On the occasion of CII 1000 Visionary SME Programme Launch on 17th July 2013 in New Delhi, Pravesh Srivastava, Group President for Excellence in Manufacturing and Education, Anand Automotive Limited shared the success story. With learnings from VSME we have started our own "SSI Sahastra SME Institute". Under the leadership of Mr Deep Anand we have dedicated team of more than 150 managers and 250 engineers to transform our tier 2 companies in 3 years. We will also help other companies through CII to develop their SME's to achieve the target of 1000 SME's in next 3 years. For more information, please contact p.girish@cii.in

1. 1
Impressive Results
Anand T1 & T2
2010~2013
17-07-2013

2. 2
ANAND CORPORATE
ORGANISATION
VSME
*VLFM Opportunity “A” : 54
VLFM Opportunity “B” : 5
CS Patel
Sahastra SME
Institute
(SSI)
S Rathnam
(President)
Team (2)
VSME
Rajesh Kakkar
(Sr. Director)
Team (7)
PK Srivastava
(Member - Anand Supervisory Board)
(Group President-Excellence in Manufacturing)
17-07-2013

3. 3
COMPANY ORGANISATION
VSME
Full Time Resources Nos.
Sr. Mgr/ Mgrs - Plant 35
Mgrs/ A. Mgrs - VSME 11
Full-time Engineers 42
17-07-2013
Ten Plants

4. 4
COMPANY REVIEW SCHEDULE
Frequency
• Annual Graduation
Convention
Chairman
Mr. Deep C
Anand
Chairman
Mr. Deep C
Anand
ANAND REVIEW SCHEDULE
17-07-2013
Top Leadership Commitment

5. 5
Journey - The Snow Ball
Y2010-
T2-23
T1-5
Y2014-
T2-235
T1-23
Skill
Breakthrough
thinking
Small m toBIG M
Y2013-
T2-180
T1-18
Journey - The Snow Ball
17-07-2013

6. 6
T1 Improvements Glimpse
Business Growth (Rs.Bil)
Efficiency
COPQ (Rs.Mil)
23%
27%
37%
17-07-2013

7. 7
T2 Improvements Glimpse (VSME)
Business Growth (Rs.Bil)
Direct On Line PartsQuality PPM
8X
2X
2X
17-07-2013

8. 8
T1 Transformation
Space
Created for
New line
Element line
Manual Seaming
WIP-35000
inserts
Machines
Shifted
Project Objective:
1.Space creation for new roll
type line-business worth
110.0 mil per annum
Process :
1.Combining element lines
with seaming lines .
(T1 & T2)
2.WIP reduction from 35000
nos. to 4000 nos
3.Space creation of 690
Sq.mt
4.Reduce turnaround lead
time from 5 to 1 day
5.Manpower reduction of 12
nos from coil line
Element line
Manual Seaming
Before
After
Material
Movement-100ft
Tier-1
Tier-2
Online -singleTier
Mahle Parwanoo
17-07-2013

9. 9
Project : To reduce WIP between
paint booth and GRC packing
line from 20 to 5 trolley
Process:
1. Planning as per Heijunka for Painting
and Bush/Pack online
2. Balancing cycle Times across
operations
3. Reducing WIP of 4500 shox
between paint shop and packing
Line
4. Space Saving of 150 Sq ft
5. Lead time reduced from 5 to 1 days
Before
After
T1 Transformation
Gabriel Parwanoo
17-07-2013

10. 10
Project : To create Space for New
2 wheeler Line inside Factory –
additional business of Rs 240 Million
Process:
1. Made V-Map of the current state
2. Re-layout of Welding cell, outer
shell Machining center.
3. Space saving of 50 sq. mtrs
4. Additional business of Rs
240 mil started
50 sq. mtrs space
created
Gabriel Parwanoo
T1 Transformation
17-07-2013

11. 11
Combining
Coating
Screen
Printing
Blank
Reblank
Closing
Hyd
Flatt
RMS
Combining
Coating
Screen
Printing
Blank
Reblank
Closing
Hyd
Flatt
RMS
Project :Space created
for Multi layered steel
gaskets mfg cell- 144 Sq
Mtrs.
Potential sale – Rs 30
Mil/ annum
Process:
1. Drawn V-Map
2. Relocated coating area
3. Reduced travel distance
by 150 mtrs
4. Created a space of
144 sq. mtrs
Before
After
Space created-144
sq. mtrs
Victor Pune
T1 Transformation
17-07-2013

