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WINNERS OF THE QUALITY CIRCLE COMPETITION FOR 2006 - 07 NATIONAL WINNERS Position Name of QC Team Company Name First Lupinus Sundaram Auto Components Ltd., Hosur Second Magic Delphi-TVS Diesel Systems Ltd., Chennai Third Newton Rico Auto Industries Ltd., Gurgaon Position Name of QC Team Company Name First Utsah Motherson Sumi Systems Ltd., Noida Second Lakshya Minda Corporation Ltd., Noida Third Newton Rico Auto Industries Ltd., Gurgaon Third Tiger Asahi India Glass Ltd., Rewari First Lupinus Sundaram Auto Components Ltd., Hosur Second Magic Delphi-TVS Diesel Systems Ltd., Chennai Third Vikasa Rane Madras Ltd., Mysore First Prajakta Harita Seating Systems Ltd., Pune Second Patang Jaya Hind Industries Ltd., Pune Third Rajgarh Kirloskar Oil Engines Ltd., Ahmednagar Third Achievement Tata Yazaki Autocomp Ltd., Pune REGIONAL WINNERS Northern Region Southern Region Western Region Auto News Auto News Special Edition September 2007

WINNERS OF THE QUALITY CIRCLE COMPETITION … OF THE QUALITY CIRCLE COMPETITION FOR 2006 ... Bharat Rajadhyaksha, General Manager (TQM), F orce Motors Ltd., Mr . A. K ... Sundaram

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Page 1: WINNERS OF THE QUALITY CIRCLE COMPETITION … OF THE QUALITY CIRCLE COMPETITION FOR 2006 ... Bharat Rajadhyaksha, General Manager (TQM), F orce Motors Ltd., Mr . A. K ... Sundaram

WINNERS OF THE QUALITY CIRCLE

COMPETITION FOR 2006 - 07

NATIONAL WINNERS

Position Name of QC Team Company Name

First Lupinus Sundaram Auto Components Ltd., Hosur

Second Magic Delphi-TVS Diesel Systems Ltd., Chennai

Third Newton Rico Auto Industries Ltd., Gurgaon

Position Name of QC Team Company Name

First Utsah Motherson Sumi Systems Ltd., Noida

Second Lakshya Minda Corporation Ltd., Noida

Third Newton Rico Auto Industries Ltd., Gurgaon

Third Tiger Asahi India Glass Ltd., Rewari

First Lupinus Sundaram Auto Components Ltd., Hosur

Second Magic Delphi-TVS Diesel Systems Ltd., Chennai

Third Vikasa Rane Madras Ltd., Mysore

First Prajakta Harita Seating Systems Ltd., Pune

Second Patang Jaya Hind Industries Ltd., Pune

Third Rajgarh Kirloskar Oil Engines Ltd., Ahmednagar

Third Achievement Tata Yazaki Autocomp Ltd., Pune

REGIONAL WINNERS

Northern Region

Southern Region

Western Region

Auto NewsAuto NewsSpecial Edition September 2007

Page 2: WINNERS OF THE QUALITY CIRCLE COMPETITION … OF THE QUALITY CIRCLE COMPETITION FOR 2006 ... Bharat Rajadhyaksha, General Manager (TQM), F orce Motors Ltd., Mr . A. K ... Sundaram

2September 2007

Auto NewsAuto News

The ACMA Quality Circle Competitions

Over the years, training and development of skills has emerged as a critical requirement for the Auto-Component

Industry in its current high growth phase. The industry has taken many initiatives in this direction, some of which are firm

level steps and some are industry-level initiatives taken through ACMA.

One of the most important initiatives taken by ACMA is to involve the Shop-Floor Associates in the Quality Circle

Movement. ACMA and ACT organized QC Competitions at the Regional and National Level with the objective of

bringing Organizational Development through Total Employees Involvement, by promoting Team Building and problem

solving skills at the Grass Root Level.

All the Regional QC Circle Competitions have been successfully held in the Northern, Southern and Western Regions.

Total 102 teams participated at the regional level competitions. The 2nd National QC Competition was held on 10th

August, 2007 in New Delhi wherein the winners of the Regional Competitions participated for the 1st, 2nd and 3rd

Positions at the National Level.

An eminent Jury comprising of experts from OEMs and QCFI adjudged the presentations made by all the QC Teams in

the National Competition. The Jury comprised of Mr. M. Muthuraj, Senior Vice President Operations, TVS Motor

Company Ltd., Mr. Bharat Rajadhyaksha, General Manager (TQM), Force Motors Ltd., Mr. A. K. Verma, Asstt. General

Manager, Hero Honda Motors Ltd., & Mr. Mahendra Aggarwal, Director, QCFI.

Dr. Krishan Kumar, Director, Maruti Centre for Excellence, was present as the Chief Guest. He also graced the occasion

and distributed the trophies to the winning teams. A brief summary of the top three award winning QC Circles at the

National level is as follows:-

LUPINUS QC Group Team Members are:

To recognize the outstanding contribution of the Associates, the QC Team who won the First Position at the National QC Competition will be awarded the Trophy by the Chief Guest at the Awards distribution ceremony of ACMA Annual Session.

