CII Best Kaizens

Kaizen Best Practices Case Studies by Member Companies of CII Southern Region June 2012

Kaizen Best Practices Case Studies by Member Companies of CII Southern Region Kai-Zen is Japanese for "improvement", or "change for the better“. It refers to philosophy or practices that focuses upon continuous improvement of processes in manufacturing, engineering, game development, and business management, amongst others. When used in the business sense and applied to the workplace, kaizen refers to activities that continually improve all functions, and involves all employees from the CEOs to the assembly line workers. Over the years, organizations have been successfully practicing Kaizen for excellence and have realized that the basic imperatives to survive in today’s competitive environment need “Kaizen Continuous Improvement”. With this background CII Southern Region Manufacturing Competitiveness Sub-Committee started the initiative of Kaizen Competition in 2006 in order to create awareness of the Best Kaizen Practices in the industry and make them known to all. The compilation of case studies provided in this publication are the entries of CII SR Kaizen Competition 2011 Winners Of CII SR Kaizen 2011 First Place

Large & Medium Scale – Manufacturing Category

Second Place

Large & Medium Scale – Manufacturing Category

Third Place

Large & Medium Scale – Manufacturing Category

Brakes India Ltd Toyota Kirloskar Motor Pvt Ltd Mahle Filter System (India)

New Horizon Engineering Ltd

First Place

Small Scale – Manufacturing Category

Second Place

Small Scale – Manufacturing Category

Farida Leatherware Pvt Ltd

Third Place

Small Scale – Manufacturing Category

Sunbeam Generators Pvt Ltd

First Place

Large & Medium Scale – Service Category

Second Place

Large & Medium Scale – Service Category

Third Place

Large & Medium Scale – Service Category

NCR Corporation India Pvt Ltd Cognizant Technology Solutions India Pvt Ltd T V Sundram Iyengar & Sons Ltd Tirunelveli

2

Case Study

Pg#

JK Tyre & Industries Ltd

53

Komatsu India Pvt Ltd

55

Lap Ross Engineering Ltd

57

Lapp India Pvt Ltd

63

Mahle Group

64

NCR Corporation India Ltd

65

Rane Engine Valve Ltd

68

Sansera Engineering Pvt Ltd

69

TVS Sundaram Iyengar & Sons Ltd

70

SRF Ltd

73

Sterlite Industries India Ltd

78

Sunbeam Generators Pvt Ltd

81

TaeguTec India Pvt Ltd

82

Tata Advanced Systems Ltd

85

Titan Industries Ltd

87

40

Toyota Kirloskar Motor Pvt Ltd

91

Greaves Cotton Ltd

44

TVS & Sons Ltd

94

Harita Fehrer Limited

46

Voith Turbo Ltd

97

Harita Seating Systems Ltd

49

WABCO India Ltd

99

ITC Paperboards and Specialty Papers Division

50

Wheels India Ltd

100

Wipro Infrastructure Engineering

102

Case Study

Pg#

3M

04

Ashok Leyland

08

Anand Engineering Corporation

10

Bharat Earth Movers Limited

13

Bosch Ltd

16

Brakes India Limited

21

Caparo Engineering India Pvt Ltd

22

Cooper Bussmann India Pvt Ltd

23

CRI Pumps Pvt Ltd

25

CUMI Ltd

31

Cura Healthcare Pvt Ltd

32

Dell

33

Farida Group

35

Fenner India Ltd

38

Flextronics International Ltd

39

Ford India Pvt Ltd

Kaizen Best Practices Case Studies by Member Companies of CII Southern Region

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The CII SR 8th Kaizen Competition is held to motivate member companies striving towards continuous quality improvement (Kaizens) of standardized activities in the process or product in the machine or design thereby saving time, cost, and minimizing wastage. To be held on 28 September 2012

For details on CII SR Kaizen Competition 2012 Please contact: Savitha Rao [email protected] | 044 4244 4555 104