadership the whole company became a team and decided to work with full enthusiasm.

We started our journey with 5S and Gemba visits, Red tag campaign was practiced all over plant, 3M helped in identifying and eliminating waste - resulting in implementation of Kaizens. The ACT/ACMA Cluster provides a very practical approach, giving all the advantages of global systems. The guidance and support of Mr. V. K. Sharma, Sr. Counselor ACT., motivates our organisation to strive for excellence.


Achievements of ACT ACMA Foundation Cluster 7Energy Conservation-

By the application of transparent sheets, power consumption cost has reduced. In-addition, visibility and circulation of natural air have increased.

Use of Natural Light by Transparent Sheets

Productivity improvement

Through SMED and reduction in MUDA in the production line, productivity of Frame Line as well as BIW has increased. (Through r e d u c t i o n i n u n - n e c e s s a r y movements, waiting losses, over inventory, more cycle time etc.)

Finish Good Super Market

Productivity

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Reduction in PPM

Achieved reduction in Frame rejection PPM from 10000 to 2579.

Major contributing factors for this reduction is up gradation of machines & child parts, correction in dies, improvement in stage wise inspection.

Improvement in sales

In FY 2012-13 the sales has improved from 6.10 Crores to 10.33 Crores. The major contributing factors for increase in sales are: Involvement of every employee in the improvement activities, kaizens, single-piece-flow for frame & BIW, initiation of productivity improvement projects, etc.

SHINING EXAMPLES :

Unhygienic condition in press shop

Before After

Improvement in material handling system

Mayank Dixit CoordinatorACT Foundation Cluster VIIRojee Tasha Stampings Pvt. Ltd.

Sale

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Condition improved


April 2013 21 www.acma-act.in

Besides improving operational performance, the cluster program aims to enhance the capability and competence of the employees of company. This program also provides a platform of shared learning that helps build better competencies among team members.

Main achievements after joining foundation cluster are briefly summarized below -

Reduction of Plant Preparation Time

This has been done by sorting and scrapping unwanted material, systematic arrangement and improved visualization. This resulted in huge saving of the shop-floor space and opened new avenues for better storage of required items.

Improvement in Total Employee Involvement & 5S

We have taken initiatives for achieving Total Employee Involvement by training, documentation and implementation of suggestions, Shining Kaizens, SGIA projects, my machine campaign / PM Initiatives and countermeasures on unsafe conditions. We have started monthly awards for the employees who are contributing in these improvement projects. In addition, the best performing employees are felicitated during monthly CEO meet.

Sandhar Components (A unit of Sandhar Technologies Ltd.)Bawal

Sudhir Kumar Rana, Vice President, Operations

In these testing times of constantly changing market and business environment worldwide, a change in mind-set of the organisation’s employees, at all levels, is of utmost importance to emerge a winner and become a world-class manufacturer.

After 16 Months into the ACT/ACMA Foundation cluster program, I am pleased to witness that there have been radical changes in the company. These changes have been possible mainly by changing the mindset of all employees across all levels. We indeed give our special thanks to Mr. V. K. Sharma (Sr. Counselor ACT), who enabled us to transform our organization and reach a higher level. In addition, the expert guidance given by Mentor Mr. Rakesh Gupta has helped Sandhar to become a better company.

Sudesh S. Kavathekar, CEO, ACT Foundation Cluster

A great learning experience and change in paradigm helped individuals as well as company in all aspects of day to day working. This journey helped understand how small things can lead to great innovation. It is said that knowledge shared is knowledge increased. We have already started visualizing the benefits of joining this cluster program i.e. major change in the mind set of all employees, maintaining positive attitude, inculcating ownership, system oriented approach, consistent level of performance in quality and quantity, enthusiasm for continual improvement and customer satisfaction - resulting in more business.


Achievements of ACT ACMA Foundation Cluster 7

Productivity ImprovementProductivity improved by 25 % through implementation of auto spray in high pressure die casting and machine shop area. We achieved highest production (shots per shift) in Jan’13.

