Hi-Tech Gears Dec-10
Hi-Tech Gears Dec-10
Dec-10
Introduction
Founded in year 1986 A part of 100 million USD multi-location, multi-dimensional diversified Hi-Tech Group Products ranges from Automotive transmission parts to Industrial Robots Inbuilt Lean and TPM philosophies in operations Over 1600+ people ranging from Operational technologist to AI researchers Applied excellence in:
Manufacturing Transmission & Engine Components Engineering Services Industrial Automation & Robotics Embedded Systems and Artificial Intelligence
Be A Global Footprint Company and A Benchmark For World Class Manufacturing Systems
Hi-Tech Gears Mission
We will be the preferred partner in delivering engineering products and design solutions through lean philosophy with a focus on: Building a customer centric organization Rapid development of products and innovative solutions Ensuring cost effectiveness Developing competent and committed people
Organization
Deep Kapuria
50-50 Joint Venture with GETRAG
Getrag Hitech Gears I. pvt Ltd
Timing Gears
Pranav Kapuria
Hitech Gears Ltd
Anuj Kapuria
Hitech ESoft Hitech Robotic Systemz
Robotics
Power Transmission & Two-Wheeler Precision Forging/ Engineering Prec. Machining Transmission Unit Solutions Engine Components
Suman Kumar
GETRAG Hi-Tech
Rajesh Magoo
HGL Bhiwadi T&EC Plant
A.K. Verma
HGL Bhiwadi 2W Plant HGL Manesar Plant
Prashant Joshi
Millennium Plaza
K. Srinivasan
Info City Gurgaon
Bhiwadi
Gurgaon
Avinash Rao
Prashant Kumar
S.K. Chatterjee
cc A.K. Verma
Human Resource
Business Development
Milestones
1986 - 1990 The Beginning Product Indigenization 1991 - 1995 Technology Tie-Ups & Indigenization 1996 - 2000 Extending Partnership to Global Supply Chain 2001 - 2005 Growth for Domain Leadership 2006 - . Consolidation & Moving up the Value Chain
Incorporated as a Public Ltd Co. Production Commencement Single Source to Hero Honda
Technical Tie-Up with MUSASHI (Honda Motors, Japan) Backward Integration into Precision Forging
Technical Partnership with GETRAG, U.S. (1996 ~2006) Started Business with TATA CUMMINS LTD.
Launched initiative of Lean Manufacturing Certified for TS 16949 ISO 14001 OHSAS 18001 State-of-the-art manufacturing facility set up at Manesar Established HiTech Robotic Systemz
TPM implemented in full-scale across the group; TPM Excellence Award Awarded by JIPM ACMA Gold Medal for Manufacturing Excellence
HI-TECH e-Soft
Gurgaon / Pune / Chennai
A Division of Hi-Tech Gears e - Engineering Services ISO 9001
Clientele
Strategic Alliances
Broaden the customer base Marketing of Engineering Services & robotics as a separate division
TPM
03-Dec-10
14
Europe
GAWD JCB Cummins Robert Bosch Lister Peter
Europe
FCL ~ 4 Shipments (L.T. 25~30 Days) LCL ~ 5 Shipments (L.T. 25~30 Days)
Single point contact to the export customers for cargo related queries Cost minimization by maximizing returnable packaging & other improvements e.g. started long term contracts with i3PL for better rates negotiation, importing packing material from Sweden on behalf of one customer under bond to reduce cost
# of shipments are expressed in per month basis
Manufacturing Processes
Forging
Hot Forging Warm Forging Cold Forging Cold Extrusion Coining
Finishing
CNC Turning Gear Cutting (Wet & Dry Hobbing / Broaching / Shaping / Shaving) Spline Rolling Auto Shaft straightening Deep Hole Drilling, etc
Machining
Die Manufacturing
Vertical Machining Center EDM, etc.
Heat Treatment
Normalizing Case Carburizing, Carbo-nitriding, Nitro Carburizing, Press QuenchingNew Hardening Tempering etc.
Automation
Automation design and fabrication unit, Vision Inspection Robot integration setup
Manufacturing Infrastructure
AFTER
Example of POKA YOKE to avoid Punching angle out due to wrong broaching operation
Testing Infrastructure
Standard Room
Metallurgy Lab
Microscope
Strive for Business Excellence & Policy Deployment thru Mini-Factory Concept
Hi-Tech Group has the clearly defined process for 'Business Plan Development' and 'Policy Deployment
Business Strategy Development Mid-Term Plan Annual Operating Plan & Project Bank Policy Deployment (Linked with Performance Management System)
PRODUCTIVITY QUALITY
COST
DELIVERY
SAFETY
MORALE
ENVIRONMENT
TPM TPM
S.H.E. S.H.E.
All TPM 8 Pillars Structure & activities are in place at all manufacturing location at Hi-Tech Gears
Visual Factory
YEAR
2010 2010 2009-10 2009
RECOGNITION BY
QUALITY CIRCLE FORUM OF INDIA QUALITY CIRCLE FORUM OF INDIA (DELHI CHAPTER) ACMA SHINGO PRIZE ACADEMY, U.S.
