Today, a growing and competitive manufacturing sector has become the prime mover of the modern economy. Given the forces at work, manufacturing firms are taking a variety of approaches to radically transform their businesses and find new ways to differentiate themselves. This has necessitated companies to constantly innovate, redefine paradigms, adopt cutting-edge technology, enhance productivity and optimise resources. Keeping this in the backdrop, IMTMA had recently organised the National Productivity Summit at BIEC, Bengaluru.
Inaugurated by L Ganesh, Chairman, Rane Group; B Muthuraman, former Vice Chairman, Tata Steel; Parakramsinh G Jadeja, President, IMTMA and V Anbu, Director General & CEO, IMTMA, the 10th edition of the summit showcased the best practices in manufacturing through inspiring keynotes, live case study presentations, plant visits, focused technical sessions and success stories. Speaking on the occasion, Ganesh said, “Productivity is achieved over a long period of time. It's a marathon and Indian companies in manufacturing sector need to constantly work on skill enhancement of their employees and push for labour laws that will enable re-skilling of workers for future jobs.”
Day 1 started with a keynote session by Muthuraman, who
traced back the major transformation of the Indian industry and enforced that the industry must realise that the labour issue will go away in due course of time. He said, “Amidst the rebalancing of the world economy, manufacturing needs to adopt technology from other fields too, like the IoT practices, Additive Manufacturing and prototyping techniques.”
Moving on, an interactive success story was presented by MS Shankar, Senior Director—Technology & Innovation, Anand Automotive, where he pointed out the parameters to track improvement in productivity. “This can be done by attracting stakeholder groups, top leaders and each employee of an organisation to create business. The concept of manufacturing excellence involves problem solving techniques, continuous improvement methodology and achieving a quantum leap,” he added.
Productivity Championship Awards
Toyota Kirloskar Auto Parts bagged the first prize and won Rs 3 lakhs cash prize
Mahindra and Mahindra, Mumbai, bagged the second position with Rs 2 lakhs cash prize
VE Commercial Vehicles bagged the third position with Rs 1 lakh cash price
Certificates of merit were given to Brakes India, Super Auto Forge and TTK Prestige
Vox Populi Award was given to Toyota Kirloskar Auto Parts
Enhanced productivity methodology
The first case study of the event was presented by Vijay Mewada, Senior Manager—Foundry, Mahindra & Mahindra, on “Journey towards excellence through technology upgradation”. This was followed by a presentation on “Productivity improvement of hole drilling by innovative production techniques,” by R Sahayasubramanian, Senior Manager—Projects, Super Auto Forge. Next, R Saravana Kumar, Senior Manager—TPM & EHS, TTK Prestige, spoke on “Improved productivity by eliminating man and machine efficiency losses”.
The day was concluded with a success story on “Operational excellence: Scaling up to meet market demand,” by R Prabhakar, Chief Operating Officer, Ace Designers. He, along with his team members, delivered an interesting presentation on how the previous method of assembly has now evolved.
Meeting competitive standards
Day 2 began with a case study on “Reducing the fettling content and improving the aesthetic look of sand foundry casting” by R Ramsharan, General Manager Technical, Brakes India. The next case study was on “Productivity enhancements - chipless machining” by Dilip Rathod, DGM— Head of Manufacturing, VE Commercial Vehicles. This was followed by a case study on “Productivity improvement in transmission assembly line through Jishuken and low-cost automation (Karakuri)”, by Tabrez Ahmed, DGM— Manufacturing 2 department (R T/M & C T/M), Toyota Kirloskar Auto Parts.
The first keynote of the day was addressed by Dr Andreas Wolf, Senior Executive Vice President, Bosch, on “Productivity, quality and cost—3 nodes of manufacturing competitiveness triangle”. Here, Wolf discussed the manufacturing triangle comprising quality, cost and delivery that are centred around the roadmap ton achieve excellence. Then, the second keynote was presented by Anoop Chaturvedi, Senior Advisor—Production & Engineering, Maruti Suzuki, on “Innovation for manufacturing excellence—Maruti Suzuki’s success story”. The session was addressed on leveraging technology & IT systems, enhancing quality, importance of timely communication, having a robust traceability process, etc.
Concluding the event was Shailesh Sheth, Corporate Strategy Advisor, IMTMA, who briefed the session on how the world will look like with future factories by 2020 and also moderated the Productivity Championship Awards.
Speaking on how the summit will act as a platform to meet the evolving knowledge and skill requirements of overall manufacturing industry in India, Jadeja said, “The manufacturing industry is growing rapidly in India and is at the cusp of embracing Industry 4.0 that offers huge growth prospects for the industry. Summits like these are the key enablers to address learning and best practices requirements of manufacturing industry and raising its competitiveness.”
Besides the two-day summit, IMTMA also organised plant tours of Toyota Kirloskar Auto Parts & Toyota Kirloskar Motor and Volvo Buses and Honda Motorcycle & Scooters, India. The next edition of the National Productivity Summit will be held in August 2017 at Pune.☐