Application of Industrial Engineering and Productivity Improvement in India.
Thursday, April 30, 2015
Wednesday, April 15, 2015
2nd International Conference on Industrial Engineering ICIE 2013, NIT Surat, 20-22, November, 2013 - Interesting Papers
Identification and Shifting of Bottlenecks in A Radiator Fabrication Line of Transformer Manufacturing Industry Using Theory of Constraints (TOC) Approach: A Case Study.
"AHP-QFD Integrated Approach for Process Selection: Make or Buy"
Saturday, March 28, 2015
Top Companies of India - Productivity and Industrial Engineering Initiatives and Achievements
20 Bharat Heavy Electricals Ltd.
3 Bharat Petroleum Corporation Ltd.
12 Bharti Airtel Ltd.
25 Chennai Petroleum Corporation Ltd.
9 Coal India Ltd.
10 Essar Oil Ltd.
19 GAIL (India) Ltd.
24 HDFC Bank Ltd.
11 Hindalco Industries Ltd.
4 Hindustan Petroleum Corporation Ltd.
14 ICICI Bank Ltd.
1 Indian Oil Corporation Ltd
13 Larsen & Toubro Ltd.
16 Mahindra & Mahindra Ltd.
17 Mangalore Refinery And Petrochemicals Ltd.
23 Maruti Suzuki India Ltd.
15. NTPC Ltd.
7 Oil And Natural Gas Corporation Ltd.
21 Punjab National Bank
22 Reliance Industries Ltd
5 State Bank of India
22 Steel Authority of India (SAIL) Ltd.
18 Tata Consultancy Services Ltd.
6 Tata Motors Ltd.
8 Tata Steel Ltd.
Friday, March 27, 2015
NTPC Ltd. - Productivity and Industrial Engineering Initiatives and Achievements
NTPC looks forward to boost manpower productivity
Sep 23, 2012
The company has a workforce of about 25, 511 people and an installed power generation capacity of 39,174 MW.
The company is aiming to bring down the Man-to- MW (megawatt) ratio -its workforce productivity -- to as low as 0.3 or 0.4 in the coming years.
In 2011-12, NTPC's overall Man-to-MW ratio, excluding JV/subsidiary capacity, stood at 0.74.
In 2006-07 fiscal -- it stood at 0.91 per cent. The ratio was brought down to 0.87 in the next financial year, followed by 0.85 in 2008-09. Further, it fell to 0.82 in 2009-10 and then to 0.77 in 2010-11.
Reflecting the same, the generation of electricity per employee has been on the rise. The figure touched 9.25 million units in the last financial year as compared to 7.99 million units in 2006-07.
The power generator's employee strength, including those at subsidiaries and joint ventures, stood at 25,511 people at the end of March 31, 2012.
NTPC expects to add 14,038 MW in the 12th Five-Year Plan (2012-17).
http://articles.economictimes.indiatimes.com/2012-09-23/news/34040569_1_generation-capacity-ntpc-attrition-rate
International Simulation Conference of India 2015 - Pune
http://indiasim.org/
The International Simulation Conference of India (ISCI) 2015 is the fourth edition of the very successful premier international forum in India for sharing and spreading recent developments in the field of system simulation. This initiative has been taken by Production Modeling India (PMI).
ISCI aims to provide a meeting place for simulation engineers, practitioners, researchers, and vendors working in the area of system simulation across disciplines in industry, service, government, and academia. The conference will provide a forum to discuss research ideas, exchange knowledge and practice, and review advancements in related topics. The last three editions of ISCI together had over 300 attendees, 15 keynotes and 100+ world class presentations.
ISCI was held on 10th January 2015.
Venue of ISCI 2015:
Hotel Le MERIDIEN,
RBM Road, Pune - 411001
Maharashtra [INDIA]
Conference Program Details
The conference consists of keynote presentations, special focused tracks and parallel sessions. The exhibition area includes some of the leading companies in simulation services and software industry.
Technical/research papers and industry case study presentations in sessions in the area of simulation modeling and analysis of complex systems.