BEST ZONE FEB.2013 BEST KAIZEN FEB.2013 BEST OPERATOR JAN.2013

ITR ImprovementITR improved from 17.49 to 35.49 by way of increased control on raw material in-warding and close coordination with various functions. SMED Concepts were given a major thrust during this phase. Die setups were categorized into various segments as a first step of improvement and then the actions were initiated to reduce the changeover times in prioritized manner.

GO GREEN INITIATIVE

It is a journey and not the destination for us. ACT Cluster has given us the path and the foundation. We are on our way to excel.

Hitesh ChopraCoordinator ACT Foundation Cluster 7 Sandhar Components, Bawal

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MANUAL SPRAY AUTO SPRAY

Online Trimming Online Fettling Online Inspection


April 2013 23April 2013 22

With the cluster program we have achieved a better TEI. Also the culture change across various levels in the organization has happened resulting in a overall better workplace.

The SGIA projects initiated through this program have had a great impact on the employee morale.

The continuous involvement of the various teams in the cost savings activities through the VAPCO improvement projects has yielded good results and also this has provided good learning to employees.

The visits to various cluster companies and the MRMs have provided a good scope for cross learning platform. It has provided us with learning by seeing and learning by practicing.

This program has helped the team with visits to model companies and has provided with the insight on the industries’ best practices and the methods to implement and more importantly sustain them.

www.acma-act.in www.acma-act.in

Stumpp Schuele & Somappa Springs Pvt. Ltd.Gurgaon

Satish Machani, Managing Director

Our company was fortunate to be part of the First ACT Foundation Cluster that was conducted during early 2000. We had 3 plants at that time. Though there was lot of scepticism in the beginning, all the 14 cluster members quickly realized that this was the only way forward to stay in this competitive game. In particular for us, we changed from being unionized lethargic workforce to a dynamic and enthusiastic one. Our globalized customers today see that we are as good as any other spring maker in the world, if not better.

Our Gurgaon operations started at the new location about 4 years back. We heard about the launch of 7th Foundation Cluster, for me it was almost automatic decision to enroll my Gurgaon Unit to this wonderful program. I am happy to say that my factory is today unrecognizable from 16 months ago and all for the better. The entire factory is full of buzz and vibrations led well from the front by my Gurgaon unit leaders. It's now a challenge to sustain these efforts to realize continued benefits.

Manoj Tandon, CEO, ACT Foundation Cluster

ACT Foundation Cluster 7 program has brought great learning for our team. This cluster has helped individuals as well as the company to improve in all aspects, especially in day to day working - by following Daily Work Management (DWM). It has also helped us in improving the TEI (Total Employee Involvement).

The foundation cluster journey has taught us better space utilization which is the most expensive resource in the present scenario. We have already started visualizing the benefits of this cluster program.

The customer continually demands better quality product at a reduced price. This leaves us with no other option but to reduce the conversion costs - through innovations, however small they are. The constant thrust on the VAPCO improvement projects is helping us move in the right direction.


Achievements of ACT ACMA Foundation Cluster 7

Customer Rejection Suggestion Trend is improving

We have improved ITR.

Shining Examples:

Only Documents File kept in file rack Cards other documents Kept in File rack

Gang Way & Not FIFO maintain in R/M Store Clear Gang Way & FIFO maintain in R/M

Bike Parking area not defined Bike parking area made by cement Concrete

P. ThirumalCoordinator ACT Foundation Cluster7

V K SrivastavaDy. Coordinator ACT Foundation Cluster 7

Before After

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We are a developing country and we are very proud for our companies who believes -Quality is directly proportional to Cleanliness across the company from inside and outside . Company should be Hospital Clean for all times. This should be a principle of company’s top management .

First Cleanliness and then Business ( Vise a versa is difficult )

Counselor - Company Bonding- Employees Love Joyful Shop-floor

VE Commercial, Dewas – First cleanliness then business ( Part of ACT Advance Cluster -3 )

Compiled by Deepti Panikker ACT

From Left : Mr. T. Nagappan , CEO , Mr. Dinesh Vedpathak , Principal Counselor ACT , Mr. Ganesh Prabhu , Maintenance Head , Mr. Ranjan , Head QA and Mr. Manimaran , Plant Head .

