Driven by a vision to build the company into “A Temple of Technology”, Jyoti was established in 1989 and today, it is one of the largest multinationals in India. Back in 1989, it was a small job shop at Rajkot, executing machine tool activities and establishing machine tool components for the local manufacturers. Things have majorly transformed since then and, today, the job shop has evolved into a leading CNC machine manufacturer in India, under the mastermind of Parakramsinh Jadeja, Chairman and Managing Director, Jyoti CNC Automation. The company has grown manifold from manufacturing gearboxes for machines to developing precision all-geared head lathe machines to today’s highly sophisticated CNC machines.
The company has three different plants located at GIDC, Metoda, Rajkot in Gujarat, having a present plant capacity of manufacturing 3000 machines pa, equipped with state-of-the-art Providing an edge in manufacturing machine shops having the latest and technologically advanced plant and machineries, assembly shops, foundry, sheet metal, paint shop and other allied infrastructure. Tracing down the company’s journey, Jadeja highlighted, “We started as a job shop, and gradually developed assemblies, sub-assemblies and gearboxes. Thereafter, we started developing special-purpose machines using low-cost automation and finally underwent a major transformation and adapted the CNC concept and, thereby, built our first CNC machines. We have been experiencing rapid growth since then.”
However, the success story of this company doesn’t end here. In 2007, it acquired a 159-year old French machine tool giant, Huron Graffenstaden SAS, which has two manufacturing plants at Strasbourg and a strong sales and service network all over Europe. The acquired company is a pioneer across world for its 5-axis machining centres, having a renowned clientele like Volkswagen, Ferrari, Rolls Royce, Siemens, Boeing, Air Bus, Fiat, BMW, Mercedes, GE, etc.
Endowing product development
The Rajkot-based company is spread across three facilities, wherein, the first facility consists of five machining shops and two grinding shops. The machine shops include various machines starting from 2-axis turning centres, 3-axis vertical machining centres, 4-axis horizontal machining centres & 5-axis machining centres up to 10 m length. The grinding shop consists of various horizontal & vertical grinders and the unit also comprises of a technology centre and administration office. The second facility re-conditions the company’s own machines and the third facility has major backward integration like foundry, sheet metal shop, paint shop, sub-assembly, main assembly, store areas as well as an R&D centre.
Jyoti CNC Automation incorporates a systematic approach, emphasising quality at every stage of product development through manufacturing so as to achieve excellence. Addressing this, Arun Nene, Manager—Channel Support, Jyoti CNC Automation, said, “We are mainly using our own machines as the mother machinery. In fact, we have installed 2-axis turning centres, 3-axis vertical machining centres, 4-axis horizontal machining centres and Huron-made state-of-the-art 5-axis machining centres like KX-50, MX-12M, MX-12MT, KX-200. In addition, we have also installed few foreign brand mother machinery like Shin Nippon, Nicolas Correa, Mitsuiseiki, Studer, Kellenberger, DMG, etc.”
Interestingly, the company has also been the only machine tool manufacturer in India to start such facilities, where customers can recondition their machines with some of the latest features. In addition, all units are built in such a way that expansions of any kind can be done on the adjacent side.
Making machine tools precise
With rapid rise in automation levels today, latest technologies and automation practices are being deployed across factories in and outside India. When asked about the practices implemented in the company, Nene said that the designing team of Jyoti has specifically designed and developed twin spindle & multitasking machines to reduce set-up & cycle time of the component gaining maximum accuracy levels. “We have specialised in integrating robots with our machines to reduce human interference, which helps in achieving better productivity and minimum errors,” he stressed.
It has become all the more vital today to monitor advanced practices on shop floors so as to make machine tools more rigid and precise. Highlighting the same, Nene opined that the company has implemented cellular manufacturing Explaining this further, he shared, “The goal of cellular manufacturing is to move the products as quickly as possible and make a wide variety of similar products maintaining high accuracy & repeatability of the products. We have implemented probing systems in our various machines for online & offline inspection of the components to maintain accuracy & repeatability levels of the components. For critical components like spindle shaft & spindle cartridge, turret tool disc, machine tables, etc, we do 100% inspection. We also have our own standard quality room, where equipment like CMM, roundness tester, roughness tester and profile projector are used to check various component batches.”
Upgrading productivity levels
According to Jadeja, training modules are a prerequisite for achieving higher productivity levels and enhancing quality standards. Starting from operating CNC machines and later programming them, the company provides training that covers all aspects of CNC machine operations and manufacturing. All new employees in different departments are trained in their respective fields. Based on this a special emphasis has been given to the R&D cell of the factory.
As per Nene, for skill development and employee productivity, the company has been taking care of some initiatives, including safety aspects. “We have formed quality circles for improvement in areas like foundry, sheet metal and assembly. These teams meet on a regular basis to discuss various issues faced today and ways to resolve them. In fact, the team has participated in Quality Circle Forum of India, Vadodara Chapter, for the last three years with various case studies and has also been felicitated with each participation,” he averred.