Topics Include
Simulation Modeling and Analysis
Agent based simulation
Discrete event and Continuous time simulation
Monte Carlo simulation
Stochastic simulations and approximations
System dynamics simulation
Web-based / Distributed / Grid simulation
Hybrid simulation methods
Simulation and decision making
Simulation and artificial intelligence
Human performance modeling
Random number and random variate generation
Modeling simulation inputs
Model verification and validation
Sensitivity analysis
Design of simulation experiments
Metamodeling and regression
Simulation optimization
Simulation in Practice
Simulation in Manufacturing
Simulation in Services
Simulation in Supply Chain
Simulation in Healthcare
Simulation in Finance
Simulation in Energy and Environment
Simulation of Social Systems
Other general applications of simulation
Location: ISCI 2015 will be held at Hotel Le MERIDIEN, Pune, Maharashtra, India.
Le Meridien Pune is an exotic five-star property in which staying has been an experiencing in itself. It is strategically placed near to the commercial, residential and entertainment hubs of this wonderful city in Maharashtra. The hotel is blessed with extensive ambiance in which lots of modern amenities are obtainable for the guests such as world-class accommodation, scrumptious dining arrangements and more importantly, the warm presentation of traditional Indian hospitality.
Pune: Queen of the Deccan, Oxford of the East, and cultural capital of Maharashtra, Pune is a city with a future that promises to be as interesting as its history. Today, Pune is the centre of traditional Marathi culture, in which education, arts and crafts, and theatre are given pride of place. It has one of India's oldest universities and its numerous colleges attract both Indian and international students, which is probably why it is called the Oxford of the East. Pune is a cosmopolitan city and is now an important commercial centre.
Pune has a temperate climate and is among the greenest urban areas in the country.
Pune is one of the premier industrial centers of India. It is home to one of the world's three largest two-wheeler manufacturers. Other global automobile companies (US & GERMAN) also have huge manufacturing facilities here. Apart from the auto giants, a large number of engineering, electronic and electrical industries have set up base in the large, medium and small scale sectors. The industrial township of Pimpri Chinchwad, adjacent to the main city, is dotted with over 4,000 manufacturing units. This vast and well established industrial base has imbibed the city with a 'professional' ethos and work culture.
Key Note Speaker Profiles
http://www.indiasim.org/Portals/0/image002.png
http://indiasim.org/QuickLinks/KeynoteSpeakers.aspx
Dr. Dhananjay Kumar - CEO & Head (Engineering, Global Project & Business Development)
KLT Automotive & Tubular Products Ltd.
Dhananjay Kumar, Ph.D. has over 29 years of professional experience and out of the same nearly 19 years as profit center head of medium to large corporate MNC across the globe. He has worked in highly diversified sector namely Defense & Aerospace where he was responsible for Advance Composite structural, new Gas turbine engine and also worked extensively in avionics, advance signaling and control system including counter warfare technique. Subsequently, he has lead one of the largest power electronic and joining technology company where he was also involved in diversification and strategy which has led to 100% growth consistently for 3 years. Also worked with infrastructure, process, energy, environment and Special Purpose Machine (SPM) manufacturing company and successfully lead it from front for multi fold growth across the globe.
For last 7 years, working with automotive giant where he has successfully developed the complete platform in MUV, LCV & HCV segment and set up the plant across the world which has consistently given 100% growth on Y2Y basis. For last 3 years, also working on EV program where 1st time 3D solar concept along with all-wheel drive & recycling the thrust using micro turbine is being used all at a time which has potential to bring complete revolution in Mobility solution.
Rajesh Deshpande - Head (Transmission Product Unit)
Escorts Ltd.
Mr. Rajesh Deshpande is presently working with Escorts, Agri Machinery Group, Faridabad and Haryana India as Associate Vice President (Transmission Product Unit). His 23 years of experience includes working in various other automotive industries like: Mahindra and Mahindra Farm Equipment sector, Siemens Ltd, JCB India Ltd. His Academic Qualification includes: M.E. PRODUCTION with Specialization in Industrial Engineering.
He is a Versatile professional having experience of key areas across functions viz. Projects, Strategy Development, Industrial Engineering, Operations, Process Engineering, Capital Equipment / Indirect Material Procurement, Human Resource, Performance Management, Tool room, Production Planning etc.
He is also certified as an "Applicator in Basic MOST" (Maynard Operation System Technique), certified by Maynard institute, USA and Assessor of “Lean Manufacturing practices”, certified by Frost & Sullivan He played a key role in Major capacity expansion project of one of the green field plant and Installation paint shop facility.
http://www.indiasim.org/Portals/0/Alvis.png
Alvis Lazarus - Global Patron & Supply Chain Mentor at ISCEA
Alvis Lazarus is a Global supply chain consultant & speaker with more than a decade of Operations & Consulting Experience in Logistics, Supply chain and Process Excellence. Alvis has worked across multiple sectors - Ecommerce, Automotive, Mining, Retail, FMCG, Manufacturing, IT, and HealthCare. Alvis has managed multiple Supply Chain Programs across APAC, EMEA and Americas regions.
