Company Profile AceMicromatic Group PRODUCT PROFILE CNC & - - PowerPoint PPT Presentation

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1 N K Dhand CMD

“ Our Journey of Business Excellence”

5th National Quality Conclave 19-20 February 2010 at New Delhi

Largest Indian CNC Lathe Manufacturer India’s Widest range of Vertical Machining Centre’s now with Horizontals

India’s #1 Precision Cylindrical Grinders ‐ CNC & Hydraulic

India only Global manufacturer

• f Tool

Turrets & ATC’s India’s Largest Selling Productivity Monitoring Solutions

Largest Machine T

• ol Group in India

AceMicromatic Group

PRODUCT PROFILE CNC & Hydraulic Cylindrical, Internal, Universal and Special Grinding Machines. SPACE OCCUPIED Main plant in Ghaziabad, New plant in Bangalore : Total Covered area 1,80,000 Sq.ft MARKET SHARE IN INDIA 40 % in our segment. NO OF MACHINES INSTALLED 3500 TRAINED WORKFORCE 250 People EXPORTS More than 150 Machines Exported across the world to Europe, Middle East, Australia, China, S.E. Asia. COMPUTER AIDED DESIGN FACILITY Pro E - 6 seats, Solid Works - 21 Seats, Cosmos - 4 Seats, Algor – 1 Seat MANUFACTURING SYSTEMS Lean ENTERPRISE RESOURCE PLANNING SAP R3 NEW PROJECT Sheet metal project in Ghaziabad

Company Profile

3 4 1973 - Established 1977 - First Cylindrical Grinding Machine manufact ure d 1979 - Best Design & Best Product Award at IMTEX 79 1982 - In- House R& D Center Recogniz e d by Govt. Of India 1983 - Valve Seat Grinding Machine 1985 - Auto Profile Dressing Machine

• APD

1986 - First CNC Cylindrical Grinder 1993 - Stroke & Length Match Grinding Machine 1995 - Heavy Duty Cylindrical Grinding Machine 1996 - Piston Ring Profile Grinding Machine 1997 - Production Internal Grinding Machine 1998 - GCH - CNC Heavy Duty Cylindrical Grinder 1999 - Collabora ti on with Lizzini Spa.Italy for CNC Int. Grinder “i – Grind 300” 2000 - Compact CNC Grinder model “e GRIND 320 ” 2001 - Compact CNC Grinder model “e GRIND 200 ” 2002 - Low cost high performance CNC Grinder model “eco tech 650”

Timeline

2002 - Sales & Service agreement with TOYODA-JAPAN for CBN Crankshaft and Cam lobe Grinders 2003 –Heavy Duty CNC Grinder “H Grind 360” for Crankshaf t Rear and Flange end Grinding 2006 - High Speed CBN Cam-Lobe Grinder GC20M-25S 2006 - “HMSI”, Best Supplier Award. 2007 FIE Award for Best Product at IMTEX’07 2007 - Universal Grinder B – Axis machine “FLEXI 65” 2007 - Crankshaf t Main Journals Grinder “RHINO 80” 2007 - Heavy Duty Cylindrical Grinding machine upto 2000 mm length. 2008 – TOYODA MICROMATIC Machinery India Ltd. – Joint Venture with JTEKT Japan. 2009 - “STALLION” series of new CNC grinding machine . 2009 - “BOSCH” Best Supplier Award.

YOUR TECHNOLOGY PARTNER SINCE 1973 YOUR TECHNOLOGY PARTNER SINCE 1973

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Products

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New Products

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Hero Honda 115 Rane Group 104 BOSCH India 62 TATA M OTORS 44 TVS 39 DTVS 35 Guehring OHG 32 Sona Group 30 Bajaj Auto 29 Kirloskar Group 23 Sriram Pistons & Rings 20 Cummins Turbo 17 Escorts Group 16 Defence Factories 15 M ahindra & M ahindra 13 Godrej 12 Indian Railways 12 Honda Scooters & M otor Cycle 11 Toyota Kirloskar Auto parts 10 Shri Ram Honda Siel 10 Sundaram Group 09 TATA Cummins 04 BPL, India 04 Tata Timken 03