IM Gears Pvt Ltd , Chennai ( Part of ACT Engineering Excellence Cluster – 1, Indian Production System )

Samarth Engineering Co. Pvt. Ltd., Jamshedpur (Part of ACT SME Cluster ) Work floor , a personalize space

From left : Mr. Tapas Sahu ,ED, Highco, Mr. Nayak, Mfg.Head ,Mr. K.P.S. Raghuvanshi , Sr. Counselor ACT and Mr. Killol Kamani, Chairman, ACMA (ER ) & MD M/S. Samarth Engineering Co. Pvt. Ltd, Jamshedpur

Menon & Menon Ltd , Kolhapur ( Maharashtra ) .. Safety starts at TOP ( Part of ACT Engineering Excellence Cluster – 2 , Indian Production System ) Working conciously & courageously, emerging as winners against all odds

Enjoying the environment at the workfloorWABCO India Ltd , Chennai - Brightness at machine bottom ( Part of ACT Engineering Excellence Cluster - 1 , Indian Production System)

ACT - Give opportunity to Explore potential of employees A team of enthusiasm and joy

ACMA – ACT Team - Come together to give more


WIL

• Five decade old company.

• Leading manufacturer in India for Steel Wheels.

• Collaboration with Titan UK and Technical alliance with Topy Japan.

• Six Plants across India.

• Suppliers to all major OEMs in India.

• Manufacturing range from 8”to 51” dia steel wheels.

• Pioneer in Air Suspension products in India.

• Sole Manufacturer of Forged Aluminium Wheels and Wire Wheels in India

Marketing Office:Padi, Chennai – 600 050. Phone No. – 26234300 / 2625 851www.wheelsindia.comemail:[email protected]

PASSENGER CAR

TUBED WHEEL

FORGED ALUMINUM

CONSTRUCTION


Know Our Team

Tell me about yourself, what are your strengths & weaknesses?

What do you regard as the significant achievement in your life?

What is the one thing you would like to change about yourself ?

I have worked in hospitality Industry as a Banquet Sales Executive. Joined ACMA in Sep, 2011 as Executive in ACT {Division of ACMA}. I am responsible for the secretarial and administration work. Currently pursuing Post Graduation in Human Resource Management. My strengths are : my life partner, confidence, honesty, willing to learn and accept suggestions to do my job better. My weaknesses are believing people blindly, emotional attitude & extra thinking.

Success in life with honesty, happiness & continuous learning.

LIFE IS TOO WONDERFUL TO BE SPENT WORRYING.

What makes you angry?

Why did you choose this profession/field?

How do you deal with criticism?

Did you have any failures in your life?

What have you learnt from your failures?

People who are untrue, misuse authority and underestimate others.

Every career has its Unique Selling Point. And the person attempting it also has a set of strengths and weaknesses to handle it. Since I am passionate about what I choose, I am on the right path to build my career in this particular field.

“You can’t please everyone, so just please yourself. You are your best critic. Some people are just not going to like you. Accept it.”

Yes , of course but they were the pause in life not the full stop.

I have learnt to analyze myself, find out shortcomings and these become areas of improvement.

Sakshi KarkamkarExecutive Incharge of Secretarial & Administrative Work ACT, Pune Office

Farewell

Dear Friends,

Mr. K.N.D. Nambudiripad retired from his services in ACT-ACMA in March’2013 after completing over 12 and a half years. He was bid farewell at ACT headquarters, Pune on 15th March’2013 in a ceremony attended by ED-ACMA and ACT/ACMA Pune staff. We wish Mr. Nambudiripad a very happy and peaceful retired life.

K.N.D.NAMBUDIRIPAD – A BRIEF.

Mr.Nambudiripad was born in an Aristocratic Nambudiri family in Kerala on 19th July 1938.

