EXCELLENCE IN CONSISTENT TPM ACHIEVEMENT 2023

LUMAX INDUSTRIES LIMITED
Plot No.-69 & 70-A, Phase-2, Sector-2
Bidadi Industrial Area, Bidadi
Ramanagar Taluk
Dist.- Bengaluru
Pin- 562109
State – Karnataka(India)

TPM-Lighting LUMAX, Lighting Life

1. Organization profile:In the 80s and 90s, when the Automotive Industry was taking shape inIndia, a huge opportunity arose. The opportunity of being a potential
leader in the Automotive Lighting and Allied Automotive components
industry. Lumax took firm hold of this opportunity and turned it into areality lived every day by its 12,000-strong workforce, working across 38
modern manufacturing locations across India. This manufacturing
strength is backed by 3 Research Centers, 1 Engineering Centre in Indiaand 2 design centres in Taiwan and Czech Republic. The Lumax Group
has a turnover of over INR 6,800 Crore FY22-23, and diligently
empowers the assembly lines of almost all Top Automotive OEM brands.
Lumax is also improving its international footprint with real intent and isaccomplishing all this with the timeless values of Respect, Integrity,Passion and Excellence. The rich legacy withstanding the fact thatLumax is still young at heart and ever evolving, and it believes thatsuccess has just begun to unravel!
The DK Jain Group has Auto Component manufacturing capabilities
across several product categories including end-to-end Automotive
Lighting solutions, Air Intake systems, Urea Tanks, Integrated Plastic
Modules, Gear Shifters, Transmission Products, Seat Structures, 2Wheeler Chassis & Swing Arm, 3W Trailing Arm, Electric & Electronic
Components, HVAC Panels, On-board Antennas, Power Window
Switches, Vehicle Interior Systems & Components etc.

TPM-Lighting LUMAX, Lighting Life

Plant at Bengaluru Location:
Lumax DK Jain Group is owned by DK Jain Family and consists of two listedcompanies, i.e. Lumax Industries Limited and Lumax Auto Technologies
Limited. Lumax is currently operating with 15 entities spread in sevenstates across India. There are thirty-seven manufacturing plants across India.

Our Partnerships:

TPM-Lighting LUMAX, Lighting Life

Ground breaking ceremony of Lumax Bengaluru Plant started on 12th June
2011 and production commenced on 27th Aug 2012 with manufacturingof Automotive Lights for Toyota Kirloskar Motor Ltd. Lumax Bengaluru
Plant is having installed capacity of 26 million Two-Wheeler Sets perannum and currently its capacity utilization up to 24 million Sets perannum and for four-wheeler Capacity is 1.4 million of automotive lighting& current utilization is up to 1.2 million vehicle Sets

Total area in Lumax Industries Limited, Bengaluru Plant have 21812
Sq.Mts. and Built-Up area is 12000 Sq. Mts. Total Manpower Strength is609 Nos.

2. Milestones on Journey of manufacturing Excellence
The LIL Bengaluru Plant started TPM with management declaration on
05/07/2013 and Kick off on 17/12/2013 by Customer & our M.D. Mr.
Anmol Jain. We considered this year as Benchmark 1. By Deploying TPM
Methodologies & Achieving Targeted Results, we challenged TPM
Excellence Award in year 2018-19 and achieved TPM Excellence Award
from JIPM. After this we are continually practicing TPM Methodologies
by Deepening & Widening TPM. We considered 2018-19 as BM2(Benchmark 2) and defined Targets & Prepared Master Plan byDeepening & Widening TPM till Special Award target Year 2026-27
TPM-Lighting LUMAX, Lighting Life

Key Milestones of LIL Bengaluru Plant

TPM Journey of manufacturing Excellence

TPM-Lighting LUMAX, Lighting Life

Process Technology & Plant Uniqueness:
Process technologies available in our plant are Plastic Injection moulding,Plasma coat metalizing, Hard coat, Base coat, Top coat, Antifog, Plastic
paint shop and assembly lines. In assembly process we are having Glue
dispensing robots, conveyorized assembly lines, robotic ultrasonic welding
technology, Impulse welding, vibration welding machine, In-built photo
testing and basic mould maintenance facilities.

