Company Profile
Sigma Electric Manufacturing Corporation Private Limited,
VKIA Jaipur

TPM – The Prime Mover Towards Excellence

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Index#1-1

1-2

Contents

Sigma Group

Page #
3–10

1-1.1

Company Profile31-1.2Outline of the Group

41-1.3Global Footprint

41-1.4

Organization Chart – Group Level

51-1.5Sigma Core Values

51-1.6

Manufacturing and Engineering Capabilities

61-1.7

Global Partners

6

Sigma Jaipur

7-18

1-2.1

Outline of the Unit

71-2.2Business Model

81-2.3

Plant Milestones

91-2.4

Organization Chart – Plant Level101-2.5Product Portfolio

101-2.6

Key Customers

111-2.7

Unit Layout

111-2.8

Staffing Structure121-2.9

Major Equipment

121-2.10

Manufacturing Processes Flow131-2.11

TPM Organization Structure131-2.12

Milestone on the Journey of Manufacturing Excellence141-2.13

Results and Benefits Achieved161-2.14

Recognitions in External Competitions18

1-2.15

Way Forward

18

TPM – The Prime Mover Towards Excellence

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1-1 Sigma Group1-1.1 Company Profile
Brief History
Sigma Electric is a global leader in the 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 ahighly 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 tool
room and design /engineering capabilities. Plants operate on Lean manufacturing system,
certified for ISO 9001, ISO 14001, ISO 45001 certifications.
Global Supply Chain
Warehouse, sales, customer service teams are at Garner, NC, USA.

TPM – The Prime Mover Towards Excellence

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1-1.2 Outline of the Group

1-1.3 Global Footprint
Sigma group is having total 12 manufacturing facilities throughout the world. Out of which 6
manufacturing plants are located in Pune, 2 plants in Jaipur and 4 plants are in US and Mexico.

TPM – The Prime Mover Towards Excellence

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1-1.4 Organization Chart – Group Level
Organization chart at group level is shown below

1-1.5 Sigma Core Values

TPM – The Prime Mover Towards Excellence

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1-1.6 Manufacturing and Engineering Capabilities
Manufacturing and engineering capabilities are shown below

1-1.7 Global Partners
These are our key customers.

TPM – The Prime Mover Towards Excellence

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1-2. Sigma Jaipur
1-2.1 Outline of the Unit

Plant

Sand Casting for Ferrous & Non-Ferrous

Product Range

Electrical, Lighting, Hydraulics and Household Appliances

Plant Area

26749 Sq. Ft.

Installed Capacity(2023)

7752 MT / Annum

AlloysSG, Gray, white Iron, Copper alloy, Aluminum, Zinc.

Total Employees

1027 nos.

Equipment’s

03 Sinto Moulding Machine, 05 Jolt squeeze Machine, 10Induction furnaces, 9 Robotics loading, unloading arm, In-houseSpectro, Precision Machining – CNC and VMC, SPMs, Zinc
Plating & Powder Coating plants

TPM – The Prime Mover Towards Excellence

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1-2.2 Business Model
Inventory build-up in US warehouse based on customer demand

Supply Chain Model
Sigma is supplying more than 95% of parts to US customers. Material is stored in our own
warehouse (Garner, US) and based on the customer orders material is dispatched from ourwarehouse. Sigma Jaipur manufactures and supplies the material as per customer requirement
to the Garner warehouse. In some cases, Sigma Jaipur is directly supplying to the endcustomers.

TPM – The Prime Mover Towards Excellence

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Scope of Supply Chain
The scope of supply chain is to receive the order from the customers, wherever required
generate forecast, load the plants with monthly/weekly plans and ensure material availability at
Customer’s place / Sigma warehouse in a timely manner.
Material procurement and input supply chain is taken care by Purchase function.

1-2.3 Plant Milestones
Plant milestones mentioned below

TPM – The Prime Mover Towards Excellence

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1-2.4 Organization Chart – Plant Level
Organization chart is shown below

1-2.5 Product Portfolio
Sand Cast Ferrous and Non-Ferrous Products for: Electrical, Lighting, Power & transmission
system, Hydraulic and Household Appliances

TPM – The Prime Mover Towards Excellence

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1-2.6 Key Customers
These are our key customers with sale contribution.