Prior to joining ACT, he had over 35 Years of experience in, Service, Sales, Marketing, Project Engg. and Business Development – of Products including - Diesel Engines, Pump sets, Shot blasting plant & machines, Pressure Die casting Components, Power & Mechanical Steering Gear Systems. He was associated with - Walchand Group - Cooper Engineering Ltd and Firodia Group- Jaya Hind Industries Ltd. and ZF Steering Gears India Ltd.

His assignment with ACMA began from July 2000. Mr.Nambudiripad represented ACMA in the Standard Formulation Committees (AISC, CMVR-TSC, BIS etc.) and interacted with members of ACMA and Testing Agencies, relating to the formation of various automotive Standards.He also coordinated with ACMA members and ARAI regarding WP29-GR activities.

Mr.U.S.Harite, who joined ACT in March’2013 will henceforth be responsible for all activities hitherto taken care of by Mr.Nambudiripad. We welcome Mr.Harite and wish him all the success in his endeavors at ACT-ACMA.

An ACMA Non member Company


ACMA Centre for Technology, in association with HIDA (Human Resources and Industry Development Association, Japan) and AOTS (The Association for Overseas Technical Scholarship, Japan), has organized three training programs in Aurangabad, Ahmedabad and Vadodara. Through these programs a total of 90 participants have been trained in Japanese production techniques. The city-wise program details are as given hereunder :

1. Training on Next Level of Gemba Kaizen in Aurangabad29-30 Jan, 2013, Total Participants: 29 Nos.Faculty: Mr. Norio Suzuki, President of Consulting Bell Office Private Ltd.Chief Guest: Mr. Shekhar Thorat- Executive Director, Metalman Auto Pvt. Ltd.

2. Training on Basics of Japanese Productivity ImprovementAhmedabad: 21~23 Feb, 2013, Vadodara: 25~27 Feb, 2013Total Participant: 61Faculty: Mr. Susumu Takahashi, Consultant, Intelligent Production Japan Inc.Chief Guest: Mr. Ranjeet Gupte, DGM (SQIG), Tata Motors Ltd.

During this training, participants got the opportunity to analyze the necessity of initiatives aimed at continuous improvement. They also got opportunity to visit Sanjeev Auto Parts Manufacturers Pvt .Ltd, in Aurangabad, Rucha Engineering in Ahmedabad and Munjal Auto in Vadodara. These plant visits provided an opportunity to the participants to witness the best practices followed by the model companies.

The overall feedback received from the participants was excellent. ACMA Centre for Technology (ACT) is in discussion with HIDA/AOTS Japan for organizing more such programs in India.

ACT – HIDA – AOTS Training Program Aurangabad: 29-30 January, 2013Ahmedabad: 21~23 Feb, 2013Vadodara: 25~27 Feb, 2013

Launch of “Quality Improvement Project” for Tata Motors' Sheet Metal Suppliers11th February, 2013, Pune

ACMA Centre for Technology (ACT), Pune office launched a “Quality Improvement Project” for six sheet metal suppliers of Tata Motors Ltd, Pune. This 12 months project will focus on “Quality Deliverables”. Mr.Srivats Ram, Chairman ACT and Mr.S.B.Borwankar, Executive Director, Tata Motors Ltd. were present during the launch ceremony organized on 11th February, 2013.

This project will be counseled by Mr. K. G. Kutty, Counselor ACT under the guidance of Mr. K. Chandrasekhar, Principal Counselor ACT. Monthly Review Meetings (MRMs) will be held in Tata Motors’ premises.

Mr. Borwankar, Executive Director , TATA Motors Mr. Srivats Ram, Chairman ACT lighting the lamp

ACT NewsDecember 2012 - March 2013

April 2013www.acma-act.in 31

Completion of Certified Course on Train the Trainer – Productivity Improvement, 2nd Batch

To cater to the needs of the auto component industry, ACMA Centre for Technology (a division of ACMA) regularly organizes distinctive training programs aimed at closing the gaps between existing and required skills. One such certificate program on “Train the Trainer – Productivity improvement” was organized in Oct’2012. This training involved 5 full days of class-room sessions spread over 5 months, from October 2012 – February 2013. The venue of the program was ACT Headquarters, Pune. Mr. Dinesh Vedpathak, Principal Counselor, ACT was the faculty for the Training Program. 32 participants from the auto component manufacturers’ fraternity were part of this journey.