Customers

3500 Installations, MGT is No. 1 in India

8 Plant 1 C ‐ 27, Ghaziabad 1997 Air‐conditioned plant C ‐ 28, Ghaziabad 2006 Air‐conditioned plant Plant 2 Plant 3 Feb’ 2009 MMS ‐ Micromatic Manufacturing Systems Pvt. Ltd for Sheet Metal parts Started in 1973 C ‐ 40/1 , Ghaziabad Air‐Cooled Assy. 1977

Plants

Plant 4 5/A , Dobaspet, Tumkur Road

• Bangalore. 2008

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State of the art Modern Plants at Ghaziaba d & Bangalore with Total State of the art Modern Plants at Ghaziaba d & Bangalore with Total Production Capacity to build 500 machines per year Production Capacity to build 500 machines per year CFC free air CFC free air-

• condi ti one d

Assembly plants condi ti one d Assembly plants Over 3500 machines installed Worldwide Over 3500 machines installed Worldwide

Assembly Facilities Assembly Facilities

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Factory Trained Service Engineers All Over India Time to Respond - 8 Hours Spare Part Stocking At Regional Level Tailor Made Training For All Levels Continuous Hand Holding

We Know ,We Care & We Perform to Satisfy Y

• u

TOTAL CUSTOMER SERVICE

CREA TING VALUE

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Customer Support Network in India

Contd……. Pune Gurgaon Bangalore & Chennai in 2010 Tech Centers to provide full support to customers 13

Customer Support Network 30 locations all over India

RS S GRINDERS ‐ US A Quality Machine Tools ‐ Australia Machinery Emporium ‐ Thailand REWITECH S A ‐ S WITZERLAND PAS S TECH Eng g . ‐ UAE TEMS AN MAKINE TURKEY MI‐ACE ‐ CHINA

Foreign Associates

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Global Leadership

IN

W orld Class High Technology

RINDING MACHINES

CREA TING CUSTOMER DELIGHT by

VISION

Self Motivated Team Members In Harmony with the Environment & Society

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Unchanged Core

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Our Values

Our ETHICAL VALUES have remained rooted in the past and remain non‐negotiable. Honesty Integrity Trust Equity Fairness Justice Respect

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Need for Business Excellence

Delivery Cost Quality

• Changing Business environment demanded

better performance on the above.

• MGT Management decided on the

Holistic Business Excellence approach.

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Excellence Journey – Roadmap

Daily management discipline Improvement culture Customer complaints Quality Excellence Working capital mgmt Improved Cash flow Value added to employee cost Job enlargement Process ow nership Productive Work culture Zero breakdow n Zero defect Paradigm shift Stability in process Reduced lead-time Customer satisfaction Lean thinking OEE increase Production increase

Result Input Impact Process

Waste elimination Operator ow nership In-house rejection Warranty claims High ITR

TPM Lean

M y m achi ne cam pai gn 3M 5S S t andards S M E D R ed t ag S i ngl e component f l ow C el l l ayout P l anned mai nt enance A ut onomous mai nt enance K anban l i nkage Takt t i me P

• ka Y
• ke

C

• nt ai neri sat i on

M ul t i machi ne manni ng Q ual i t y mai nt enance K

• bet su

K ai zen Logi st i cs P rocess capabi l i t y

Productivity improvement

5S

Quality M anagement Inventory M anagement

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Our Values

Changing business environments, impose need for changing OPERATIONAL VALUES (2010) Ownership & Commitment Exactness Self Discipline 360° Involvement & Feedback Speed Safety Responsible citizenship Law abiding Care for Society & Environment

Leadership Processes Key Performance Results People Results Society Results Customer Results People Partnerships and Resources Policy & Strategy I n n o v a t i o n and L e a r n i n g Enablers Results