12. 12
Befo
re
Project : Additional Revenue
Generation with Same Space
Lines 2011 2013 Additional
Sales
Capacity
Condenser
Assy Line
2 3
135 Mil
Condenser
Core builder
2 3
Radiator Auto
Core builder
2 3 84 Mil
CAC Auto Core
builder
0 1 60 mil
HVAC Lines 8 11 40 mil
Total 14 21 319 mil
SHIPMEN
T
STORE
NOCOLOK LINE 1
EP1REW OR
K
Folded
TubeMill
U
n
l
o
a
d
i
n
g
B
a
y
s
L
o
a
d
i
n
g
B
a
y
s
NOCOLOK LINE 2
AFTERMARKET
AREA
Packing Area
EVAP
ASSYLIN
E
‘
SHIPME
NT
STORE
SHIPME
NT
STORE-
ET-V
VISCO CLUTCH
INCOMING STORE
EP2
QUARANTINE - AG
QUARANTINE -
EC
REW OR
K
KAIZEN
CORNER
KAIZEN
CORNER
CONTROL
PANEL
TMLVISTA
HVAC
TMLINDICA
HVAC
LoganHVAC
M&MSCORPIO
HVAC
GM&
MANHVAC
VW
HVACINCOMING
QU ALITY
INSPECTION
QU ALITY &
LOGISTIC
OFFICE
AREA
PLANT
BOARD
NOISE
CHAMBER
EVAP
MFG
Superma
rket AH
EVAP
COR
E
Build
er
HEATER
MFG
COND
MFG
COND
MFG
Office
Prodn Office
CRIMPING DIE
STOR AGE
SUPER
MARKET
EP
EC 2EC 1
EC
supermark
et
EC
3
Tooli
ng
area
Main. Stores
Con
d.
CB 3
FreeSpace
Mat
erial
MP
V
Hea
ter
Blo
wer
cell
INCOMING STORES WITH
SECTIONING
SHIPMEN
T
STORE
NOCOLOK LINE 1
EP1REW OR
K
Folded
TubeMill
U
n
l
o
a
d
i
n
g
B
a
y
s
L
o
a
d
i
n
g
B
a
y
s
NOCOLOK LINE 2
AFTERMARKET
AREA
Packing Area
EVAP
ASSYLIN
E
‘
SHIPME
NT
STORE
SHIPME
NT
STORE-
ET-V
VISCO CLUTCH
INCOMING STORE
EP2
QUARANTINE - AG
QUARANTINE -
EC
REW OR
K
KAIZEN
CORNER
KAIZEN
CORNER
CONTROL
PANEL
TMLVISTA
HVAC
TMLINDICA
HVAC
TMLVISTA
HVAC
TMLINDICA
HVAC
LoganHVACLoganHVAC
M&MSCORPIO
HVAC
M&MSCORPIO
HVAC
GM&
MANHVAC
VW
HVAC
VW
HVACINCOMING
QU ALITY
INSPECTION
QU ALITY &
LOGISTIC
OFFICE
AREA
PLANT
BOARD
NOISE
CHAMBER
EVAP
MFG
Superma
rket AH
EVAP
COR
E
Build
er
HEATER
MFG
Superma
rket AH
EVAP
COR
E
Build
er
Superma
rket AH
EVAP
COR
E
Build
er
HEATER
MFG
COND
MFG
COND
MFG
Office
Prodn Office
CRIMPING DIE
STOR AGE
SUPER
MARKET
EP
SUPER
MARKET
EP
EC 2EC 1
EC
supermark
et
EC
3
Tooli
ng
area
Main. Stores
Con
d.
CB 3
FreeSpaceFreeSpace
Mat
erial
MP
V
Hea
ter
Blo
wer
cell
MP
V
Hea
ter
Blo
wer
cell
INCOMING STORES WITH
SECTIONING
Space Creation
For additional Business
After
Behr Pune
T1 Transformation
17-07-2013

13. 13
Project Objectives:
1. Reduce Raw Material inventory from
Rs. 70 Mil to Rs.35 Mil.
2. Implement 3 “C” concept.
3. Delivery window adherence > 95 %.
Process:
1. Fixing Heijunka Frame
2. Calculating theoretical inventory &
keeping safety Stock
3. Preparing delivery window quantity
and timing for all suppliers.
4. Devising “consumption based” buying
strategy for import items.
RM Inventory reduction graph
70
42 35
0
10
20
30
40
50
60
70
80
June'12 Aug'12 Dec'12
Month
ValueinRs.Million
Mahle Pune
T1 Transformation
17-07-2013

