Year
| 04 - 05 | | 05 - 06 | | 06 - 07 | | 07 - 08 | | 08 - 09 | | 09 - 10 | | 10 - 11 | ||
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Year : 04 - 05
| Sr.No | Company | Project |
| 1 | Abicor Binzel Production (I) Pvt.Ltd. | Setting Production Norms |
| 2 | Alfa Laval (I) Ltd. | Setting Production Norms |
| 3 | Cadbury (I) Ltd. | Productivity Improvement |
| 4 | Carraro India Ltd. | Process Sheets Setting Production Norms |
| 5 | Fleetguard Filters Pvt.Ltd. | Setting Production Norms |
| 6 | AIndo Schottle Auto Parts Pvt.Ltd. | Setting Production Norms |
| 7 | Invensys India Ltd. | Motion Economy Improvement & Setting Production Norms |
| 8 | St. Joseph's Technical Institute | Business Potential of Machining Facilities |
| 9 | Trumbak Rubber Industries Ltd. | Manpower Assessment |
| 10 | Larsen & Toubro Ltd. | Plant Layout Study |
| 11 | DGP Hinoday (I) Ltd. | Setting Production Norms |
| 12 | Hindustan Coca - Cola Beverages Pvt. Ltd. | Productivity Improvement |
| 13 | L & T Johndeere Pvt. Ltd. | Productivity Improvement of Tractor Assembly Productivity Improvement of Paint Shop |
| 14 | Parle International Ltd. | Manpower Restructuring |
| 15 | L & T John Deere Pvt. Ltd | Productivity Improvement of Engine Machine Shop |
Year : 05 - 06
| Sr.No | Company | Project |
| 1 | Garware Polyster Ltd. | Manpower Assessment |
| 2 | Trinity Die Forges Ltd. | Setting Production Norms |
| 3 | CL & T John Deere Pvt. Ltd. | Productivity Improvement of Transmission Machine Shop |
| 4 | Behr India Ltd. | Production Norms for AIR – Conditioner Assembly HVAR & Die Models. |
| 5 | Mahyco Seeds Ltd. | Manpower Assessment of BT Cotton Packing Line |
| 6 | Trinity Die Forges Ltd. | Setting Production Norms |
| 7 | L & T John Deere Pvt. Ltd. | Plant Layout study |
| 8 | Ruchi Soya Industries Ltd. | Manpower Assessment |
| 9 | Hardik Founders & Engineers Pvt. Ltd. | Productivity Improvement |
| 10 | Sujanil Chemo Industries | Manpower Assessment of pesticides packing lines |
| 11 | Besqaure Packing | Manpower Assessment of pesticides packing lines |
| 12 | John Deere equipment Pvt. Ltd. | Production Norms for Transmission Lines-s and AA Models. |
| 13 | Briocia Pharma (India) Pvt. Ltd. | Setting of time standards & Assessment of existing man power |
| 14 | Henkel Loctite (I) Ltd. | Productivity Improvement |
| 15 | DGP Hinoday India Ltd. | Setting norms for inspection activities (visual): Finishing |
| 16 | John Deere Equipment Pvt. Ltd. | Setting Production Norms for Turbo Engine Assembly Line. |
| 17 | Garware Polyster Ltd. | Manpower Assessment. |
| 18 | Sussen Asia Pvt. Ltd. | Set Production Norms for Machine Shop. |
Year : 06 - 07
| Sr.No | Company | Project |
| 1 | Baxter (India) Pvt. Ltd. | Manpower Assessment |
| 2 | JCB Manufacturing Ltd. | Layout for Fabrication Assemblies |
| 3 | Suessen Asia Pvt. Ltd. | Production Norms Setting |
| 4 | Franke India Pvt.Ltd. | Production Norms Setting |
| 5 | DGP Hinoday India Ltd. | Revised norms for melting activities after tapping due to method change |
| 6 | Birla Corporation Ltd. | Production Norms Setting. |
| 7 | Garware Polyesters Ltd. | Manpower Assessment |
| 8 | Garware Industries Ltd. | Manpower Assessment |
| 9 | Renfro India Pvt. Ltd. | Productivity Improvement |
| 10 | JCB Manufacturing Ltd. | Fabrication layout for Trackframe |
| 11 | Enkei Castalloy Ltd. | Setting Production Norms for LPDC Operations |
| 12 | Indofil Chemical Company | Productivity Improvement |
| 13 | Knorr - Bremse Systems. | Productivity Improvement |
| 14 | M & M | 5 'S' Auditing |
| 15 | Tata Motors Ltd. | 5 'S' Auditing |
| 16 | SKF India Ltd. | Productivity Improvement in FPS |
| 17 | Century Enka Ltd. | Work study and Improvements |
| 18 | Sarod Engineering Pvt.Ltd. | Setting Production norms |
| 19 | Spaco Carborattors Ltd. | Setting Production norms |
Year : 07 - 08
| Sr.No | Company | Project |
| 1 | Suzlon Structures Pvt. Ltd., Gujrat | Productivity Improvement Study |
| 2 | Automotive Stampings, Chakan | Production Norms Setting s |
| 3 | JCB manufacturing Ltd., Talegaon | Production Norms Setting |
| 4 | Oriental Synthetic & Rayon Mills Pvt. Ltd., Umbergaon | Restructuring of Manpower |
| 5 | Raymond Fedora Pvt. Ltd., Jalgaon | Restructuring of Manpower |
| 6 | Mahindra Hinoday Ltd., Urse, Talegaon | Production Norms Setting |
| 7 | Mahle Filter Systems Pvt. Ltd., Mulshi, Pune | Productivity Improvement Study |
| 8 | EPCOS India Pvt. Ltd., Nasik | Production Norms Setting |
| 9 | Garware Polyester, Garware Industries AURANGABAD | Manpower Restructuring |
| 10 | Metachem Mfg. Co. Ltd., Chinchwad | Productivity Improvement Study |