The Excellence Model The Excellence Model

EFQM Model 22

‐Leadership ‐‐People ‐Policy & Strategy ‐Partnership & Resources ‐ Processes ‐Ownership & commitment ‐Self‐Discipline, 360º Involvement & Feedback ‐ Business Planning ‐Resources Management ‐Responsible Citizenship Care for Society & Environment ‐Exactness Business Excellence Operational Values

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Leadership Initiatives

New Plant in Bangalore Sheet Metal Plant at Ghaziabad Group Synergy SAP Partnership with world class companies

Started in 2005: forum at the highest level amongst all the group companies i.e. ACE, AMS, MGT, PRAGATI, MMT, PCT, & associate companies to create and utilize synergy amongst the companies on 7 disciplines: 1. People 2. Branding 3. R&D 4. IT 5. Vender 6. Common Sourcing 7. Cost Effective Part Production

Group Synergy

<<Back>>

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People-Employee Engagement Initiatives

Survey on:

• Passion
• Self‐Discipline
• 360º Feedback

Work Samiti Safety Committee Monthly General Meeting 5S being reinforced

<<Back>>

Findings of survey

There were three type of findings: 1. 84% Employees have passion. Its either the current work they are doing or some other related work. 2. 70% are satisfied with their current work & 14% have found passion in other work 3. 16% Employees think success can gives them passion. Total 25 employees were covered in this survey

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Self-Discipline

My Self Family Work Society switch off your phone spare time for your family come on time to stand in que at railway crossing. daily exercise. preparing children to go to school on time commitment not to spit / smoking in public places no smoking no guthka serve your parents training of juniors helping others follow rules don’t lie. honesty at work respecting younger's and elders

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360 Feedb ackQue sti

• nn

aire

D at e:

Seniors Peers Subordinates Intern al Customers Total Score

S . N

• .

P aramet ers S core S core S core S core S core 1 Focus

• n perf ormance

del i verabl es, excel l ence

• 1. 1

Fee l s c onc er ne d ab out pr o bl em s t hat f ace t h e or g an i zat i

• n

& w

• r ks w

i t h

• t her

depar t m ent heads t o r esol ve t hem

• 1. 2

E nsur es t hat depar t m ent al t ar get s not onl y m et but exceeded

• 1. 3P

ut s pr e ssur e on h i s t e am m em b er s t o e nsur e t h at dea dl i n es & qua l i t y r equ i r em ent s ar e m et . I n ot her w

• r ds

hol ds t eam m em ber s account abl e f or del i ver abl es

• 1. 4

Feel s t her e i s no poi nt i n t r yi ng har der as no one el se does A t t ri but e A verage 2 C

• mmuni cat i on

and Teamw ork

• 2. 1E

nc our a ges w

• r ks hop

m em ber s t o sp eak f r ank l y t o eac h

• t her about i

ssues upper m ost i n t hei r m i nds.

• 2. 2I n

com m un i cat i ng w i t h

• t h er

depar t m e nt al h ead s, has t he ski l l s t o r e sol ve pr o bl em s r eg ar d i ng c o- or d i n at i

• n so t hat w or k

i s com pl et ed sm oot hl y and ef f i ci ent l y.

• 2. 3I n case
• f f ai l

ur e/ pr o bl em o w n s t he r e spo ns i bi l i t y r at her t ha n shi f t bl am e t o j uni

• r s/ ot her

col l eagues.

• 2. 4I s an em phat i

c l i st ener

• f your / ot her peopl

es i deas

• 2. 5

H i s act i

• ns

cr eat e an envi r onm ent

• f t r ust i

nsi de t he com pany A t t ri but e A verage 3 S ubordi nat e D evel opment and G ui dance

• 3. 1C
• m m un i

cat e s cl ear l y a bout t he r ang e

• f

j obs & r esponsi bi l i t i es he expect s m e t o per f or m

• 3. 2C
• m m un i

cat e s cl e ar l y t he per f or m a nce st an dar ds ex pect e d f r om hi s j uni

• r s.
• 3. 3Tel l

s j un i

• r s

sp eci f i ca l l y w h at t hey have d one w e l l , w hi c h encour ages t hem t o per f or m bet t er .

