Improving plant and machinery equipment efficiency through Original Equipment Effectiveness (OEE) drive
Learning from each other in developing best practices across the plants
Improving workforce efficiency of operators through Maynard Operation Sequence Technique (MOST)
Aligned with the ‘Make in India’ philosophy, we manufacture over 90% of our products in-house. We have fully integrated manufacturing set-up across all our plants. During the year, we invested in setting up a new greenfield manufacturing plant spread across 45 acres in the most modern industrial area of South India at Sri City near Chennai. With this, we now have 15 state-of-the-art manufacturing plants spread across 8 locations in India.
Each plant is equipped with high depth of in-house manufacturing with all major components being produced under the same roof. The “Quality first” is in-built in the operations which ensures production of a reliable product with a longer life and consistent performance. In addition, we are consistently investing in upgradation and establishment of the most modern manufacturing set up and optimum level of automation. Across the plants, we have automatic high-tech machines procured from Japan, Europe and other leading manufacturers across the globe.
With more than 20,000 SKUs across the plants, we believe that Operational Excellence at the factory is paramount, and hence a roadmap has been drawn for implementation and strengthening of various key initiatives. Global benchmarking of manufacturing plants have helped us in continuous upgradation of manufacturing set-up to take it to Industry 4.0 standards. Across the plants, section-by-section analysis is done for promoting digitisation and use of Internet of Things (IoT).
We have undertaken several steps for enhancing operational efficiency, upgrading machines and processes and making them digitally connected. Our intent is to maximise the use of Artificial Intelligence (AI), Big Data, and Cloud Computing to raise the performance standards and drive the next chapter of Industry 4.0.
Our new greenfield manufacturing plant at Sri City near Chennai adds to the AC manufacturing capacity to produce 1 million ACs per year. With this addition, we have now 2 million ACs per year capacity (including Ghiloth). It is a fully-integrated and best-in-class plant with majority of the parts produced in-house. It will facilitate production of ACs in every 20 seconds and will increase exports and sales to South Indian markets. We have in place a product testing laboratory, NABL accredited which allows us to make and test ACs for extreme test parameters. The use of robotic points and AGVs ensures deskilling of operation and lower manual dependence thereby delivering high productivity at global quality standards.
We make our own Heat Exchangers here both for the Evaporator and the Condenser. These are made on globally best standard Japanese machines. We make high class plastic moulded parts for Indoor units, produced on world best fully electric Japanese Moulding Machines. The copper tubing section produces 100% in-house parts helping in maintaining high quality standards.
This is a significant step and will reduce our dependence on the import of components in line with the Make in India vision of the Government of India.