Alvis is a Certified Lean Six Sigma Black Belt and Champion and also a Certified Program Manager.
Dr. B. K. Mohanty - Professor (Decision Sciences)
IIM Lucknow.
Dr. B. K. Mohanty is a Professor in Decision Science Area at Indian Institute of Management Lucknow, India. He received his M.Sc. (Mathematics) from Berhampur University, India, and his Ph.D. in Operations Research from Indian Institute of Technology, Kharagpur. India. He has more than 100 publications in various national / international journals and conferences. His research interest includes Fuzzy Multi-Criteria Decision Making Problems, Electronic Business under Fuzzy Environment, Software Reliability, Fuzzy Logic in Data Mining and Business Intelligence.
Key Speech Topics
http://indiasim.org/QuickLinks/KeySpeachTopics.aspx
'Does Simulation Stimulate Supply Chain?' – Mr. Alvis Lazarus
Supply chain model and structure, SC Models - Ecommerce, FMCG, Automotive etc. What makes Supply chain management challenging and exciting? What is the role of simulation in overcoming key challenges faced by supply chain professionals?
'Highly Automated Automotive Chassis Manufacturing line for A global vehicle platform' – Dr. Dhananjay Kumar
With increasing global competition, quality cost & delivery are three important consideration and highly automated, flexible, robust and accurate manufacturing process is the answer for large variation of models on the same platform. KLT being a world class Chassis manufacturing company and system supplier for many global OEMs, has developed one such manufacturing line in S Africa for Ford Ranger which has not only constantly produced high quality product with large variation consistently in last 3 years but our platform has been adjudged the best vehicle in this category the world over ranging from Asia-Pacific-S Africa to European Union & S America.
The International Simulation Conference of India (ISCI) 2015 is the fourth edition of the very successful premier international forum in India for sharing and spreading recent developments in the field of system simulation. This initiative has been taken by Production Modeling India (PMI).
ISCI aims to provide a meeting place for simulation engineers, practitioners, researchers, and vendors working in the area of system simulation across disciplines in industry, service, government, and academia. The conference will provide a forum to discuss research ideas, exchange knowledge and practice, and review advancements in related topics. The last three editions of ISCI together had over 300 attendees, 15 keynotes and 100+ world class presentations.
ISCI was held on 10th January 2015.
Venue of ISCI 2015:
Hotel Le MERIDIEN,
RBM Road, Pune - 411001
Maharashtra [INDIA]
Conference Program Details
The conference consists of keynote presentations, special focused tracks and parallel sessions. The exhibition area includes some of the leading companies in simulation services and software industry.
Technical/research papers and industry case study presentations in sessions in the area of simulation modeling and analysis of complex systems.
Topics Include
Simulation Modeling and Analysis
Agent based simulation
Discrete event and Continuous time simulation
Monte Carlo simulation
Stochastic simulations and approximations
System dynamics simulation
Web-based / Distributed / Grid simulation
Hybrid simulation methods
Simulation and decision making
Simulation and artificial intelligence
Human performance modeling
Random number and random variate generation
Modeling simulation inputs
Model verification and validation
Sensitivity analysis
Design of simulation experiments
Metamodeling and regression
Simulation optimization
Simulation in Practice
Simulation in Manufacturing
Simulation in Services
Simulation in Supply Chain
Simulation in Healthcare
Simulation in Finance
Simulation in Energy and Environment
Simulation of Social Systems
Other general applications of simulation
Location: ISCI 2015 will be held at Hotel Le MERIDIEN, Pune, Maharashtra, India.
Le Meridien Pune is an exotic five-star property in which staying has been an experiencing in itself. It is strategically placed near to the commercial, residential and entertainment hubs of this wonderful city in Maharashtra. The hotel is blessed with extensive ambiance in which lots of modern amenities are obtainable for the guests such as world-class accommodation, scrumptious dining arrangements and more importantly, the warm presentation of traditional Indian hospitality.
Pune: Queen of the Deccan, Oxford of the East, and cultural capital of Maharashtra, Pune is a city with a future that promises to be as interesting as its history. Today, Pune is the centre of traditional Marathi culture, in which education, arts and crafts, and theatre are given pride of place. It has one of India's oldest universities and its numerous colleges attract both Indian and international students, which is probably why it is called the Oxford of the East. Pune is a cosmopolitan city and is now an important commercial centre.