| 11 | TC Springs, Pune | Production Norms Setting |
| 12 | Knorr Bremese, Pune | Production Norms Setting |
| 13 | Briocia Pharama, Jejuri | Restructuring of Manpower |
| 14 | Serum Institute, Pune | Restructuring of Manpower |
| 15 | Ruchi Soya, Patalganga | Restructuring of Manpower |
Year : 08 - 09
| Company Name | Company Profile | Client Needs | Pdpc's Services | Productivity Achivements | Report Date |
| JCB MANUFACTURING LTD., Talegaon, Dabhade. | JCB Manufacturing Ltd. is a leading name in Earthmoving, Agriculture and Material Handling Equipment. | To set production norms for Hydraulic tanks To suggest methods improvement , if any | To set production norms for Hydraulic tanks To suggest methods improvement , if any | PDPC HAS SET THE PRODUCTION NORMS Reduction in efforts of workmen Productivity improvement by 40% | Aug. 2008 |
| Serum Institute Of India, Hadapsar | Serum Institute of India Ltd. is a leading name in vaccines, Biotech products, Anti cancer and other pharmaceutical Products. | To study existing processes in screening and packing and suggest methods improvements To set the norms for production To balance Lines | Every activity is studied with respect to
1.Operator- competence 2. Machine- Maintenance , Working conditions 3. Methods- SOPs, WI, Ergonomics 4. Material- Flow, Identification 5. Work measurement using stop watch After the data collection, analysis was done to achieve 1.Minimize the time required to perform the task 2.Optimization of manpower on shop floor |
1. PDPC has set the norms for the production The shift changeover time was reduced from 70min. to10 min. making 60 min. productive Low cost Automation was suggested by PDPC for pick up vials during checking. Due to this out put can go up by 10 to 15% Improvement in system / methods suggested by PDPC can optimize manpower (present manpower - 30 proposed manpower- 12) Various methods improvement and layout improvement suggestion were give by PDPC can reduce the cycle time | Sept. 2008 |
| Serum Institute Of India, Hadapsar | Serum Institute of India Ltd. is a leading name in vaccines, Biotech products, Anti cancer and other pharmaceutical Products. | To evaluate the need to enhance officer level staff | 1. The workload of the officer level staff is basically supervisory in nature and consists of a major component of data keeping and co-ordination. Methodology used for the study was Observation, Data collection for previous period Discussion with officers and other staff interacting with them Making projection for a changed method of working. | A rearrangement of working method is proposed by PDPC to optimally utilize the officers available ( Current officers-20 Proposed Officers-17) PDPC suggested if single shift Operation becomes feasible, staff requirement for packing/ labeling/domestic distribution will go down. PDPC also suggested that all officers should be competent of doing machine setting and testing and all operators should be capable of setting the machine to avoid the bottlenecks | Sept. 2008 |
| Automotive Stampings & Assemblies Ltd. Pune | Automotive Stampings & Assemblies Ltd is situated at medankarwadi Pune. The organization is involved in manufacturing of pressed components for reputed industries like Tata Motors etc. | Establish Production Norms for various components. Suggest method improvements | Work measurement is carried out using Predetermined Time standard Technique Observations / Suggestions recorded in the report for productivity | PDPC has set the production norms. PDPC has given various suggestion to maximize machine utilization PDPC has given to make use of staggered lunch system to reduce the impact of loss of production Various methods improvement suggestions were also give by PDPC to improve the productivity. One of them is - Die should be designed is such a way that after press stroke scrape should fall automatically in the duct. this will reduce the cycle time & hence improving productivity Material handling improvements were also suggested by PDPC. | Aug. 2008 |