During this session spread over 5 months, the “Train the Trainer Program” helped the participants to understand the finer points of being a trainer and the role that they play in the larger scheme of the organization’s learning process. Participants have gained a deeper knowledge about productivity improvement through concepts of Flow Manufacturing, Single-Piece-Flow, Line Balancing, Low Cost Automation and Integrated Quality through Process Improvement.

The structure of this program has been thoughtfully designed for successful implementation. The intensive class room sessions held for one day every month were followed by practical study, review and follow up thus ensuring thorough understanding.

Pre-training Test and Post-training test was conducted for this course. Pre-test average score of 44 % improved to average score of 98% after training.

The closing ceremony of the program was held on 27th February, 2013. Mr. Srivats Ram, Chairman ACT, handed over “Trainer Certificates” to the participants.

Mr. Srivats Ram, Chairman ACT, addressing the participants

Mr. Dinesh Vedpathak, Principal Counselor,

ACT addressing the participants

All participants made presentations on the project completed during this period at their respective companies and the benefits accrued. The presentations were witnessed by CEOs and owners of participating companies. Apart from major breakthrough improvements in layouts, space reduction and quality improvements, monetary savings of more than Rs.6 Crores were achieved by the 2nd Batch participants.

Mr. Srivats Ram- Chairman ACT congratulated all participants and companies. He acknowledged three major challenges faced by the industry : (1) Rising quality requirements from customer (2) Rising labor cost and (3) Scarce availability of skilled labor in industry. This course is one of the means to control cost and improve productivity + quality by building in-house competencies.

This program is an outcome of more than a decade long engagement of ACT with ACMA member companies in the field of manufacturing excellence.


AISC/CMVR-TSC/BIS.

AISC

Meetings took place during the reporting quarter:

1) 42ndAISC committee meeting at ARAI Pune

2) BIS TED-4 sectional committee meeting at CIRT Pune

42nd AISC meeting was held in ARAI on 23rd Nov, 2012 under the Chairmanship of Shri. Shrikant Marathe, Director ARAI.

Major points deliberated -

1. AIS-062 (Revision 1), Performance requirements for Lighting & Light Signaling devices , Agricultural Tractors

Ø The matter was deferred to next meeting.

2. AIS-17 (Rev1, part 1), Procedure for TA & Certification for vehicles for compliance to CMVR.

Suggested to study ECE directives for variants & versions of four wheelers.

3. AIS-113, Automotive Trailer code:

The draft standard is finalized with Implementation in 2 years along with Truck code.

4. AIS-005 / IS: 15140, Safety belts.

The proposed Amendment approved. Same would be forwarded to BIS - TED 6 for action.

5. AIS-015 / IS: 15139, Safety belt Anchorages.

The Amendment is under wide circulation. Component Manufacturer’s views are expected.

Suggested to formulate Part-2 standard to cover Installation requirements.

6. AIS-038,039,040, 041, 049,-Standards for battery operated vehicles.

Modified Standards in line with panel discussions will be worked out by ARAI, Maruti, M&M and GM.

It will be put on ARAI Website.

7. AIS-120 External projections for M1.

Panel needs final discussion on lead time before placing in the Next AISC.

8. Discussed status of Alignment of national standards with GTRs and implementation w.r.t:

Door latches & Hinges

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Motorcycle brakes - Standard on procedure for measurement of PBC will be finalized after VRDE test track is ready

Safety glazing – TED 6 will work on this after AIS-118 IS FINALISED.

Motor cycle controls & indicators, tell-tales - To be finalized and placed in next AISC.

9. Provision for dealing with Amendments, revision and changes in approved / notified standards-

Draft standard will be finalized after BIS comments received.