Pune has a temperate climate and is among the greenest urban areas in the country.
Pune is one of the premier industrial centers of India. It is home to one of the world's three largest two-wheeler manufacturers. Other global automobile companies (US & GERMAN) also have huge manufacturing facilities here. Apart from the auto giants, a large number of engineering, electronic and electrical industries have set up base in the large, medium and small scale sectors. The industrial township of Pimpri Chinchwad, adjacent to the main city, is dotted with over 4,000 manufacturing units. This vast and well established industrial base has imbibed the city with a 'professional' ethos and work culture.
Key Note Speaker Profiles
http://www.indiasim.org/Portals/0/image002.png
http://indiasim.org/QuickLinks/KeynoteSpeakers.aspx
Dr. Dhananjay Kumar - CEO & Head (Engineering, Global Project & Business Development)
KLT Automotive & Tubular Products Ltd.
Dhananjay Kumar, Ph.D. has over 29 years of professional experience and out of the same nearly 19 years as profit center head of medium to large corporate MNC across the globe. He has worked in highly diversified sector namely Defense & Aerospace where he was responsible for Advance Composite structural, new Gas turbine engine and also worked extensively in avionics, advance signaling and control system including counter warfare technique. Subsequently, he has lead one of the largest power electronic and joining technology company where he was also involved in diversification and strategy which has led to 100% growth consistently for 3 years. Also worked with infrastructure, process, energy, environment and Special Purpose Machine (SPM) manufacturing company and successfully lead it from front for multi fold growth across the globe.
For last 7 years, working with automotive giant where he has successfully developed the complete platform in MUV, LCV & HCV segment and set up the plant across the world which has consistently given 100% growth on Y2Y basis. For last 3 years, also working on EV program where 1st time 3D solar concept along with all-wheel drive & recycling the thrust using micro turbine is being used all at a time which has potential to bring complete revolution in Mobility solution.
Rajesh Deshpande - Head (Transmission Product Unit)
Escorts Ltd.
Mr. Rajesh Deshpande is presently working with Escorts, Agri Machinery Group, Faridabad and Haryana India as Associate Vice President (Transmission Product Unit). His 23 years of experience includes working in various other automotive industries like: Mahindra and Mahindra Farm Equipment sector, Siemens Ltd, JCB India Ltd. His Academic Qualification includes: M.E. PRODUCTION with Specialization in Industrial Engineering.
He is a Versatile professional having experience of key areas across functions viz. Projects, Strategy Development, Industrial Engineering, Operations, Process Engineering, Capital Equipment / Indirect Material Procurement, Human Resource, Performance Management, Tool room, Production Planning etc.
He is also certified as an "Applicator in Basic MOST" (Maynard Operation System Technique), certified by Maynard institute, USA and Assessor of “Lean Manufacturing practices”, certified by Frost & Sullivan He played a key role in Major capacity expansion project of one of the green field plant and Installation paint shop facility.
http://www.indiasim.org/Portals/0/Alvis.png
Alvis Lazarus - Global Patron & Supply Chain Mentor at ISCEA
Alvis Lazarus is a Global supply chain consultant & speaker with more than a decade of Operations & Consulting Experience in Logistics, Supply chain and Process Excellence. Alvis has worked across multiple sectors - Ecommerce, Automotive, Mining, Retail, FMCG, Manufacturing, IT, and HealthCare. Alvis has managed multiple Supply Chain Programs across APAC, EMEA and Americas regions.
Alvis is a Certified Lean Six Sigma Black Belt and Champion and also a Certified Program Manager.
Dr. B. K. Mohanty - Professor (Decision Sciences)
IIM Lucknow.
Dr. B. K. Mohanty is a Professor in Decision Science Area at Indian Institute of Management Lucknow, India. He received his M.Sc. (Mathematics) from Berhampur University, India, and his Ph.D. in Operations Research from Indian Institute of Technology, Kharagpur. India. He has more than 100 publications in various national / international journals and conferences. His research interest includes Fuzzy Multi-Criteria Decision Making Problems, Electronic Business under Fuzzy Environment, Software Reliability, Fuzzy Logic in Data Mining and Business Intelligence.