| Raymond Fedora Pvt. Ltd.Jalgaon | Raymond limited, leading name in premium textile, has 4 plants in India manufactures worsted fabrics & blankets. The company's products are well known in the market for quality. | Assess the present utilization status of existing manpower. Provide a base for performing restructuring activities. Suggest method improvements. | Work measurement technique , Time Study was carried out using stop watch and wherever possible the past data such as production reports, Log books , etc were referred Based on office workload clerical staff were assessed Suggestion for improving productivity is suggested. | Improvement suggestions are given by PDPC to reduce the manpower PDPC recommended that the machines having low utilization should run on two shift basis or single shift basis which will reduce the consumption of utilities like Electricity, Steam, Oil & further will improve the utility consumption. Additional manpower saved/ generated by implementation improvement is 82 workmen/ day. Method Improvement suggestions given by PDPC doubled the machine capacity | June 2008 |
| Epcos India Pvt. Ltd. ,Satpur, Nasik | The organization 'EPCOS India Pvt. Ltd.' is situated at Satpur, Nasik. The organization is involved in manufacturing of film capacitor. | Setting the norms for Production Suggest method improvement | Work measurement carried out using Predetermined Time Standards Technique Relaxation allowances were considered as per ILO guidelines Production norms calculated based on the PTS output | Production norms were set by PDPC. Method improvement suggestions were given by PDPC. Layout improvement suggestions were also given by PDPC to improve material handling | March 2008 |
| Spaco Technologies (I) Pvt. Ltd., Chinchwad | M/S SPACO Carburetors are in the business of manufacturing automotive carburetors and the major customers are z Bajaj Auto Ltd., Kinetic Engineering Ltd.,TVS Motors | To map current state value of facelift II Indica Front Bumper. | Work measurement of the operations was carried out using stopwatch Method improvement were suggested | Production norms are set by PDPC
PDPC suggested improvements in the method of working on pressure die casting machine
PDPC suggested improvements in work allocation system and work practices to avoid wastage of production time
Following revised shop working methods are suggested by PDPC so as to get half an hour extra production 1. Staggered lunch break system production 2. regular operator taking care of additional automatic machines during lunch recess 3. Additional reliever operators in relevant area. |
May 2008 |
| Mahle Filter Systems (I) Pvt. Ltd. | Production norms are set by PDPC PDPC suggested improvements to maximize operator utilization PDPC has given Material Handling; Method improvement suggestions which inurn will increase the Productivity. | April 2008 | |||
| Kalyani Forge Ltd., Koregaon Bhima, Pune | Kalyani Forge Ltd. is a leading name in Automobile Sector for Forging Component. | Setting production norms Suggesting method improvement. | Work measurement was carried out using stopwatch Observations / suggestions recorded in the report for productivity improvements. | Production norms are set by PDPC Material handling suggestion given by PDPC will reduce fatigue of the operator Method improvement suggestions were given by PDPC. This improved the machine utilization and reduced the cycle time. Layout improvement suggestions were given by PDPC Low cost automation was suggested by PDPC Tooling improvements suggested by PDPC will reduce the cycle time thereby improve machine utilization | Nov. 2008 |
Year : 09 - 10
| Company Name | Company Profile | Client Needs | Pdpc's Services | Productivity Achivements | Report Date |
| Alfa Laval, Pune | Alfa laval Pune(HSS, Module, Decanter, PEM, Service Group) | 1. Assess the effictiveness of the present incentive schemes. 2.To suggest a common incetive scheme if any |
Alfa laval management approched PDPC to evaluate & revise existing incentive scheme. | Improvements in manufacturing effectiveness is recommended for all direct and indirect | April. 2010 |
| S.B. Reshellers.Pvt.Ltd., Kolhapur | S.B.Reshellers Pvt. Ltd. Located at Shiroli M.I.D.C., Kolhapur manufactures shell & rollers. | To set standard times for the operations in machine shop such as boring of shell, shell parting etc. To suggest methods improvement if any | 1.To Set production norms using video Timer Pro : Work
Measurement by Video shooting & Analysis using Software. 2.Allowances were decided as per ILO guidlines. 3. Method improvement |
Machine parameters were actually implemented & no resultant adverse effects observed. 1. Shell Tapping - Drill cycle is incresed by 21%. 2.CNC Grooving incerase by 28.57% |
Mar. 2010 |
| Grindwell Norton Ltd, Nagpur. III and IV. | Grindwell Norton Ltd, Located at Nagpur Manufactures Abrasive wheels required throughout industrial sector | 1.To set a production norm by timestudy using stop watch. 2.To suggest method improvement. if any |
Relaxation Allowances were decided as per ILO guidlines. 2.Method Improvement suggest 3. Set Production Norm and Time study techanique. |
