13th Kaizen Conference
Rs 50 crores worth savings discussed in just 2 days
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In the present challenging economic scenario, to support the industry in their cost reduction efforts, TPM Club India organized the 13th Kaizen Conference in Pune on 10-11 August 2009 with the focus on “Cost reduction and Manufacturing optimisation techniques”.
20 successfully implemented kaizens were presented on the topic of Cost reduction which had resulted in great savings for the companies. The most significant achievement was “how even the operator’s could contribute” along with the others in the company. The topics covered had great relevance to energy, material and tool cost reduction.
On Manufacturing optimization, 18 companies competed on topics such as Easy to adjust, Elimination of minor stoppages, defect reduction, easy to inspect which had the operators direct contribution and set up time reduction, low cost automation and layout changes which had the contribution from the Managers. |
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| 13th Kaizen Conference |
48 Kaizens presented in the Conference : Benefits achieved by the TPM Implementing Companies |
Key Indicators |
Productivity |
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Set-up time |
Defect |
MTBF |
MTTR |
Energy Cost Saved (Rs.) |
Result |
3% - 200 %  |
10% -24%  |
90% |
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100% - 50% |
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3hrs to 8760 hrs |
15 hrs to 15 min. |
Rs. 1.21
Crore |
Key Indicators |
Inventory Saved(Rs.) |
Lead Time |
M/c Breakdown |
Maint. Cost Saving |
Capital Cost Saving |
Total Annual Saving(Cummulative) |
Result |
Rs. 10 Crore |
50% |
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40% - 90% |
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Upto Rs. 85000 |
Rs. 35 Lac |
Rs. 32.6 Crore |
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Major changes which could significantly contribute to cost reduction or manufacturing optimization techniques were also discussed. There were 10 presentations covering Lead time reduction, Equipment related design changes and new technology introduction / process modification.
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| View of audience attending the Conference |
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In all, 48 Kaizens were presented during these 2 days with the participation of around 180 delegates from 110 companies. The selection of the best kaizens was done by the participants, selected Jury members from the industry and Counsellors of the TPM Club India. The competition was tough and a very narrow gap differentiated the winners.
The winners in different categories were:
S no |
Category |
Company |
Topic |
1 |
Operator’s Category |
Mahindra & Mahindra Ltd, Nashik |
Defect Reduction |
2 |
Visaka Industries Ltd |
Easy to Adjust/ Adjustment Elimination |
1 |
Manager’s Category |
Sundram Fasteners Ltd, Krishnapuram |
Energy Loss Reduction |
2 |
TVS Motor Co Ltd, Mysore |
Low Cost Automation |
1 |
Sr.Manager’s Category |
Brakes India Ltd (Brakes Division), Sholingur |
New Technology introduction / process modification |
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Mr Ram Deshpande, Country Head, Vishay Components India Pvt Ltd and Mr Anil Parasharami, DGM, BE Division , Tata Motors Ltd were the Chief Guest at the Award Ceremony and distributed the Trophies to the winners. |
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The highlight of the conference was the winning of Brakes India Ltd, Brakes Division, Sholingur for a record 9th consecutive time. They have won the trophy in all the Kaizen conferences they have competed so far.
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| The 5 winners in the 13th Kaizen Conference with their trophies |
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| For more details please contact rajesh.parim@cii.in or jayashree.das@cii.in at the CII Institute of Quality |