• 3. 8Tr eat s hi

s j uni

• r s

w i t h i m par t i al i t y and f ai r ness A t t ri but e A verage

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Business Planning Initiatives

Preparation of Business plan FY 2009‐10 Set Company level objectives in key areas namely ‐ Customer , Business, Process & Learning Market analysis and identification of new segments Capturing VOC ‐ visits by senior managers. Divided in to strategic & operational issues Departmental targets & Reviews at MCM level <<Back>>

Compa ny Obje ctive s ‐ FY2 0 0 9 ‐1 0 Custome r Busine ss Proce ss Le a rning C1 Improve custome r sa tisfa ction inde x for Automotive a nd Ge ne ra l E ngine e ring ‐ 7 .7 to 9 B1 Improve T

• p Line ‐

MGT G‐ 4 5 MGT B ‐ 1 2 P1 De live ry time re duction/Re duce product Le a d T ime ‐ ST D ‐ 3 5 to 1 5 d a ys CNC ‐ 4 5 to 3 5 d a ys L1 Upgra da tion of skills(a quire d from Ja pa n/Swiss) a nd the ir Horizonta l De ployme nt in the Orga nisa tion up to 9 0 % ‐ b y Sep temb er 0 9 C2 Improve Qua lity Re duce wa rra nty cost, fie ld fa ilure s ‐ 5 0 % red u ctio n o ver la st yea r B2 Ma inta in Bottom line ‐ 4 Cr P2 MGT B‐MGT G inte gra tion ‐ b y E ND SE P T E MBE R 0 9 B3 Improve Ca sh Flow ‐ mo n th o n mo n th p o sitive P3 Re duce cost of ma nufa cturing ‐ BY 2 0 % FOR IDE NT IFIE D MODE LS B4 IT R ‐ 8 B5 Cre ditor Da ys ‐ 6 0 B6 Incre a se Ma rke t Sha re ‐ CNC ‐ 5 0 % HYD ‐ 6 0 %

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Resource Management Initiatives - Suppliers

Build Supplier Database Planned Audits at supplier end Pattern life monitoring Partnership with domain experts ‐ Castings Establish Vendor rating <<Next>>

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Resource Management Initiatives - Finances

Better Cost analysis – now available through SAP, helping to focus on reducing costs all across the organisation Better reporting to Board <<Next>>

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Resource Management Initiatives – A ssets & Infrastructure

TPM exercise in machine shop Tracking slow & non‐moving Inventory Tracking consumables usage Modification of Assets like electrical panels f

• r

improving Maintainability & Safety <<Next>>

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Resource Management Initiatives - T echnology

Joint development with customers – Bosch, high precision machine Training in key skills of machine assembly , scraping from Japan & Switzerland Association with Japanese & Swiss partners Working with IIT‐M & IIT‐D on next generation high precision machines, lifecycle monitoring etc. <<Back>> Responsible Citizenship Care for Society & Env ironment <<Next>>

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Operations Management Initiatives

Gemba meetings with CFT – Spindle Assy, Packaging, Cost saving, productivity improvement PQ/PP analysis Supermarkets for Sub assembly, Raw material Energy Saving – Reducing dependence on DG power Power Factor improvement Elimination of Drilling & T apping in Assembly Dust free Spindle Assembly area Elimination of Waste by Video analysis <<Next>>