1.Remarkable increase in production within various departments. 2. Very strong workers union agreed for accepting PDPC production norms. |
Jan 2010 |
| S.B. Reshellers.Pvt.Ltd., Kolhapur | S.B.Reshellers Pvt. Ltd. Located at Shiroli M.I.D.C., Kolhapur manufactures shell & rollers used by sugar industries both nationally & internationally. | To set standard times for the operations in machine shop such as boring of shell, shell parting etc. To suggest methods improvement if any | To Set production norms using video Timer Pro : Work Measurement by Video shooting & Analysis using Software. | Cycle time reduction by 72% | Feb. 2010 |
| West Coast Paper Mills Ltd.,BangurNagar,Dandeli (Karnataka) | West Coast Paper Mills Ltd. Is situated at Bangur Nagar, Karnataka. The organisation is involved in manufacturing of print paper & duplex boards of various sizes & GSM in reams of reels. | To improve productivity through manpower assessment and restructuring | Assessing manpower utilization of direct on the shop floor as well as indirect staff i.e.planning, maintenance, stores, purchase, logistics , HR etc. | 1. Manpower productivity rise of 12.3% by
the way of utilization. 2. Identification of excess manpower to the tune of 67.3% by the way of optimization & atomization of methods in operations, raw material, yard,chemical & paper godown |
Jan. 2010 |
| Grindwell Norton Ltd., Nagpur | Griendwell Norton Ltd., located at Nagpur, manufactures Abrasive wheels required throughout industrial sector. Company has a very strong workers union. | To set production norms for various products & convince worker union members. | 1. Grindwell union leaders visited
companies where PDPC had conducted productivity studies & discussed with
their management as well as union leaders & unanimously decided the
acceptance to PDPC services
2. Set production norms. |
Production rise -
1. 40% in Thin wheels, 70% in bonded & 30% in coated disc. 2. Very strong workers union agreed for accepting PDPC production norms. |
Dec. 2009 |
| Tata Yazaki, Wagholi, Pune | Tata Yazaki, situated at Wagholi, Pune is in the business of wire harnessing for auto sector. | To stream lining the subcontractors supply chain. ( Selected 04 subcontractors) | Improvement in supply chain process | Identified reasons for late supplies and areas for defect reduction. Study was utilised for Costing purpose. | Dec. 2009 |
| Hindustan Coca Cola Beverages Pvt. Ltd., Pirangut, Pune | Hindustan Coca Cola Beverages Pvt.,Ltd. Is situated at Pirangut near Pune, is the market leader in soft drinks. | To assess the present utilisation of existing manpower in stores & logistics. To set production/service norms. To suggest method improvements if any. | Manpower utilization & restructuring in stores & logistics including material handling | Productivity raised by 40%. With improved work planning, improved response time & manpower reduction | Nov. 2009 |
| Nakshtra Enterprises Pvt. Ltd. Pune | Nakshtra Enterprises Pvt. Ltd. Is situated at Markal near Pune, manufactures steel flanges & is 100% EOU | Setting of production norms for the warming, forging,triming & piercing operations. | Work measurement using stop watch. | 30% overall productivity rise. | Oct 2009 |
| Tata Autocomp Syatems Ltd., Hinjewadi,Pune | Tata Autocomp Syatems Ltd., IPD Division,located at Hinjewadi, manufactures plastic moulding components such as bumpers, door trims etc. , required for automobile sectors. | To map current state value of facelift II Indica Front Bumper. | Productivity improvement using VSM (Value Stream Map) | 1. All Processes were brought down below
the TACT time practically. 2. Down time analysis done to improve up time. 3. Additional reliever operators in relevant area. |
Jun 2009 |
| Tata Autocomp Syatems Ltd., Hinjewadi,Pune | Tata Autocomp Syatems Ltd., IPD Division,located at Hinjewadi, manufactures plastic moulding components such as bumpers, door trims etc. , required for automobile sectors. | To assess the present utilisation of existing manpower in mould shop, assembly, painting, paint assembly. To provide base for performing restructuring activity. | Manpower utilization & restructuring in mould shop, assembly, painting, paint assembly. | Manpower productivity rise - 1. Assembly activities - 40% in mould shop & 58% in old & new paintshop. 2. 24% in old paint shop 3. 30% in new paint shop |
Feb 2009 |
Year : 10 - 11
| Company Name | Company Profile | Client Needs | Pdpc's Services | Productivity Achivements | Report Date |