Business De-risking

TPM-Lighting LUMAX, Lighting Life3. Benefits Achieved: TPM Implementation at Lumax Industries Limited Bengaluru Plant helpedin achievement of business results. Our financial & other Business
Parameter growth which has seen a steady upward trend right since TPM
Kick-off. All Improvements shown w.r.t BM2 (2018-19) to YTD(Sep-23)

3.1 Key Tangible Benefits:••••••••••

LIL Bengaluru Plant Sales Improved by 90% from BM2 (2018-19).
We achieved >18% PBDIT.( Improved by 45% from BM2 (2018-19).
Sustenance of Zero Reportable Accident
Productivity Improved by > 42% from BM2
Breakdown Reduced by > 83% (All Machines)
Mfg. conversion Cost reduced by 36%
In-house Quality Defect Reduced by > 50%
Warranty Complaints Reduced by 70%
Achieved > 7 Training Man-hours Per Month per Employee
Sustenance of 100% Delivery Performance

3.2 Intangible Benefits:
Apart from Tangible Benefits we achieved Intangible benefits also throughTPM ways.
Key Intangible benefits are given below.
• Created Mind set Culture towards Zero BAD (Breakdown, Accidents,Defect)• Improvement focused Environment• Employees Morale, Skill & Will Improved• Safe Culture• Total Employee Involvement• Way forward approach towards Digitalization
These Benefits achieved through TPM Methodologies & by 100%
Employees Involvements. Few Glimpses of Employee Involvement is given
below:TPM-Lighting LUMAX, Lighting Life

Employee Involvement is achieved through TPM Circle, 5S, QCC, CCC(CostCutting Champions) & Kaizen Competition initiatives. Promotion andreward mechanism is in place for all improvement initiatives

TPM-Lighting LUMAX, Lighting Life

4. Key of Our Manufacturing Excellence
We are Committed to Execute Excellence at LIL Bengaluru Plant throughTPM ways. We will extend TPM in End-to-End Supply Chain.
Our future Plan for Manufacturing Excellence is as Follows:
••
••••
•••
•

Integrating Industries 4.0 with IOT
Synchronization of three processes Moulding, Surface treatment andAssembly for Runners.
Sequential Production System
To become Sustainable Manufacturing Plant
Real Time Monitoring of production and machine down time.
To achieve Benchmark Level of End-to-End Lead Time
Future Ready Capability Development – Data Analytics & Digitization
To create TPM Cluster at Southern India – with Consideration of Local
Vendor Base
Focus on Localization
Lumax Production System

TPM-Lighting LUMAX, Lighting Life

6. Achievement Sheet
2023 TPM Award - Achievement Sheet
Company & plant name Lumax Industries Limited, Bengaluru
TPM Slogan/Objectives

TPM - Lighting Lumax, Lighting Life

▼ Please fill in the range of data you are collecting ▼ID- 23027

CategoryIndex

Unit

Enter the year →BM(TPM Started or lasttime awarded)

Actual Status Upto Dec'23

2018-19

2023

S

Number of work-related accidents
Cases/ year
requiring days off work00S

Number of work-related accidentsCases/ year
not requiring days off work

20P

Productivity for main products

Parts/Operator hours

9.8

14.4

POEE(or Overall Plant Efficiency)

%

85.9

90.4

P

Availability%

88.7

97

P

Performance Rate%

80.2

95.2

P

Quality Products Rate%

88.998P

Number of breakdowns

Nos

61

5PMTTR

Minutes

49

15P

MTBF

Days

940

245

Q

Number of customer complaints(2018- 19 3 Customer & 22-23 8Customer)

Number/year

21

Q

In-line defect rate (scrap) wrt RMC %1.20.7Q

In-line defect rate (rework)%

0.40.1

CCost Index (Conversion Cost)

Cost index % sales

8.9

5.7

DProduction Lead time

Hour

9136

DDelivery performance%100100SFrequency rate of Occupational
Accident with Leave

Number of occupational
accidents with leave for
1 000 000 worked hours

00M

Number of Employee Suggestions Number/Qtr

34

TPM-Lighting LUMAX, Lighting Life