Key Speech Topics
http://indiasim.org/QuickLinks/KeySpeachTopics.aspx
'Does Simulation Stimulate Supply Chain?' – Mr. Alvis Lazarus
Supply chain model and structure, SC Models - Ecommerce, FMCG, Automotive etc. What makes Supply chain management challenging and exciting? What is the role of simulation in overcoming key challenges faced by supply chain professionals?
'Highly Automated Automotive Chassis Manufacturing line for A global vehicle platform' – Dr. Dhananjay Kumar
With increasing global competition, quality cost & delivery are three important consideration and highly automated, flexible, robust and accurate manufacturing process is the answer for large variation of models on the same platform. KLT being a world class Chassis manufacturing company and system supplier for many global OEMs, has developed one such manufacturing line in S Africa for Ford Ranger which has not only constantly produced high quality product with large variation consistently in last 3 years but our platform has been adjudged the best vehicle in this category the world over ranging from Asia-Pacific-S Africa to European Union & S America.
Sunday, March 22, 2015
Making India Cost Competitive - Role of Industrial Engineering
"Make in India" campaign was announced by Prime Minister of India. Make in India to be successful needs market demand in India as well as abroad for Made in India products. Will there be sufficient demand? What parameters will determine demand. The performance of the product will determine demand. But demand is expressed as certain volume of products at a price specified by customers. Unless the manufacturers deliver or supply the product at that price, demand will not be there. To supply the product at a specified price, the cost of production has to be less than the price minus the marketing and distribution costs, and profit margin required.
Target costing is the approach now followed by manufacturing companies to design product as well as production system that supplies the product at the cost derived from the price giving adequate volume of demand.
Industrial engineering was described as profit engineering by Taichi Ohno, the developer of Toyota Production System. Industrial engineers, analyze the resource used in the proposed or existing production systems, identify waste, remove it, make systems more efficient and thus contribute to reduction of cost. Recently an author recommended five iterations of cost reduction. Each cost reduction iteration has to be followed by a prototype whose technical feasibility is established and this exercise helps industrial engineering team as well as the original product and production system design teams to come out with new ideas for the next iteration of cost reduction ideas.
Industrial engineering departments of the companies, industrial engineering professional societies and academies, and individual industrial engineering faculty members have to focus on cost reduction intensely to make Make in India a great success.
The Institute of Cost Accountants of India is also making serious efforts to measure costs and compare them with various types of standards (some of them determined by industrial engineers) to point out areas of potential cost reduction. Industrial engineering profession has to collaborate with the ICMAI to facilitate proper cost measurement and reporting.
ICMAI is presently doing research on Power Sector, Health Care Sector, Higher Education Sector, MSMEs, Infrastructure, Government Services, Manufacturing Sector and Banking Sector to identify cost measurement issues and potential for cost reduction.
Target costing is the approach now followed by manufacturing companies to design product as well as production system that supplies the product at the cost derived from the price giving adequate volume of demand.
Industrial engineering was described as profit engineering by Taichi Ohno, the developer of Toyota Production System. Industrial engineers, analyze the resource used in the proposed or existing production systems, identify waste, remove it, make systems more efficient and thus contribute to reduction of cost. Recently an author recommended five iterations of cost reduction. Each cost reduction iteration has to be followed by a prototype whose technical feasibility is established and this exercise helps industrial engineering team as well as the original product and production system design teams to come out with new ideas for the next iteration of cost reduction ideas.
Industrial engineering departments of the companies, industrial engineering professional societies and academies, and individual industrial engineering faculty members have to focus on cost reduction intensely to make Make in India a great success.
The Institute of Cost Accountants of India is also making serious efforts to measure costs and compare them with various types of standards (some of them determined by industrial engineers) to point out areas of potential cost reduction. Industrial engineering profession has to collaborate with the ICMAI to facilitate proper cost measurement and reporting.
ICMAI is presently doing research on Power Sector, Health Care Sector, Higher Education Sector, MSMEs, Infrastructure, Government Services, Manufacturing Sector and Banking Sector to identify cost measurement issues and potential for cost reduction.
Saturday, March 7, 2015
Productivity and Industrial Engineering in APSRTC, Hyderabad
In 2000, for every bus operated around 11 employees were required.
In 2015, 5.9 persons are operating a bus on an average.
(Informed by Chief Industrial Engineer of APSRTC through a Linkedin Message)
Tuesday, February 24, 2015
Operations Research and Quantitative Optimization Techniques for Productivity - Success Stories in India
2010 - 2011
Decision Support System for Optimization of Material Procurement at SAIL
http://bvicam.ac.in/bijit/downloads/pdf/issue7/05.pdf
SAIL - Productivity and Industrial Engineering Initiatives and Achievements
2013 - 14
State-run Steel Authority of India's (SAIL) production grew to 3.2 million tonnes, the highest ever in the first quarter, clocking a six per cent rise over the same period last year.