Today, it has also become significant for Indian manufacturing companies to join hands with major trade bodies and industrial associations. Commenting on the growing importance of such associations, Jadeja said, “For skill development and employee productivity, we regularly arrange skill development programmes and send them to the training programmes of associations such as IMTMA and CII, with respect to their core working profile.” Besides, the company has recently been felicitated with the OHSAS 18001 certificate for environment & safety, and has been conducting exchange programmes between the Indian and European offices.
Times have changed now and a growing importance is being given to women on shop floors as well. In Jyoti CNC Automation, 5% of the total workforce is women and special training programmes have been incorporated for their empowerment across the working crescendos of manufacturing shop floors. When asked, Nene elaborated that the company has specially started a certified CNC programming & operating training course of 140 hours for 10th and 12th drop-out females. “This will boost their confidence and make them self-dependent, thereby, assisting them to an upliftment in society. We have successfully trained 50+ female operators out of which 17 candidates are already taken on payroll.”
Taking it forward…
It goes without saying that a pursuit of excellence is the most challenging aspect of any manufacturing company. To achieve the same, the Rajkot-based company has deployed a five-phase CNC machining centre that contributes towards quality and productivity through head changer and multitool ATC.
The R&D centre of Jyoti has been dedicated to an ancient design genius Leonardo Da Vinci, who designed the first lathe machine in early 16th century. It has been established to design and develop technologically-advanced world-class machines, where the active R&D team has achieved outstanding success by developing TPM-friendly machines, CNC machines with linear technology of higher dynamics and productivity. Following lean principles is also considered crucial in this regard and the management of the company is quite receptive to such practices. Sharing insights on the lean principles incorporated in the organisation, Nene said, “We are using 5S & Kaizen tools to make our shop floors and processes more and more organised. We conduct 5S audit every month and have a dedicated team of 5S auditors and results are circulated to motivate employees to keep their workplace organised.”
Sharing his vision for the company, Jadeja concluded that there is a huge gap between the import and export proportion in India. To address the same, he believes and envisions to make Jyoti CNC Automation an export-oriented company and be equipped enough to develop world-class products. “We look forward to becoming the top 10 machine tool companies across the globe,” he shared. ☐
“Reaching higher technology levels”
Parakramsinh Jadeja, Chairman & Managing Director, Jyoti CNC Automation, in an
interaction with EM, details the company’s management mantras to provide manufacturing
solutions for the Indian market and highlights the roadmap so as to become one of the
prominent 10 machine tool manufacturers across the globe. Excerpts…
How has been your company’s performance this year? Which areas have been the major target sectors for your company?
Currently, we are witnessing a growth rate of 15-20%, in terms of order booking and dispatch. We look forward to meeting a net growth of 20-25% this year, particularly from the auto and auto component manufacturers. The mould industry is also performing well, and our focus this year would be on the aerospace & defence sectors. Its a growing sector and with the government’s active support, we expect to get good business here in near future.
Which areas of manufacturing do you expect to see significant levels of automation in the coming years, both globally and in India?
In India, it has become essential to adopt automation practices on the manufacturing production lines. Our company is all set to walk through the automation journey, and, for this, we have a range of products in our basket. Our focus is to offer mechanised as well as non-mechanised solutions. India is still an SME-centred market and, it becomes difficult for them to afford high-end automation solutions. Even large companies sometimes don’t vouch for high-end automation services. So, we provide a range of cost effective manufacturing automation solutions for the Indian market.
We believe that the human mind is not meant for doing repetitive tasks, and this is where automation comes into the picture. So, for such tasks, we would like to bring in mechanised applications. On the other hand, for other creative areas, we prefer involvement of the human mind. We have dedicated a team in our R&D division working towards manufacturing automation solutions.
How are you planning to drive the growth of your company in
India in the coming years?
Customers today look for machines as per the required size and functionalities. Therefore, offering them a variety of products is crucial. In India, our market share is 4%. In the next 5-7 years, we look forward to having a market share of 20%, and we are working towards it. Every year, we develop 10-12 new products. At our facility, new machine prototypes are continuously assembled and tested for its consistency. Currently, we have more than 100 products, and to achieve 20% market share, we are working towards having around 200 products in our range.
How do you plan to strategise your management mantras aligning with the Indian market dynamics?
We look forward to double our product range. Hence, we work accordingly in terms of their designing and manufacturing. The number of drawing item codes in our SAP today is much higher, when compared to the last five years and last 15 years. This states that more number of parts have been added and a variety of products is being offered to customers. This has of course increased the complexity in our range of products.
Currently, we don’t have a batch quantity to produce. I believe by 2050, the maximum batch size of production will become one-piece. We are already working towards it.
What is your company looking forward to?
We are targeting to change the complete perception of our company, and, thus, focusing more on performance, facia, looks, reliability, maintenance and Industry 4.0. As far as technology is concerned, a range of products are missing in the Indian market, for which customers have to look for foreign suppliers. We are working towards reaching higher automation & technology levels so as to address such issues.☐