TPM EXCELLENCE AWARD BEST SUPPLIER AWARD GOLD TROPHY FOR MANUFACTURING EXCELLENCE SILVER TROPHY FOR EXPORT EXCELLENCE STATE AWARD FOR EXPORT EXCELLENCE BRONZE TROPHY FOR EXPORT EXCELLENCE EXCELLENT PERFORMANCE AWARD AWARDED FOR DEPENDABILITY ON DELIVERY AWARDED FOR ACHIEVING QUALITY AND DELIVERY TARGETS AWARDED FOR VALUABLE CONTRIBUTION AND SUPPORT BEST QUALILTY AWARD
JAPAN INSTITUTE OF PLANT MAINTENANCE (JIPM), JAPAN FIAT GROUP NEW HOLLAND INDIA AUTO COMPONENTS MANUFACTURERS ASSOCATION OF INDIA ACMA GOVT. OF RAJASTHAN ACMA CUMMINS INDIA TATA CUMMINS HONDA MOTOR CYCLES AND SCOOTERS HONDA MOTOR CYCLES AND SCOOTERS TATA CUMMINS
03-Dec-10
28
Actual Forecast
Rev. 01
TO BE A BENCHMARK IN OPERATIONAL EXCELLENCE THROUGH CULTURE OF TOTAL EMPLOYEE INVOLVEMENT TO PROVIDE CUSTOMER DELIGHT
LEARNING ORGANIZATION RIGHT TALENT VISUAL FACTORY EHS SYSTEM-DRIVEN ECO FACTORY CONTINUOUS FLOW LEAN LOGISTICS ALL ROUND GROWTH SHARED LEADERSHIP
A P CONTINUOUS IMPROVEMENT D C
SUPPLIER
CUSTOMER
TPM
TEI
SO HP PA HS
. ID .C . 6.0M W E R .C ROAD
CA AD S R PY R
A TE WS ISP . D O
ID A AS W LKW Y 2.00MW E
W LKW S2.00MW A AY I
SO H PA HS
ID A AS W LKW Y 2.00MW E
ORGANIZATION
SYSTEMS
INFRASTRUCTURE
Incoming Inspection Board
Updation by - _________ Time - _____ Org Structure Dept Objective Dept. Targets Process 3 Process 1 Process 2 Process 3
Partition between Rec eipt Store & Supermarket
D I 0 AYS 2. 0M W E ALK W W
0 6. M. WIDE R.C.C. R O A D
I 0 A K AYS 2. 0M W DE W L W
SHO P F LO OR PHASE - II
R ECO SH ED
ND ITION ING
ASTE W S DI PO .
S E N W
SCRAP YARD
WALKWAYS2. 0M W DE I
WALKWAYS2. 00M DE WI
SHOP FL OO R PH ASE -I
I 0 A WALKW YS2. 0M W DE
I 0 A K AYS 2. 0M W DE W L W
Process 1
Process 2
PG L. . . RAG STO E
O AM NI A
G F. . DI SPATCH RM PLATEFO
BI N RAG E STO
BI N AS N W HI G
C AP. PANEL
1600 mm
# of Indirect Pending Lots Lots Receipt Details Vs Pending Action on Non Conformity # of Accidents DWM Action Log Audit Score
Supplier Tags Receipt Pending Lots Performance Vs Inspected Details Status # of Non Conformity Found # of Kaizen Action on Non Conformity # of Accidents DWM Action Log Audit Score
M NTAI EDLAN AI N W
VCBRO M 900X700 0 0O
M ETERRO M O 300X400 0 0
4 SF6-
SF6- 3
2 SF6-
2. 5M A V T2 SEC. . BI G W / RD E RO M O
2. M 5 VA T- 1
2PO LE STRUTURE C
Receipt Trolley
Tu n gI a r i ds e i n Rel o t t ai y A ch i ect u r e, St r ct ur e, P l ann er s & I t er i r s r t u n o J 2/1 5B as em en t , K i r i E xt n. Ma l i aN a gar h k v y N ew D el hi - 1100 17 Pho ne 011- 32565 401, 3 25654 18- 93 51409 980 e m a i - i nf o@ s hi l pka ar ar chi t ect s . o m l c
Form 1
Form 2
Form 3
Form 1
Form 2
Form 3
3500 mm
Bench for Drivers
2000 mm
Powered
<DT.>
<DT.>
<DT.>
<DT.>
<DT.>
<DT.>
PENDING KANBAN
RESP. - _______
2000 mm
Scissor Lift
Pallet Truck
Platform
1000 mm (Clear)
1000 mm (Clear )
Surface Plate
Retur n Chute
Marker Board
example
ExampleFRAMEWORK (INFRASTRUCTURE) InfrastructureDock & Receipt Area Image Plan - Incoming Materials IMAGE PLAN
200 + 550
4 .5 0 M . W ID E C .C . R O A D
S .T .P . E .T .P . SLU DG E D IS P O S A L R .O . PLANT D .M . W ATER SOFT W ATER W A L K W A Y S 2 .0 0 M W ID E W A L K W A Y S 2 .0 0 M W ID E
W A Y S 2 .0 0 M W A LK W A LK
W A LK
S H E D
Updation by - _________ Time - _____ Org Structure Dept Objective Dept. Targets
Updation by - _________ Time - _____ Org Structure Dept Objective Dept. Targets
R .C .C . R
W A Y S 2 .0 0 M
R .C .C . R
W A Y S 2 .0 0 M
SH O P FLO O R P H A S E - II
R E C O N D IT IO N IN G
A D
W ID E
W ID E
W ID E
A D
6 .0 M . W ID E
6 .0 M . W ID E
Y A R D W A S TE
D IS P O .