ARAI will prepare Draft Implementation method.

10. P r o g r e s s o n n e w a r e a s o f wo r k , D r a f t Amendments/Comments on existing AIS was briefed by respective Panel Chairmen.

Retro-fitment of Hybrid Electric Kit, CNG / LPG Retro-fitment rules, Intelligent transport system ( ITS ), Speed limiting devices, Defrost & Demist systems, Spray suppression systems, Bus code, Requirement of School Buses, etc.

Mr. Nambudiripad of ACMA made a presentation for MEI with the support of MEI Executives on ‘BRAKE LINING WEAR SENSOR’ developed by MEI.

Eighth meeting of BIS TED 2, Auto Body, Chassis, Accessories, was held at CIRT Pune on 22nd November, 2012 under chairmanship of Mr. D. P. Saste, CIRT.

The Chairman emphasized in his opening remarks that crash related standards are becoming very important day by day in view of the safety of occupants and pedestrians. Hence, it is urgent to take up the same in TED 6 and formulate Indian Standards.

Committee deliberated on composition of Sectional committee and issues arising out of the Minutes of last meeting. The following Draft Amendments were finalized for printing.

1. TED6 (723) 1st Amendment to IS 15139 : 2002 – Automotive Vehicles – Safety Belt Anchorages – Specification.

2. TED 6 (906) Amendment No. 1 to IS 15546:2005 Automotive vehicles - Seat, their anchorages and head restraints for category M1 – Specification.

BIS


Letters to the editor

Yash Vardhan, C.E.O., Neolite Zkw Lightings Pvt. Ltd, Bahadurgarh

The ACT foundation Cluster is a great platform to achieve excellence. We have completed 1st year of cluster and achieved enormous improvement in our factory such as 5-S, VAPCO, structured problem solving by using problem solving tools, WIP management, BOP parts management, reduction in breakdown times, improvement in productivity etc. We created many model machines and Assembly lines which have been appreciated by our customers as well. We managed a lot of saving in electricity consumption, heat loss etc. We also managed to optimize and re-deploy human resources in different process areas. We have read the “ACT now” magazine circulated by our counselor Mr. V. K. Sharma and found it very informative. We got a lot of innovative ideas and best Manufacturing practices shared by the other cluster companies that can be implemented in our factory. We sincerely thank our counselor Mr. V. K. Sharma and Mentor Mr. Rakesh Gupta for guiding us to move towards excellence.

Mr. Avinash Sawalka, MD Sawalka.KEL, Kolkata

Initially, we (Sawalka KEL Pvt. Ltd., Kolkata) were hesitant to join the ACT cluster program, as a supplier in Eastern India where there are very few players. Upon joining the one year QUALITY CLUSTER program, under the guidance of a very experienced Sr. Counselor Mr.Raghuvanshi, we realised the "potential of change" that the programme brought to our company. It helped us open our eyes to the complacence which had crept in and gave us renewed energy and enthusiasm to question what was being followed as the norm, and adopt better practices.

‘ACT now’ magazine covers very simple but effective live examples that many member companies have implemented & thus achieved break through results. This gives us real boost. The magazine has also been sharing the achievement of ACT Cluster programs which helps readers to properly understand the benefits of this improvement journey.

We wish all the best to the entire ACT now team for disseminating information on best practices implemented in auto industry.

Mr. N.C. Agarwal, PresidentIn August, 2011, the key decision taken to join ACMA Foundation Cluster, the idea was to change the mind set of people from casual to detail and through at all levels. Implementation from grass root level 1S & 2S, Visual displays and improvement through small kaizen like :

• Removal of unwanted items by red tagging.• Installation of Electric plug point with socket• Reduction of bend and joints in compressed air

line.• Tie of electric cable with cable tie in place of

cloth & wire.

• Termination of earthing wires with proper thimble.

• Easy to read display on machines.• Usage of standard colored bins.• Reduction in MUDA by changing layouts.