1-2.7 Unit Layout
Total Plant Area is 26,749 Sq. meter

TPM – The Prime Mover Towards Excellence

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1-2.8 Staffing Structure
Category wise manpower distribution as follows for Sep’23
CategoryUOM
Nos.
Nos.
Nos.
Nos
Nos
Nos
Nos

StaffAssociates
Asst Engineer - Line
Technician
Trainees
Contract Operator
Total No. of Employees

Employee Count
169
91124
10231
4341059

1-2.9 Major Equipment
Following is equipment classification for FY19

#Area

Equipment Classification

Equipment
Quantity

SA

B

C

1

Foundry

104

42848

24

2

Machine Shop

268

42617365

3Plating

800

624

Assembly

2200

17

55Tool Room

26079106Utility

2400420452

861257

126

Total Equipment

TPM – The Prime Mover Towards Excellence

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Following is plant process flow

1-2.11 TPM Organization Structure

TPM – The Prime Mover Towards Excellence

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1-2.12. Milestone on the Journey of Manufacturing Excellence
1 Need of TPM
To improve business performance and overcome challenges below, management decided toimplement TPM as business tool
Key Challenges•High Customer complaints•

High In-house rejection•

Segregation cost at Garner, US warehouse•High COPQ•

Safety - number of injuries•Less OEE•

Low Delivery compliance•

Scope for improvement in the culture – Low employee engagement

2 Embracing TPM for Manufacturing Excellence
Our company Vision is to ‘Transform SIGMA as the Centre of Excellence through unleashing
the passion and ingenuity in our people, building capabilities, using innovative technology andbusiness processes, and consistently delivering value exceeding stakeholder expectations;
thereby be the most preferred destination for investment’.
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 TPM Policy
To implement TPM, management established TPM policy

TPM – The Prime Mover Towards Excellence

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1-2.13. Results and Benefits Achieved
1. Key Performance Indices – Results

CategoryIndexP

Number of workrelated accidents
requiring days off work
Number of workrelated accidents not
requiring days off work
Productivity for mainproducts
OEE(or Overall Plant
Efficiency)Availability

PP

Performance Rate
Quality Products RateP

Number of breakdowns

PPMTBFMTTR
Number of customer
complaints
In-line defect rate(scrap)
In-line defect rate(rework)

SS
P
P

Q
Q
Q
C

Cost index

D

Production Lead time

D

Delivery performanceS

Frequency rate

M

Number of Employee
Suggestions
implementedUnit

BM(TPMStarted)
FY’19

ActualStatus
YTD
FY 24

Target
FY24

Cases/ year

100

Cases/ year

38

10

Kgs/Man/Month

451

611

609

%

6684.685.5%

8491.1

93%%
Breakdowns/MonthHoursMinutes

81
96.2

95.697.1695
97

563

91

80

81
86

470
64475
62

Number/year

333

00%

3.85

2.84

2.59%

20.20

3.95

4.00

1.06

0.92

0.93

3.41

2.23

2.03

89

97

100

0.32

0.93

0.00

0.92

2.82

2.8

Cost/Kilogram(Conversion Cost)
Days%
Number ofoccupational
accidents withleave for 1 000000 worked hours
Number/ Person/Year

TPM – The Prime Mover Towards Excellence

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2. Intangible Benefits
Understanding TPM in the 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 focusing on theme base kaizen & participated more in external as well asinternal competition.
✓ People started believing the possibility of Zero Customer Complaint, Zero breakdown
and Accident.
✓ People have started thinking deeply in their areas / section to improve from existing
condition to next level.
✓ People now work as per the Flexibility of requirement and does not resist to anychanges.
✓ Sustenance of Improvements done by the operators.

System Orientation:✓ TPM is integrated with IMS.
✓ Management objectives 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 seen.
✓ Well defined system for maintenance spare management, Quality monitoring andProduction 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

TPM – The Prime Mover Towards Excellence

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1-2.14. Recognitions in External Competitions
Sigma teams participated at various national level competitions and bagged awards as

1-2.15. Way Ahead#Particulars

Target Date

1

Challenging JIPM excellence award for Unit II Jaipur

FY26

2

Challenging JIPM consistent TPM commitment award forUnit-I

FY26

3

Initiate TPM practices in North America Plant

4

Sustainability Award

TPM – The Prime Mover Towards Excellence

FY24(Initiated)
FY26Page 18