Company Profile
SIGMA ELECTRIC MANUFACTURING CORPORATION PVT. LTD,UNIT III, PUNE

TPM – The Prime Mover Towards Excellence

Page 0INDEX#Contents

Page No.

1Sigma Group

3–6

1.1

Company Profile3

1.2

Outline of the Group4

1.3

Global Footprint4

1.4

Organization Chart – Group5

1.5

Vision, Mission and Values

5

1.6

Manufacturing and Engineering Capabilities

6

1.7

Global Partners

62

About Sigma Unit - III

2.1

Outline of the Unit

7

2.2

Business Model

82.3

Milestones

82.4

Organization Chart – Unit - III

92.5

Product Portfolio

92.6

Key Customers102.7

Unit Layout

102.8

Staffing Structure

112.9

Major Equipment

112.10

Manufacturing Process Flow

122.11

TPM Organization Structure

123

Milestone on the Journey of Manufacturing Excellence

3.1

Need of TPM

133.2

Embracing TPM for Manufacturing Excellence

133.3

TPM Policy

14

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3.4

Integration of all Tools and Methodologies in TPM

143.5

Evolution of Operator

154

Results and Benefits Achieved

16 – 19

4.1

Key Performance Indices – Results

16-17

4.2

Intangible Benefits

184.3

Recognitions in External Competitions

195Way Ahead20

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1. Sigma Group
1.1 Company ProfileBrief History
Sigma Electric is a global leader in manufacture of ferrous and non-ferrous castings, precision
machined components and sub-assemblies. Sigma has established long-term partnerships with
its global customers, working closely to help them meet the challenges of a highly competitive
business environment.

Sigma Electric is a 100 % Export Oriented Organization. Set up 30 years ago. HQ at Garner,NC, US. There are over 5000 team members worldwide. Sigma has a majority shareholding
from Argand Partners, USA.
Product Range
Sigma supplies to global leaders in market segments such as electrical, lighting, industrial,power tools, process instrumentation, appliances, telecom, aerospace, defence, marine, power,agricultural, food and Medical, Military, LED lightings.
LocationsTwelve world class manufacturing facilities at Pune, Jaipur, Mexico, USA for aluminum, zinc,bronze, copper, wide range alloys, iron & steel products.
PlantsManufacturing capacity is 50,000 MT/annum with world-class manufacturing equipment toolroom and design /engineering capabilities. Plants operate on Lean manufacturing system,
certified for ISO 9001, ISO 14001, ISO 45001, AS9100, ITAR certifications.
Global Supply Chain
Warehouse, sales, customer service and tech teams are at Garner, NC, USA.

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1.2 Outline of the Group

1.3 Global Footprint
Sigma group is having total 12 manufacturing facilities throughout the world. Out of which 6
manufacturing plants are in Pune, 2 plants in Jaipur and 4 plants are in US and Mexico.

TPM – The Prime Mover Towards Excellence

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1.4 Organization Chart - Group

1.5 Vision, Mission and Values
Company’s Vision, Mission and Core values are mentioned below.

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1.6 Manufacturing and Engineering Capabilities

1.7 Global Partners
These are our key customers.

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2. About Sigma Unit – III
2.1 Outline of the Unit

Plant

Aluminum High Pressure Die-Casting Plant

ProductRange

Metallic Electrical Fittings and accessories parts for industrial,house hold applications and process equipment's

Plant Area100,000 Sq. Ft.

InstalledCapacity(FY22)

4000 MT / AnnumAlloys

Aluminum Alloys

Total
Employees

580 Nos

Equipment

17 Cold Chamber HPDC Machines (Automatic)
ranging from 180 Tons to 900 Tons, 5 Central Melting Furnace,
In-house Spectro, Precision Machining –CNC and VMC, SPMs, Liquid and Powder Coating plant.

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2.2 Business Model
Business model shown below

Supply Chain Model
We have >95% customers in USA, manufacturing done in Pune plants material shift to our own
warehouse and some customer it is dispatched as per customer schedule
In few cases we are directly supplying to customer from plants

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2.3 Milestones
These are milestones of our organization.

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2.4 Organization Chart - Unit - III

2.5 Product Portfolio
Product Range - Electrical, Lighting and House Hold Appliances

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2.6 Key Customers
These are our key customers.

2.7 Unit Layout

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2.8 Staffing StructureCategory wise manpower distribution as follows
Category
Staff
Associates
Assistant Engineer - Line
TechnicianDETContract Operator
Total No. of Employees

Unit
Nos
Nos
Nos
Nos
Nos
Nos
Nos

Employee Count
61
188114239
167580

2.9 Major Equipment
Following is equipment classification
Equipment Categorization Criteria
Ranking

Overall Rating

Category

Machines

S-Class

22 to 25

Super Critical

18

A-Class

16 to 21

Critical65

B-Class

10 to 15

Semi Critical

121

C-Class

0 to 9Non-Critical

3

Total Equipment

207

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2.10 Manufacturing Process Flow
Following is plant process flow

2.11 TPM Organization Structure

TPM – The Prime Mover Towards Excellence

Page 133. Milestone on the Journey of Manufacturing Excellence
3.1 Need of TPM
Implementation of TPM is for changing the mind-set of the organization. Organizationalchange is needed in order to align the company with changing business environment.
There are external and internal factors, which necessitate the change to achieve Operational
Excellence. Sigma found TPM as an Effective tool to address its needs and hence decided toadopt TPM as a Business Tool to improve the efficiency of Plant Operation.