Mr. R. Palvannan- Member

Mr. V. Bhaskar Reddy- Member

Mr. Vijaya Kumar P- Facilitator

Mr. R. Venkataramanan- Team Leader

Mr. M. Muniraju- Member

Mr. V.V. Srinivasan- Member

Winner

'LUPINUS' Quality Circle from Sundaram

Auto Components Ltd., Hosur

Sundaram Auto Components Ltd. is a TVS /

Sundaram Clayton group of company and

manufactures precision injection molded Plastic

Components for Automobiles.

The problem selected by the QC team was

“Reduction in High Breakdown Occurrence in

SM Series Molding Machines”. Total no. of

breakdown occurrence reported in the year

2005-06 were 323 which finally got reduced to

52 in the year 2006-07, which amounts to 84%

reduction in total machine breakdown.

Various QC tools like Pareto Analysis, Cause &

Effect Diagram and Scatter Diagram were used

extensively to find out the root cause of the

failures. Poka-Yoke and Horizontal Deployment

were applied to prevent the occurrence of the

defects.Cost saving achieved was Rs. 2.59 Lacs

/Annum by elimination of start-up rejection due

to power failure and increasing the availability

of machines for production.

Page 3: WINNERS OF THE QUALITY CIRCLE COMPETITION … OF THE QUALITY CIRCLE COMPETITION FOR 2006 ... Bharat Rajadhyaksha, General Manager (TQM), F orce Motors Ltd., Mr . A. K ... Sundaram

3

Auto NewsAuto News

September 2007

MAGIC QC Group Team Members are:Mr. S. Raja -Team LeaderMr. S. Gokulakrishnan - Member Mr. S.N. Parthasarathi- Member

Mr. K. Nanda Kishore- MemberMr. L. Navaneetha Krishnan-MemberMr. S. Hariharan- Facilitator

NEWTON QC Group Team Members are:Ms. Pushpa Bisht - LeaderMs. Monika Jindal- Dy. LeaderMr. Nitin Bharadwaj - Member

Ms. Vikky Chauhan - MemberMs. Anjum- MemberMr. Jayarama Pradhan- Facilitator

1st Runner Up'MAGIC' Quality Circle from Delphi-TVS Diesel Systems Ltd., Chennai

Delphi TVS is a joint venture between Delphi Automotive Systems, USA and T V Sundaram Iyengar & Sons, India. The Company is one the largest manufacturers of Rotary Fuel Injection Equipment in India.

The problem of low OEE of Parishudh Grinding machine was selected by QC Team for the improvement through Brainstorming & Pareto Analysis.

Team has used various QC tools like Cause and Effect Diagram, Histogram and Control Charts to arrive at the root cause of the problem and the controls thereof.

Overall equipment efficiency 74.81% has gone up to 88%. Other benefits like Setup Change Over Time has also got reduced from 4859 minutes to 125 minutes. Finally group succeeded in meeting the customer demand from same equipment.

2nd Runner Up

Rico Auto is one of the known manufacturer of Pressure Die-Casting & machining parts, supplying to major OEMs in India and abroad.

Newton QC circle of Rico Auto has selected the problem of high rejection due to Over Flatness in Rear Cover 7231 which results into the leakage from the Cylinder Block.

QC tools used to find out the root cause for the problem are Cause and Effect diagram, Pareto Analysis and Histogram.

Rejection because of over flatness got reduced from 6000 PPM to 0 PPM which has resulted in cost saving of Rs. 2,70,000/- per annum.

'NEWTON' Quality Circle from Rico Auto Industries Ltd., Gurgaon

The Jury ……………..

Dr. Krishan KumarChief Guest

Mr. Mahendra AggarwalMember

Mr. A.K. VermaMember

Mr. Bharat RajadhyakshaMember

Mr. M. MuthurajMember

Page 4: WINNERS OF THE QUALITY CIRCLE COMPETITION … OF THE QUALITY CIRCLE COMPETITION FOR 2006 ... Bharat Rajadhyaksha, General Manager (TQM), F orce Motors Ltd., Mr . A. K ... Sundaram

Edited & Published by Vishnu Mathur, Executive Director, Automotive Component Manufacturers Association of India,The Capital Court, 6th Floor, Olof Palme Marg, Munirka, New Delhi-110067 • Designed and Printed by Creation Prints # 9810416816

Auto NewsAuto News

Regional Award WinnersRegional Award WinnersNR

SR

Utsah Motherson Sumi Systems Ltd., Noida

Lupinus Sundaram Auto Components Ltd., Hosur

WR Prajakta Harita Seating Systems Ltd., Pune

Separate category for SMEs & Non SMEs from the year 2007-08. Equal opportunity to win Trophies at Regional/National level.

Good News for SMEs

NR-Utsah from Motherson Sumi Ltd., Noida

SR-Lupinus from Sundaram Auto Components Ltd., Hosur

WR-Prajakta from Harita Seating Systems Ltd., Pune

UTSAH TEAM

LUPINUS TEAM PRAJAKTA TEAM