Thanks to our counselor Mr. V.K. Sharma and mentor Mr. Rakesh Gupta, they gave us valued guidance in bringing overall improvement in organization. Today we see drastic positive change all over in our organization and I am sure this change wave will continue.In the present issue of this newsletter, we have shared our achievements during this cluster journey. ACT is doing a great job by publishing this newsletter and sharing the best practices for the benefit of entire auto component industry.

www.alliednippon.comAllied Nippon Limited

t f e

A-12 , Site – IV, Industrial Area, Sahibabad – 201010, Ghaziabad, Uttar Pradesh, India +91 120 4539600 +91 120 2896685 [email protected]

April 2013www.acma-act.in

Forthcoming Activities

1. Launch of ACT SME Cluster for NCR Planned in May 2013

2. ACMA Awards 2013Circular released on 16th March, 2013 (Last date to submit applications: 21stMay, 2013)(http://www.acma.in/acmaact/ )

3. Launch of Certificate Course 3rd Batch “ Train the Trainer – Productivity Improvement” ( 5 days spread over 5 Months ) Starting in May, 2013, Delhi

4. Two Days Workshop on “Profit management through inventory control ’’ ( 2nd Program ) May 2013 , Kolhapur

5. Training program “Hands on experience on working on FMEA , SPC & MSA Software”May , 2013, Pune

6. Training program “Managing Production with TOC way ”May , 2013, Pune

7. Training program “Productivity Improvement through Activity Analysis ( Product , Person , Machine ) ”May, 2013, Pune

8. Training program “Advance 5 S - Improving resource efficiency”May , 2013, Pune

9. Launch of ACT SME Cluster for Pune June , 2013, Pune

10. Training program “Cost Reduction by making machines Lean”June, 2013, Pune

11. Training program “Making Chip / Burr free machines from inside ”June, 2013, Pune

12. Training program “Cost reduction through better management of Cutting tools ”June, 2013, Pune

13. Training program “Designing of Contamination free coolant tanks ”June- July , 2013, Pune

14. Training program “Designing of Lean & Self cooling hydraulic Tanks “ June-July , 2013, Pune

15. Training program “Designing of Lean & Self cooling Electrical panels- Without Air conditioning units ”June-July, 2013, Pune

16. Training program “Achieving Dent & Damage free Production”June-July , 2013, Pune

17. Training program “Green Manufacturing – Concepts and ways to Achieve greening of Production”June –July , 2013, Pune

18. Launch of Certificate Course on Train the Trainer “Creation of IPS Trainer ( IPS = Indian Production System )” ( 12 days spread over 6 Months - One day class room session and one day hands on experience at Plant , Full day visit and working at 6 Model Plants in & around Pune ) Proposed in July-Aug , 2013, Pune

1. ACT-AOTS training programme on Next Level of Gemba Kaizen

29th -30th January, 2013, Aurangabad

2. Quality Improvement Project for TATA Motors’ Suppliers

11th February, 2013, Pune

3. ACT -HIDA -AOTS Training programme on Basic of Japanese Productivity Improvement

21st-23rd February, 2013, Ahmedabad

4. ACT -HIDA -AOTS Training programme on Basic of Japanese Productivity Improvement

25th-27thFebruary, 2013, Vadodara

5. One- day Training programme on Identification & Elimination of Wastes

28th February 2013, Bangalore

6. “Certified Course on “Train The Trainer – Productivity Improvement”

October 2012 ~ February 2013, Pune

7. Training Program on Optimization of Metal Cutting Tools in Manufacturing

9th April, 2013, Pune

8. Two Days Workshop on “Profit management through inventory control ’’

19th– 20thApril, 2013, Pune

9. Launch of ACT SME Cluster at Pantnagar

18thApril 2013, Pantnagar

Missed Activities

For participation and blocking your seat in advance, contact or write to :

Mr. Uday Harite , Counselor & Training In-charge , ACT

08149099959, [email protected]

Contact or write for Technical information to :

Dinesh Vedpathak , Principal Counselor, ACT


Mr. Rakesh Gupta, Principal Counselor , ACT


Mr. V K Sharma, Sr. Counselor ACT


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