Production efficiency also got a boost with energy consumption lower by one per cent and blast furnace productivity improving by two per cent.
With several projects on the anvil, the annual production capacity of hot metal of the company is expected to grow to 19 million tonnes by next fiscal from the current level of 14 million tonnes.
http://www.thehindu.com/business/Industry/sail-notches-up-best-ever-q1-production-at-32-mt/article4873684.ece
2010 - 2011
Decision Support System for Optimization of Material Procurement at SAIL
http://bvicam.ac.in/bijit/downloads/pdf/issue7/05.pdf
2002 - 2003
A cost cutting target of Rs 500 crore was also being chased by SAIL, which effected a sizeable decrease in its losses in the first half of 2002-03.
http://www.thehindubusinessline.com/2002/11/14/stories/2002111402170200.htm
Time Study, Work Measurement and MOST STudies - Success Stories India
Consultants
Baroda Productivity Council
http://www.bpcindia.org/Services.aspx?Service=3
Dassault Systemes
3D Manufacturing Time-Motion Study
http://www.3ds.com/products-services/3dexperience/on-premise/manufacturing-planning-on-premise/manufacturing-time-motion-study/
SNIC, India
http://www.snic.co.in/services.php
Sunday, February 22, 2015
Production Methods Efficiency Engineering - Success Stories in India
Improvement of Productivity through Line Balancing - Case Study
IIIE Journal, October 2013
http://www.vcs.co.in/news-room/publications/3237-article-3.html
Consultants
Vrunda Consultancy Services
VCS is a IE & management consulting company, with more than 120 Clients in Asia Pacific region. Combining unparalleled experience, comprehensive capabilities across all industries and business functions, and extensive research on the most successful companies, we collaborates with clients to help them become high-performance businesses. Our "high performance business strategy" builds on our expertise in IE & Management consulting, to help clients perform at the highest levels so they can create sustainable value for their customers and stakeholders.
http://www.vcs.co.in/consulting/3233-vcs-company-profile.html
Value Engineering Success Stories - India
A global leader in the elevator and escalator industry achieves reduction of cost by drawing on Pricol Technologies’ Value Analysis and Value Engineering expertise.
Reduction in weight of the component and costs were the key objectives of the client. Pricol Technologies deployed its team of experts to perform a preliminary analysis to understand the strength of the components and fatigue requirements. 3D CAD models were developed from the existing mechanical components. Value Analysis/ Value Engineering teams sought to redesign the components, preserve the functional value and reduce the cost of manufacturing. The reliability and robustness of the existing model was maintained while redesigning the structure. The approach followed by Pricol Technologies helped the client in accomplishing their objectives.
Benefits
Reduction in the weight of the component by almost 70%
Reduction in cost of the component by 40%
Reduced process time of manufacturing
Optimised inventory and maintenance levels
Complexity of operations reduced significantly
Consultants
Leveraging on its integrated eco system and the frugal engineering methodologies, Pricol Technologies brings in its palette a spectrum of services to help your businesses in each stage of your Product Life Cycle (PLC). March ahead by synthesizing innovation with engineering.
New Product Development
Mechanical Design
Embedded Systems
Visualization and Technical Publication
Value Analysis / Value Engineering
Manufacturing Engineering
Product Realization
Low Volume-High Mix Manufacturing
Pricol Technologies
Corporate Headquaters
II Floor, Srivari Srimath,
1045, Avinashi Road,
Tamil Nadu, India.
Email: sales@pricoltech.com
Saturday, February 21, 2015
Coal India Limited - Productivity and Industrial Engineering Initiatives
Coal India Vision 2020 - One Billion Tonnes Production
February 2015
Shri Bhattacharya, CMD of CIL said that the strategies for future include Technology Upgradation in Opencast Mines with high capacity equipment , Operator independent Truck Dispatch System, Vehicle tracking system using GPS/GPRS, Coal Handling Plants (CHPs) and SILOS for Faster Loading and monitoring using Laser Scanners. As far as productivity improvement in Underground mines is concerned, Shri Bhattacharya said that the steps taken by CIL will include introduction of Continuous Miner Technology in large scale, Long-wall Technology at selected places, Man Riding system in major mines and Use of Tele monitoring Techniques.