| Lear Auto Motive India Pvt Ltd Tata Area Line Bhosari, Pune | Lear corporation is suppplier of automotive seating systems at Bhosari, Pune | 1.To conduct work measurement activities for the decided operations. 2. To establish production norms for various manufacturing process components. 3.To suggest method improvements, if any. |
1.Different manufacturing processes components were recorded using camcorder. 2. Work measurement was carried using Predetermined Time Standards Technique (PMTS). |
1. Remarkable increase in production within various departments. 2. Very strong workers union agreed for accepting PDPC production norms. |
Dec. 2010 |
| NAGREEKA EXPORTS LTD., Yavluj, Kolhapur | Nagreeka Exports Ltd. Is a 100% Export Oriented Unit (EOU) having its manufacturing plant of cotton yarn and knitted fabrics. | Time study has been conducted using stopwatch technique to evaluate current manpower utilization in different departments. | Assignment of more machines and loads has been recommended for the maximum manpower utilization in respective departments. |
1. Remarkable increase in production within various departments. 2. Very strong workers union agreed for accepting PDPC production norms. |
Dec. 2010 |
| MAHINDRA HINODAY LIMITED., PUNE | The organisation is situated at Urse, Pune. The organisation manufactures SG Iron castings for Automobile sector. | 1.To Assess current allocation of manpower in mould shop. 2.To optimise work allocation for present manpower in mould shop. 3.To suggest possible restructuring in manpower. 2.Suggest Method improvement.if any |
Work measurement carried out by A)Using predetermined Time Standards Technique. |
A)Hydraulic / Pneumatics lifting : Reduced core handling time during core placement. B)Audio aid to be provided for over head crane movement- Reducing the chances of accidents. C) Instead of pneumatic guns ,use of Hand gloves - improving overall plant productivity. D) Changing current Line Layout from straight Line to U-Shape, etc.needs to be evalulated , in oder to further optimise the utilisation of manpower. |
Dec. 2010 |
| ESSAR STEEL LTD.,Sanaswadi, Pune | Essar Steel is a fully carbon steel manufacturer, from Iron ore to ready-to-market products with current capacity of 8.6 million tonnes per annum (MTPA) | To redesign existing 'Performance Based System (PBS) at Essar | 1. Factors like Capacity utilization, energy and material yield, On-time delivery index (OTD), Absenteeism etc. are evaluated. 2. New performance based incentive system has been proposed considering 3. operations process distinctly. |
1. Big motivation for both skilled employees. 2. More awareness about Inventory management along with increased contribution towards customer satisfaction. |
Sep. 2010 |
| Lear Auto Motive India Pvt Ltd V.W.Line Chakan | Lear corporation is a global Suppplier of Automotive Seating System | 1.Establish Production norm forvarious component mentioned in the Scope 2.Suggest Method improvement. if any |
1.Process of mapped wsing camcorder 2.Work Measurement carried out by using PMTS 3.Relaxation Allowance were considered as per ILO Guideline. 4.Production norm calculated using PTS Output |
1. Remarkable increase in production within various departments. 2. Very strong workers union agreed for accepting PDPC production norms. |
MAY. 2010 |
| Lear Auto-Motive India Pvt LtdG.M.Line Chakan | Lear Corporation is a Supplier of automotive seating system | 1.Establish Production Norm For various components 2.Suggest method Improvement,if any |
1.Process of mapped using camcorder 2.Work Measurement carried out by using PMTS. 3.Relaxation Allowance were Considered as per ILO guideline. 4.Production norm calculated using PTS output |
1. Remarkable increase in production within various departments. 2. Very strong workers union agreed for accepting PDPC production norms. |
May. 2010 |
| Kalyani carpenter Special Steel Pvt Ltd | The Comapany Manufactures forging quality steels, bearing steels And Other alloy steels. Turnover Rs.1000 cr, Employee 1500 Production 18000 ton/Anum | 1.To Provide a base for perfoming restructuring activity. 2. To Suggest method improvement as wall as potential for automation, if any |
1.To find out persent utilization status of direct staff, time study technique. 2.Relaxation allowance were decided as per ILO guidelines 3.The method improvements are suggested in report for process and System. |
Reduction in man power was recommended to achieve Manpower utilization movement. Efficient scheduled planning for daily production. Ex. Fixed 30 mins lunch break for finishing shop, which will eliminate need for relivers. |
May. 2010 |