14. 14
Before
After
Reduction of Lead Time from 12-18 days to 1-6 Days
100% (August’12) Plan vs Actual against 92% (April’12)
Form Turn
Machine1
CTB Machine
LRS
Key stone1-5
Profile
Grinder
WIP
WIP
Packing
Order Based
Production
Plan
Wait for Rings
12-18Days Lead Time
92%Plan vs Actual
•12-18 days LT
•92% Plan vs
Actual
• 1-6 days LT
• 100 % Plan vs Actual
1st
Electronic Kanban Card
System in Group
Live WIP & Inventory
Tracking, Control on Input-
Output Loss
Perfect Circle - Nashik
T1 Transformation
17-07-2013

15. 15
Analysis
ResultMajor Action Taken
Productivity improvement on Core Builder.
Units
Units per Man-day
Saving of INR 2.7 Mil
pa
Down time per Day
Combination of ramming and matrix holding plate
1.Reduce the 57min fin compression problem/day
2.10sec cycle time per core
Opportunity:-
Current production from CB is
5346nos/month against demand of
7000nos/month, which leads to loss of
1654nos/month
Goal:-To increase Productivity
to 50% through eliminating NVA
Using V-Map 3
Min
17-07-2013
T1 Transformation
Behr Pune

16. 16
Line contributing
45% of total sale
1% Line efficiency
loss contributing
` 3.4 million
sale loss
Order Fill
Ratio 83%
Project Theme: Increase Line Efficiency by 4% by
Change over time reduction
Project Theme: Increase Line Efficiency by 4% by
Change over time reduction
Opportunity:
Result:Analysis and Actions:
Efficiency Improvement
INR 4.6
Mill/Annum
added to
Bottom line
1. Reduce Change over time by 70%
2. Improve line efficiency by 4%
Goal:
17-07-2013
T1 Transformation
Mahle Pune
Order Fill Ratio
Improved from
83% to 96%

17. 17
T2 Transformation
Business with Anand
12
33
93
195
291
0
50
100
150
200
250
300
2008-
09
2009-
10
2010-
11
2011-
12
2012-
13
24
X
107
140
237
370
470
0
50
100
150
200
250
300
350
400
450
500
2008-
09
2009-
10
2010-
11
2011-
12
2012-
2013
Overall Sales
4
X
Kawach (Gabriel Pune)
17-07-2013

18. 18
BEFORE
Problem Impt.
‘U- cell’ layout for
different customers
Concern Benefit
More area covered due to
unorganized layout
Space released &
0.8 Mil new business planned
Job Shop Layout
AFTER
Open Space
Cell 5Cell 4Cell 3Cell 2Cell 1
Area Released
2150 Sq Ft i.e.
Rs10 Lacs
T2 Transformation
Sebros (Behr Pune)
17-07-2013

19. 19
BEFORE
Problem Impt.
Re-Layout using future state
V-map
Concern BenefitNo Space for additional lines New assembly lines planned
for the free space..
Business increase by 2 Mil
Capacity Constraint
AFTER
Open
space
Pratik (Victor Pune)
T2 Transformation
17-07-2013

20. 20
Tirupati (Mahle Pune)
BEFORE AFTER
T2 Transformation
17-07-2013

21. 21
17-07-2013
T2 Transformation
Precision Pressing (Spicer Jodali)
Quality
Transformation
Benefits Driven from QT- Module
1. Quality Improvement ( > 50 % Customer Complaints reduced in span for 3 month)
2. Quality Meeting (Training / Awareness on Product Quality)
3. PPM Reduction (Q1’13 - 525 PPM , Q2’13 – 236 PPM)
Improved Inspection Area
Plant operates with all women employees

22. 22
Winners Name of Awards
Victor
Pune
Platinum Prize (First) in Small scale
category of FICCI
Gabriel
Nasik
Platinum Medium size
Spicer
Jodali
Gold Medium size
Spicer
Pune
Certificate of Appreciation
Gabriel
Pune
Certificate of Appreciation
Chang
Yung
Certificate of Appreciation
Gabriel
Dewas
Certificate of Appreciation
Gabriel
Hosur
Certificate of Appreciation
FICCI Awards to VSME Plants
17-07-2013

23. 23
17-07-2013
Small ‘m’ to Big ‘M’
Creating New
Mindset
(Break Through Approach)
Reaching The Masses
The Way ForwardWay Forward…

24. 24
Thanks
VSME Anand
17-07-2013