CIL is also introducing a number of systems improvements that would help the company in realizing its challenging target. Use of ICT, remote sensing geophysical technologies and proper monitoring and evaluation methodologies will be the key features, Shri Bhattacharya added.
http://pib.nic.in/newsite/erelease.aspx?relid=115313
Monday, February 16, 2015
Six Sigma Success Stories in India
TQMI Consultancy Six Sigma Success Stories
Some Success Stories of Six Sigma
Industry Sector - ROI - Annualized Savings
Data Storage and Photo-Voltaic
50:1
Rs. 25 crores in 2006-07 and Rs. 40 crores in 2007-08 and Rs. 50 crores each for 2008-09 and 2009-10 (Total USD 37 million)
Life Insurance
10:1
Rs. 100 cores (USD 20 million) in 2008-2010
Tractors and Farm Equipment
4:1
Rs. 4 cores in one year in 2009-10 (USD 90K)
Pharma
15:01
Rs. 20 crores in 2008-10 (USD 4.5 million)
Chemicals/ Petro-Chemicals
9:1
Rs. 2.5 Crores in each in three waves (total USD 1.6 million)
Petroleum refinery
40:1
> Rs. 40 Crores in 2005-06 (>USD 20 million)
Leather and Leather Products
10:1
Rs. 2.5 Crores in 2003-04 (USD 500K)
Telecom Carrier
8:1
Rs. 5-6 Crores in each of four waves completed in 2004-07 (Total USD 5 million)
Telecom
8:1
Rs. 27 Crores in 2010 (USD 6 million)
Home Appliances
14:1
Rs. 12 Crores and Rs. 22.5 Crores in 2002 & 2003 respectively (Total USD 8 million)
Banking
10:1
Rs. 3.5 Crores in 2003 (USD 775K)
Total savings to Indian Industry: ~ Rs. 1500 Crores
TQMI Sigma Implementation - Full Case Study Presentation of an Engineering Company that won the Deming Prize from JUSE for effective implementation of TQM
Reported annualized savings of USD 3 million. ROI 15:1
Plan for 2007: Savings of USD 5million
WIPRO Case Study
Download from IIT Kharagpur Website
WIPRO is the first to implement six sigma effectively in India
It is now offering consultancy services also in Six Sigma
It achieved benefit of Rs. 120 crore due to six sigma projects in 2005-06 (reported in the case)
More case studies from TQMI
http://www.tqmi.com/case-studies.page.84.html
Friday, February 13, 2015
BPCL - Productivity and Industrial Engineering Initiatives and Achievements
BHARAT PETROLEUM CORPORATION LIMITED: FINANCIAL AND LABOR PRODUCTIVITY BENCHMARKS
Are workers at Bharat Petroleum Corporation Limited productive? There is no absolute answer to this economic question. The second study considers how labor deployment and productivity indicators for Bharat Petroleum Corporation Limited differ from the global benchmarks. It looks at the amount of labor required to operate Bharat Petroleum Corporation Limited and the resulting return on human investment. What is the ratio of short-term and long-term assets to employee? What are comparative capital-labor ratios? What are the average sales and net profits per employee in Bharat Petroleum Corporation Limited compared to benchmarks in the same economic sector?
Reports for over 54 Petroleum Refining companies are available now, including the following:
Amerada Hess Corpn
Ashland Inc.
BP Amoco PLC(BP AMOCO)
Chevron Corporation
Conoco Inc.
Cosmo Oil Co., Ltd.
Fortum Oyj
Imperial Oil Limited
Japan Energy Corporation
Lyondell Chemical Company
Nippon Oil Company, Limited
Petro-Canada
Phillips Petroleum Co.
Repsol-YPF SA
Royal Dutch Petroleum Company
RWE-DEA Aktiengesellschaft fuer Mineraloel und Chemie
Showa Shell Sekiyu Kabushiki Kaisha
Societe Elf Aquitaine S.A.
Technip Societe Anonyme
The Shell Transport and Trading Company, p.l.c.
Tosco Corporation
Total Fina Elf SA
Unocal Corporation
USX-Marathon Group
http://www.icongrouponline.com/pr/Bharat_Petroleum_Corporation_Limited_IN/PR.html
According to BPCL's own numbers, the bottle filling plant's productivity has seen a 34 percent increase since the beginning of the Facility Service Agreement;
http://www.kosancrisplant.com/en/home/cases/case-bpcl-india/
Thursday, February 12, 2015
Tata Motors Ltd. - Productivity and Industrial Engineering Initiatives and Achievements
2013-14
INFORMATION TECHNOLOGY INITIATIVES
The Company''s business strategies are well supported by IT proactively
building the capabilities. The Company''s IT leverages strong
partnerships with productand services companies to support business
growth and innovation. This has enabled us to strengthen our core
technology capabilities.