Sl. No . DATE DESCRIPTIONS Dept . PROCES S OWNER RESP Tea m Mem ber s STA TUS TRGT DATE REMARKS 1 1 1 0 /0 7 /2 0 0 9 M/C progre ss status re port as on today with single click (re asons for de lay should be re corde d) ASSL Y RAY RAY JKT OP E N 2 8 /0 2 /2 0 1 0 Has be e n communicate d to JKT . JKT te am is working on same issue . 1 4 24/10/2009 Sche duling proble ms to raise with JKT & to be re solve d the same ASSL Y RAY RAY JKT OP E N 2 8 /0 2 /2 0 1 0 Has be e n communicate d to JKT . JKT te am is working on same issue . 1 5 0 3 /1 1 /2 0 0 9 Le ad time for main asse mbly routing & Mate rial re quire me nt Date must be corre ct (Mode l wise P lan for compone nt allocation to be give n by 4 /1 2 /0 9 & Compone nt allocation data with time line to be give n by 1 3 /1 2 /0 9 ) ASSL Y RK RAY RAY OP E N 3 1 /1 2 /2 0 0 9 1 )starte d in e ve ry ne w production

• rde r Fe e dback

awaite d from mate rial supplie r 2 ) Automatic m/c compone nt allocation issue give n to JKT 7 8 0 6 /1 1 /2 0 0 9 Produc tiv ity Im prov em ent: m inim um 3 Non-v alue added work related s ugges tions per day to be giv en by As s ly team . Im plem ented s ugges tions data to be pres ented. ASS LY IJS RK Srinivasa n, Kulde e p OP E N Daily

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Global Alliances

We will work with the Global Best and enhance India’s competence in Grinding Technology

39 High Speed 120m/sec CBN Cam Lobe Grinder . 1st time in India

<<Next>>

Global Alliances

MGT’s Assurance of Technical Leadership

40 <<Next>>

Global Alliances

MGT’s Assurance of Technical Leadership

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Results

• 2. 97
• 3. 02
• 3. 77
• 2. 3
• 1. 65
• 1. 50
• 2. 61

2 4 6 8 10 Q 1 Q 2 Q 3 Q 4

AVERAGE ITR

I TR‐ 09‐ 10 TARGET

• 0. 4
• 0. 41
• 0. 5
• 0. 32
• 0. 20
• 0. 24
• 0. 49
• 0. 1
• 0. 2
• 0. 3
• 0. 4
• 0. 5
• 0. 6

Q 1 Q 2 Q 3 Q 4 Rs LACS/EMPLO YEE

VALUE ADDED PER EMPLOYEE

VAPE‐ 09‐ 10

• 2. 8
• 3. 0
• 3. 6
• 3. 0
• 1. 0
• 1. 2
• 2. 3
• 0. 0
• 1. 0
• 2. 0
• 3. 0
• 4. 0

Q 1 Q 2 Q 3 Q 4

VALUE ADDED/EMPLOYEE COST

VAPCO ‐ 09‐ 10

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Results

• 0. 935
• 0. 96
• 0. 984
• 0. 9
• 0. 92
• 0. 94
• 0. 96
• 0. 98

1 Q 1 Q 2 Q 3

POWER FACTOR IMPROVEMENT

PO WER FA C TO R I MPRO V EMEN T 25 38 9 1 0 20 30 40 50 Q 1 Q 2 Q 3

NCR

N C R 1 5. 8 1 3. 0

• 9. 8
• 9. 7

1 0. 2

• 8. 8
• 0. 0
• 2. 0
• 4. 0
• 6. 0
• 8. 0

1 0. 0 1 2. 0 1 4. 0 1 6. 0 1 8. 0 Q 1 Q 2 Q 3 R S LA C S

Fuel & Energy Cost

2008‐09 2009‐1 0 61%

• 65. 0%
• 73. 0%
• 68. 0%
• 78. 0%

90%

• 0. 2
• 0. 4
• 0. 6
• 0. 8

1 August Sept em ber O ct ober Novem ber Decem ber J anuar y

COMPLIANCE TO SUPERMARKET LEVELS 44

Conclusion

Need for Holistic approach for SME’s. BE mode l as the Gita‐Bible. Maintaining Ethical Values non‐negotiable, keep discovering Operational Values Broader & Deeper , Customer Engagement Employee Engagement Supplier Engagement Push for Alliances at Domestic & International Levels. Partnering with Academia

..…. II-47

II-50

…….

……Union With God brings Excellence in Action Y

• ur right is to Action only, not to the results thereof……

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THANK YOU THANK YOU