B IN
W A S H IN G
S E N W
S C R AP
2 3 0 T H K B R IC K W A L L ( T O B E D IS M E N T A L L A T E R )
W A L K W A Y S 2 .0 0 M W ID E
W A L K W A Y S 2 .0 0 M W ID E
F .G . D IS P A T C H
SH O P FLO O R P H A S E -I
W ID E W ID E W ID E
W A Y S 2 .0 0 M
2 .0 0 M
W A Y S 2 .0 0 M
W A YS
A M O N IA
Process 1
Process 2
Process 3
Process 1
Process 2
Process 3
L .P .G .
S T O R A G E
W A LK
W A LK
W A LK
P LA TE F O R M
B IN
S TO R AG E
3 0m LE N G T H S TRU C TU R E
W A L K W A Y S 2 .0 0 M W ID E
CAP. PANEL
1600 mm
# of Indirect Pending Lots Lots Receipt Details Vs Pending Action on Non Conformity # of Accidents DWM Action Log Audit Score
Supplier Tags Receipt Pending Lots Performance Vs Inspected Details Status # of Non Conformity Found # of Kaizen Action on Non Conformity # of Accidents DWM Action Log Audit Score
M A IN T A IN E D L A W N
4 PO LE S TR U C TU R E 3 3 K V H T L IN E
2 .5 M V A T -2
S E C ./W .B R ID G E ROOM
2 .5 M V A T -1
2 P OLE S TR U C TU R E
Receipt Trolley
T u rn in g Id e a s in t o R e a lit y
Form 1
Form 2
Form 3
Form 1
Form 2
Form 3
3500 mm
Bench for Drivers
2000 mm
Powered
VENDOR
ABC XYZ ASD ZKN ZDC
<DT.>
<DT.>
<DT.>
<DT.>
<DT.>
<DT.>
MON MON.
TUE MON.
WED
THU
FRI
SAT
DATE
RESP. - _______
2000 mm
Scissor Lift
Pallet Truck
Platform
1000 mm (Clear)
1000 mm (Clear)
Surface Plate
Return C
Marker Board
hute
Focus shall be on Efficient use of resources (on the principles of 3Rs Reduce, Reuse, Recycle) Maintenance friendliness
Implementation drive shall be through Study, analyzing the IGBC Green Factory Building Certification requirements and incorporating them into project timeline (one time tasks) and daily work management (for recurring tasks)
Business Head
LEAN LOGISTICS Each employee shall be assigned to an experienced, more HAPPY SUPPLIER (ecofac) (frequent delivery in senior employee - a mentor who provides guidance (Leveled Schedule) Operations small lots) through the process of making actual work-related Head LEAN LOGISTICS improvements GREEN BUILDING & LEAF HAPPY SUPPLIER (Leveled Schedule)
(frequent delivery in CNC MACHINES (ecofac) Supplier small lots) (technology) Production
Head
GREEN BUILDING & LEAF LEAN LOGISTICS HAPPY SUPPLIER (frequent(ecofac) in CNC MACHINES delivery Supplier (technology) Mini-Factory (Leveled Schedule) small lots)
Leader
A P CONTINUOUS IMPROVEMENT D C
oo SUPPLIER
oo oo oo LEAN LOGI SPIC N SPAN(frequent d Hi-Tech Gears 5-S) lots) (high level of small
LEAN LOGISTICS (frequent delivery in CNC MACHINES small Supplier lots) (technology)
o oo
A P CONTINUOUS IMPROVEMENT D C
oo SUPPLIER
SH
CNC (gl
A P CONTINUOUS IMPROVEMENT D C
oo SUPPLIER
o oo
CNC oo oo
CNC oo oo
CNC
CNC
LOAD LEVELING
oo
LEVELING
oo oo
CNC
oo oo
CNC
SUPPLIER
LOAD LEVELING
CNC CNC CNC
TOYOTA $ CNC CNC MUSIC KATA NOTES as SUPERMARKET RHYTHM OF WORK (pull system) (sound operating plan APPROACH
LOAD LEVELING
CNC
SUPPLIER
LOAD LEVELING
LOAD LEVELING
MUSIC NOTES as CUSTOMER HAPPY EMPLO RHYTHM OF WORK (sound operating plan) (employee frien