The major highlights of IT initiatives at the Company are:
The Company commemorated 10 years of its path breaking CRM solution,
one of the largest in automotive industry with 4,000 channel partners
and more than 50,000 users.
The Company played a key role in setting up AutoDX, a SIAM ACMA
initiative for electronic data interchange (EDI).
The Company is implementing cloud based employee collaboration tools
which will bring a diverse and multi locational workforce closer,
enabling the OneTeamOne Vision initiative.
The Company is extending its enterprise applications to mobiles through
mobile apps. First five applications have been piloted for Telematics,
Rural Marketing, Dealer Sales Force (CV and PV) and Quality
Inspections.
The Company won the ''CSI Award for the Excellence in IT'' for executing
the large and complex migration of entire Manufacturing Execution
System (MES) platform in car plant.
JLR global expansion to China is being competently supported by IT
capabilities.
All Tata Motors group companies continue to work together on IT
synergies and sharing the expertise.
DIGITAL PRODUCT DEVELOPMENT SYSTEMS INITIATIVES
Product development processes continue to grow on best of the breed
tools and technology solutions, for enhancing product development
capabilities, addressing guality and speed. Capabilities were
developed for realistic product visualization in digital platform for
product style. Bid response mechanisms for specific customers were
developed. Processes relating to early manufacturing feedback in
engineering functions were evolved with state of the art toolsets.
PLM processes continue to mature strengthening the product development
processes across the extended organization.
In-house Knowledge Based Engineering (KNEXT) applications spread
enhanced by deploying 20 new applications in various product design
functions.
Virtual validation as a strategic initiative introduced in the product
development process providing better turnaround time and understanding
of product in the field.
Tools for collaboration of engineering information across multiple work
locations, multiple geographies were developed as part of DRiVE
initiative.
Systems were developed to handle WCQ LI and other guality initiatives.
30 new applications were conceived and developed on in- house pFirst
framework to handle various cross functiona work stream delivery.
Digital Manufacturing Planning (DMP) capabilities enhanced to use
various process documents (PFD, PFMEA, CP, etc) in Pune manufacturing
location.
TECHNOLOGY AND ENVIRONMENT FRIENDLY INITIATIVES
The Tata Motors Group continues to innovate, with a view to enhance the
market share and aims at products which cater to the changing needs of
the customer for both fleet owners and individua customers. Besides new
product developments covered above, some of the key initiatives on
Environment friendly technologies include:
Fuel efficiency improvement through development of advanced driveline
oil formulation in line with previous development of engine oil only
Continuation of fuel efficiency improvement initiatives on commercial
vehicle engines through software features in engine management system
and vehicle level parameter optimization.
Downsizing of gasoline engines using pressure charging technology
(turbochargers) for Co2 reduction on passenger cars.
Designed and developed electric vehicles based on Tata Magic and Tata
Iris, which were demonstrated in Autoexpo 2014. A fleet of small
number of demonstrator vehicles is being developed.
Start of a collaborative initiative to investigate sustainable
synthetic fuels for India and developing nations.
Designed, developed and demonstrated Hydrogen fuelled zero emission
fuel cell bus for urban transportation. Further testing is in progress.
Use of bio CNG in internal combustion engines for vehicles is under
testing.
Unveiling the latest milestone of its advanced aluminium which would be
high-strength, lightweight and the Jaguar Land Rover''s most aluminium
intensive structure to date bringing considerable benefits in terms of
dynamics, safety and efficiency.
Jaguar Land Rover introduced world''s first hybrid electric vehicle with
a diesel engine by bringing down fuel consumption to 6.41/100 km. which
only few years ago, seemed to be totally unachievable in a vehicle size
of Range Rover.
Introduction of InControl Apps in the Cars manufactured by Jaguar Land
Rover to minimize driver distractions.
Collaborative innovation through Investment in a new UK advanced
research facility, the National Automotive Innovation Centre providing
dedicated facilities for an expanded Jaguar Land Rover Advanced
Research Team.
Total Factor Productivity in Indian Companies including Tata Companies - Summary of the report
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