- We visited India Piston Rings Ltd on 1st October 2012 at 12:00 P.M to 4:00 P.M at Maraimalai nagar plant, Chennai.
- Prof.Ranganathan, Ms.Renuka & Ms.Jaisuchi tailor led students on the visit.
- On behalf of Company Mr.Rajamanikam (HRD General Manager) welcomed and also gave invaluable information regarding India Piston Ring Ltd. He also accompanied and explained us the various process in the plant.
Company
Fact Sheet
Company Information : India Piston Rings is promoted by India Piston limited a memeber of the amulgamation group. It is one of the largest producers of Pistons, Piston rings, Gudgeon rings, Cylinder liners and allied components in India. Formed by Mr.S.Anantharamakrishnan in July 1949. In 2010-11 its revenue was $350 million.
Year of
Establishment : 1991
Nature
of Business : Manufacturer
Total
Number of Employees : 600 Employees
Conform
Employees (Operators) : 150
Trainee/Apprentice : 150
Management Staff : 110
Contract Employees : 125
Supervisors/B.E : 80
(75%
of employees are ITI holders & 25% are +2 & 10)
Major Markets : Indian –
OEM (Original Equipment Manufacturers)
Primary Competitive Advantage
: Technical
collaboration with Nippon Piston Rings, Japan
: Surface
Coating Technology
: Latest
Surface Coating Technology
: Experienced
R&D department
: Good
TQM implementation
Plant and Machinery:
At India piston rings, they have latest state of the art manufacturing
plants and machineries having a capacity of 10 lakh piston rings per month. India
piston ring produces piston rings, both compression and oil control rings for a
variety of gasoline and diesel engines. They offer Pistons made out of a
variety of high quality cast iron and steel materials. Their raw materials are
being imported from Japan and the materials ranges from grey cast iron; (heat treated)
alloyed grey cast iron to sperodial graphite cast iron. Their product Piston
rings which includes high alloyed steel having 17% carbon content. In India
piston rings they have process which include surface treatments or coatings
like Granoliting, Chrome plating, Chrome Molly, Molybdenum, Moly Chrome Ceramic
and Flame sprayed coatings. Their Piston rings fits for Pistons with bore
diameters ranging from 35 to 160mm.
Products of the Company:
- Piston Rings for four wheeler & Gears
Quality Assurance:
They are quality oriented organisation which is ISO 9001:2008
for management system and ISO/TS 16949 an ISO for technical specification aiming
to the development of a quality management system that provides for continual
improvement, emphasizing defect prevention and the reduction of variation and
waste in the supply chain. The company believes in providing the clients with
the premium quality products as per their specifications and requirements. In my
observation I found that their quality control is rigid and they implement TQM
(Total Quality Management) system so that the finished products are at par with
the international quality standards.
Manufacturing Units:
They have the manufacturing process in the latest technology
from Japan is installed. This ensures the quality and fast production of Piston
rings. Manufacturing is done as per the specifications and the requirements of
their clients. Major of their selling is to the OEM (Original Equipment
Manufacturer) in India and they do export a very little amount of their
products to Bangladesh, Nepal and Sri Lanka. They have divided their
manufacturing units into 24 zones for better maintenance.
Ware-housing and packaging:
They have a well spacious warehousing unit for the safe
storage of products. Quality is assured at every stage.
Current and Future Expansions:
In our conversation with Mr. Rajamanikam, he briefed us about
the future plans. In 2004 they expanded themselves into gear manufacturing from
Piston Rings. Also, by very next year they are planning to enter into the 2
Wheeler piston ring market. The entire organisation strive to achieve 5 star
because an external audit which is conducted every year by Hyundai rate in 5
star. If they achieve they bag the project to supply piston rings to Hyundai
all over the world.
Clients:
They have a huge customer base in India.
1.
Ashok
Leyland
2.
Tata
3.
Mahindra
4.
Eicher
5.
Escorts
6.
Hindustan
Motors
7.
Ford
8.
Maruti
Suzuki
9.
Royal
Enfield
1. Hyundai
Competitors:
In our conversation with Mr.Rajamanikam, India Piston Rings
currently have a 50% market share and their major competitor is Sriram pistons
& rings ltd.
Some Good Practices found in India Piston Rings:
- Hands on system – Each machine has a Beacon attached. Where three lighting are there which has specific meaning.
o
Green
Light – Machine is functioning
o
Red
Light - Some Problem in the Machine
o
Amber
- Machine is in need of materials
- OPC (Operation Control Process) – To recycle the scraps. Currently, they sell their paper scraps and 1.2% industrial scraps to the vendors.
- 2 suggestions for improvement in process is mandatory for each employee per month.
- Small Group activities scheme is introduced and managed.
Achievements:
- 100PPM certificate from Hyundai
- Gold and Platinum award for quality excellence
- Frust and Sullivan IMEA super gold award for manufacturing
- ACMA silver trophy for excellence
- HV Axles ltd – best new mod. Company
Corporate Social Responsibility:
- Rain water harvesting – Maintained in their own premises
- Commitment to Society – Park maintenance at Maraimalai nagar
- Recently donated 3 lakh worth X-ray unit to hospital
- Annually they spend 4 lakh for Single teacher program – 10 schools are being maintained by the management and 4 schools by the employees contribution.
No comments:
Post a Comment