3.2 Embracing TPM for Manufacturing Excellence
Our company Vision is to ‘To be the global partner of choice by exceeding customer
expectations’.
In line with our vision, we have felt the strong need of TPM as it will help us to achieve zero
BAD. Develop employee capability, this will result in increased productivity, improved
customer satisfaction and make profitable organization.
The below details represent the reason we embraced TPM to achieve operational excellence.

TPM – The Prime Mover Towards Excellence

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3.3 TPM PolicyTo implement TPM management established TPM Policy.

3.4 Integration of all Tools and Methodologies in TPM
Linkage of KMI KPI and KAI established for all parameters. Sample mentioned below
KMI

KPI

KAI

• Reduce Material Costs• Alternate material.
Alternate source ,negotiations• VA –VE projects – Zerobased working• Kaizen on losses /wastes• Labor productivity/Automation/ Ind. 4.0
Projects

KK,
DM• Reduce Conversion
Cost• CIP Projects• R&M reduction Projects• Energy cost reduction
projects

KK,PM,OTPM

EBITAimprovement

TPM – The Prime Mover Towards Excellence

PillarPage 15

3.5 Evolution of Operator
We have achieved a major leap in the mindset of our machine operators and maintenance staff.
This table represents the status of their mindset before and after introduction of TPM.
#Before introduction of TPM

After introduction of TPM

A

Machine Operators

1

Machine operators are mainly
responsible for production

Machine operators are assigned
responsibility of minor maintenance ofmachines

2“I produce and You Maintain” attitudeof operators“I do, I check and I Maintain” attitude ofoperators—My Machine Concept3

No formal checklist for machine
maintenance basic parameters

Use of Checklist covering C-L-I-T-A

4

Only escalating when machine isdysfunctional

knowledge of machine functioning

5

Reporting of Breakdowns- Identification and understanding ofabnormalities.
Participation in repair work during
Maintenance
Mindset change for zero breakdown

B

Maintenance Staff

1

Focus on immediate repair for fixing theproblems

Focus on preventive actions

2

Frequency and coverage of advanced
maintenance techniques was lessMore use and coverage of advancemaintenance techniques – Vibration andCurrent Monitoring (CBM)

3

Tendency to get replacement of oldmachines

Focus on increasing life of old machines

4

Limited use of root cause analysis
approach

Insistence on using Why- Why analysis
Initiated use of Phenomena Mechanism
analysis for chronic problems

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4. Results and Benefits Achieved
4.1 Key Performance Indices – Results

CategoryIndex

UnitBM(TPMStarted)
FY18

S

Number of work-related
accidents requiring days offwork

Cases/ Year

10S

Number of work-related
accidents not requiringdays off work

Cases/ Year

1660P

Productivity for main
products (ManpowerProductivity)

Kgs / Man /Month263

502

POEE(or Overall PlantEfficiency)

%

71

86.16

P

Availability%

8492.91P

Performance Rate%

92.84

94.97

P

Quality Products Rate%

9197.65

P

Number of breakdowns

Breakdowns /Month283

39

P

MTBF

Hour

317

1596

P

MTTR

Mins

137

73

Q

Number of customer
complaints

Number / Year

310Q

In-line defect rate (scrap)

%

8.99

4.90

TPM – The Prime Mover Towards Excellence

ActualStatus
YTD FY24Page 17

Q

In-line defect rate (rework)%

112.07

CCost index (ConversionCost)$ / Kg1.59

1.15

DProduction Lead timeDays

104.5

DDelivery Performance%

9498

Number ofoccupational
accidents withleave for 1 000000 worked hours

0.52

0

Numbers /Employee /Month848

8733

S

Frequency rate

M

Number of Employee
Suggestions Implemented

TPM – The Prime Mover Towards Excellence

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4.2 Intangible Benefits
Understanding TPM in right spirit & practicing it day-to-day over five years has broughtsignificant changes in work culture, system orientation, analytical approach & flexibility.
Work Culture:•••••

Sense of ownership of equipment / process i.e. “I Operate , I maintain, I Control”
People started believing the possibility of Zero Customer Complaints, Zero In process
Defects , Zero breakdowns and Accident
People have started thinking Deeply and Widely in their areas / section to improvefrom existing condition to next level
People now work as per the Flexibility of requirement and does not resist to any
changes
Sustenance of Improvements done by the operators

System Orientation:•••

TPM is integrated with IMSManagement objective are well linked to plant objective, department Objective andthen to Cell objectives so focusing cell working in more meaning full and system way
Neat and Clean working environment can be seenWell defined system for maintenance spare management, Quality monitoring and
Production monitoring

Analytical Approach:•Continuous Improvement / Focus on prevention of losses by searching theabnormalities, root cause analysis and Kaizen Implementation

Flexibility:••

Flexibility in manufacturing due to Multi-skilled operator
Production Output as per the Customer Pull

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4.3 Recognitions in External Competitions
We won 40 external awards in last 4 years. Sample National level awards mentioned below.

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5. Way Ahead#Particulars

Challenging JIPM
1 excellence award for Unit I
Pune

Action Plan

Responsibility Target Date

Horizontal Deployment ofPlant Head –TPM methodology from UnitUnit I
III

Challenging JIPM consistentContinue practicing TPM
2 TPM commitment award forpractices
Unit-IIPlant Head –Unit II

FY24

FY26

Initiate TPM practices in3 North America Plant

Horizontal Deployment of
TPM methodology from Unit- TPM-BE HeadIII

FY24(Initiated)

4 Sustainability Award

Assessment by M/s Frost and
TPM-BE Head
Sullivan

FY26

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