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Rajan Madan,
Plant Director,
New Holland India.

1 Rating

Cover Story Management “Focus on world-class manufacturing”

Dec 23, 2016

“ World Class Manufacturing principles involve every employee in the plant’s offices and on the shop-floor in a process of continuous improvement that aims to achieve Zero Defects, complaints and accidents, breakdowns of machines, inefficiencies and waste” - Rajan Madan, Plant Director, New Holland India.

How are the latest technologies being leveraged on in your manufacturing plants?

New Holland, a brand of CNH Industrial, is manufacturing tractors, fuel-efficient engines and various components for local needs and export, in Greater Noida. Besides, we are setting up a new facility on 70 acres of land at Chakan, Pune, for manufacturing of advanced farm mechanisation equipment. We also run a manufacturing plant in Pithampur, in the construction equipment business with the CASE brand that produces compactors and backhoe loaders.

We keep upgrading our facilities with the latest technologies to improve the efficiency and make our plants best in the industry in terms of quality. At the Greater Noida facility, we are using state-of-the-art CNC (Computer Numerical Control) machines from Japan and Germany, for machining of castings. We use emission & performance test benches from Italy for testing engines as per CNH Industrial Quality standards, which ensures best performance by our tractors in real-life conditions. The plant is equipped with conveyor systems, such as skid conveyor, slat conveyor, and overhead chain conveyor. We have recently established a new paint shop with the most advanced tools for top-notch paint quality.

Your CNH Industrial / New Holland plant in Greater Noida has achieved the Silver level in World Class Manufacturing. Since you were actively involved in the implementation, can you give us more details on it?

The road to Silver level in WCM was not a walk in the park. It was one of the most challenging tasks for us, mainly because of the challenging timelines given to the Greater Noida plant. However, with a continuous focus on reducing losses and improvement activities in quality, workplace organisation and logistics, our efforts paid off,
and we passed the Silver audit in the first attempt - a feat in itself. WCM also helped us in improving internal processes to reduce consumption of important resources as well as
to reduce operational costs. WCM principles involve every employee in the plant’s offices and on the shop-floor in a process of continuous improvement that aims to achieve Zero Defects, complaints and accidents, breakdowns of machines, inefficiencies and waste.

Are you following lean manufacturing practices or shopfloor Kaizens in your plant to make it more efficient and its products cost-competitive?

Yes, we do follow lean manufacturing practices at our plants. These practices help us improve the product quality, mitigate the losses, and reduce the cost of production. These are all part of World Class Manufacturing practices. WCM has 10 technical pillars such as Safety, Quality, Plant logistics, People development etc, that work together to identify losses and take countermeasures to eliminate them.

What are the initiatives taken by CNH Industrial / New Holland to ensure the green environment and to reduce energy consumption and emissions at its Greater Noida plant?

We are working incessantly towards reducing energy consumption at our Greater Noida plant. To reduce energy consumption, we have made many improvements such as replacement of normal motors with energy-efficient motors and pumps, use of LED lights in office areas and shopfloor. Air-conditioner units in our offices use environmentfriendly gases and are the most energy-efficient units available in the market. In addition, we are also making use of solar charging streetlights and latest technology of Tubular Day lighting devices. We are presently working on installation of 2.6 MW solar power systems on the rooftop of our manufacturing facility. To preserve environment, we are recycling all the waste generated in the plant, including hazardous waste.☐

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