Automotive Axles Limited
Joint Venture between Kalyani & Cummins Meritor Group
Hootagalli Industrial Area, Off Hunsur Road,
Mysuru-570 018 Karnataka State,India.

1- A. Organization Profile
Established in 1981, Automotive Axles Limited (AAL) is a joint venture of Kalyani Group andCummins Meritor. With manufacturing facilities located at Mysore (Karnataka), Pantnagar(Uttarakhand) and Jamshedpur (Jharkhand), the company manufactures drive axles, non-driveaxles, front steer axles, specialty & defense axles, and drum brakes. It provides these products
to the major domestic and global manufacturers of trucks & buses pertaining to segments suchas light, medium & heavy commercial vehicles, military & off-highway vehicles, aftermarket,and exports. As a continuous process, the company believes in introducing new products
regularly to meet the emerging needs of the commercial vehicle market.
AAL has developed an impressive domestic OEM clientele that includes Ashok Leyland, TataMotors, Daimler India, Volvo India, BEML, Mahindra Trucks & Buses, Caterpillar, Escorts.
AAL also exports axle parts to UD Trucks & Cummins Meritor entity 19 Countries. Our
Products range covers all commercial vehicles starting from 7T to 55T (GVW- Gross vehicleweight).

ProductsAxles

Brakes

1- B. Accreditations
As a part of our Vision going towards World Class manufacturer, for a consistent Quality,Safety & 5S we are certified with various certifications by prestigious certifying bodies.
1. IATF 16949:2016 for Quality Management System by DQS India
2. ISO 14001:2015 for Environmental management System by DQS India
3. ISO 45001:2018 for Occupational Health & Safety Management System by DQS India
4. 5S by QCFI & JUSE Japan.
1-C. Major Manufacturing Capabilities
Our key manufacturing capabilities include state of the art Housing Manufacturing including
robotic welding, Gear manufacturing & Axle assembly Line. We have adapted a mix ofSingle piece flow, Cellular manufacturing & Continuous manufacturing concepts in our plant
to optimize productivity.

1-D Organization Structure

1-E TPM Steering Committee

2. Milestone on the Journey to Manufacturing Excellence
In today’s competitive scenario, to achieve business excellence in all spheres, TPM is one of
the best Manufacturing Practice. 5S Implementation was started across the plant to form astrong base for TPM journey. Automotive Axles was 5S certified by QCFI & JUSE, Japan inthe year 2017, & consequently recertified in the year 2020 & 2023.
TPM Journey in AAL started in the year 2018-19 with selection of 3 Manager ModelMachines, demonstrated by team of competent and committed Managers to the workers.
Automotive Axles launched TPM activities on 4th Nov’2020 with formal kick off in thepresence of key customers, supply partners, in collaboration with JIPM under the guidance ofCII India. In the initial stage of TPM Implementation to progress and achieve TPM Excellence
the year-wise Key Activities were mapped, TPM policy and TPM objectives were formallyannounced to all employees by the Top management with an oath towards total commitment.
TPM tools & Technique is the solution we adopted for effective management of continualchange in Business Scenario.TPM Journey drives Automotive Axles towards a continuous
increase in productivity by eliminating all losses & waste.

5S Standardization across the Plant including Office areasActive participation of TPM Circles



Zero BAD & COC AdherenceCustomer centric Organizational Behaviour



Focus on 100% completion of JH Step 4 Activity

Adopting, Implementing & Sustaining TPM -JIPM 12 Step methodology to ensure
cost effective operation.

External & Internal Rewards & Recognition

3. Benefits Achieved
TPM implementation at Automotive Axles has not only helped Business results but alsobrought drastic change in organization culture.
Intangible Benefits

4. TPM Award Assessment Achievement Sheet
Below are tangible benefits on key business results in terms of PQCDSME.

2023 TPM Award -Achievement SheetCompanyAutomotive Axles Limited
Plant nameAutomotive Axles Limited, Mysuru
TPM“Together Towards World Class Through TPM”
Slogan/Objectives
Year when TPM
2018activity started
Year of2018- 2019benchmarking
Kick off/TPM
Index
Category
Unit
Started (FY 2018(Calculation Formula)
2019)
Number of work-related
S
accidents requiring days
Cases/ year3
off work
Number of work-related
S
accidents not requiring
Cases/ year
11
days off workP

Productivity for main
products

PPPOEE(Overall Plant Efficiency)
Availability
Performance Rate
Quality Products RateP

Number of breakdowns

PPMTBFMTTR
Number of customer
complaints
In-line defect rate, scrap
In-line defect rate, rework
Conversion Cost
Costindex Material CostPQ
QQCDProduction Lead time

DDelivery performanceS

Safety index

M

Number of Employee
Suggestion / Kaizen

SDLH/Manday

Actual Status
FY 2022- 2023
115

* Standard Direct
Labour Hour

4.01

5.2%

6076%%%Breakdowns/
MonthHour
Hour

74.9
80.9
9987
8899

367

132

1750
3.72401
2.2

Number/year

7041

PPM
PPM
% to Sales

2187
38136
5.1

2087
7760
3.6% to Sales
Days

73.1
775.66%Accidents per
1,000,000
operator hours

9592

0.5

0.14

2100

4500

Number/year

5.Key of our Manufacturing Excellence
The Key to our manufacturing excellence lies in continual improvement activities and periodic
review of pillar activities and achieving Mission 25 & 28 Targets.
Future Plan

6. Contact
Automotive Axles Limited
Hootagalli Industrial Area,
Off Hunsur Road,
Mysore-570 018 Karnataka State, India.
Email: sec@autoaxle.com
Phone: 0091-821-7197500