S.C.O.P.E 2016: Day 1: Wordsworth: “SMART Manufacturing”- Mr. Tabrez Ahmed, DGM-Toyota Kirloskar Auto Parts

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Mr. Tabrez Ahmed, DGM-Toyota Kirloskar Auto Parts, through a set of video presentations explained that the concept of SMART Manufacturing, which in his view was connecting Shop Floor to the Top Floor. He spoke about SMART Manufacturing deliverables: Safety, Quality, Cost, HRD and Productivity, which formed an integral part of operational effectivity.

He spoke about key things at workplace for elimination of MUDA, which is the major concern for operational efficiency. Men – Standardized work is crucial for proper functioning. He cited the example of how using a teaspoon and a tablespoon of salt while cooking on two different days would make a huge difference to the same dish. Method – Effective Process Management which means an ensemble of activities of planning and monitoring the performance of a manufacturing process. Machine – which speaks of Ownership maintenance where technicians have a system ownership where technicians take responsibility for the receiving, grinding, extrusion, drying, packaging etc.

Further, Mr. Tabrez emphasized upon the importance of ‘Jishuken’ which meant self-learning. Implying there was an operational obstacle, the worker in relation to it needed to find ways of addressing the problem and resolving it. This resolution would be considered as his ‘Jishuken’ where experience gained would result in versatility of the employee. This being mainly because “If you are not able to synchronize what you manufacture with Supply chain, it means there is no efficiency”, he said.

During his interaction with students, he pointed out various methods used by Toyota Kirloskar Auto Parts like 5S, Kaizen, Total Employee Involvement and mused on the importance of Understanding deep cleaning and concluded with a final short video of the evolution of techniques used for efficiency in operations from the 70’s.

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