COMPANY PROFILECOMPANY NAME: SOLAR INDUSTRIES INDIA LIMITED
PLANT NAME:SOLAR INDUSTRIES INDIA LIMITED, CHAKDOH

1. COMPANY PROFILE:
SIIL is one of the leading explosive groups of manufacturing companies founded by Shri
Satyanarayan Nandlal Nuwal and has crossed annualized production of 4,00,000 MT ofexplosives. Solar Group has evolved from a single site manufacturing company in 1995 to a
globally recognised industrial explosive manufacturer. With extensive experience andexpertise in Industrial Explosive segment, entered in Defence sector for manufacturing as pertheir requirement.
Company’s innovation edge is rooted in a strategic blend of talented manpower andtechnological prowess with rich experience to create sustainable value with an intend toaccelerate towards excellence and impressive pace.
The company employs comprehensive, robust and best practices, and is also committed to thesafety, health and wellbeing of the people, Communities, and the environment. Solar group is
the topmost explosive manufacturer in India having 24% market share. Having a strong
workforce of 7500+ employees.
Solar has 34 Manufacturing facilities Worldwide & Global presence in more than 65 Countries
Global Manufacturing Base:•India•Zambia•Nigeria•

Turkey•South Africa•

Ghana•

Tanzania

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Manufacturing Locations in India:•Rajasthan (4 Plant)•

Madhya Pradesh (4 Plant)•

Telangana (2 Plants)•

Maharashtra (6 Plants)•

West Bengal (1 Plant)•

Chhattisgarh (5 Plants)•

Odisha (3 Plants)•

Jharkhand (2 Plants)•

Tamil Nadu (1 Plant)

Upcoming Manufacturing facilities•

Australia•

Indonesia•

Thailand

Sectors of Solar’s presence:
Solar have established footprints in:• Construction• Road & Infrastructure• Mining• Quarries• Seismic Exploration• Tunnelling• Defence• Hydro Projects

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PLANT PROFILE: SOLAR INDUSTRIES INDIA LIMITED, CHAKDOH
SIIL, Chakdoh plant was established in 1995 and started production in Apr-1996. This plant
manufactures & exports explosives and initiating systems to over 25 countries. The plant has
number of facilities for producing various types of products which includes Slurry, Emulsion,Cast Booster, HMX, RDX, TNT, etc. SIIL, Chakdoh located near Bazargaon, Amravati Road
(NH-6). This location is 37 KM away from Nagpur city. Chakdoh plant covers 550 acres areaof land. At SIIL, there are currently 3,445 number of employees.

MAIN PRODUCTS:
SIIL Chakdoh has been a manufacturer of Industrial explosives like- Packaged Explosives,
Bulk matrix as well as Initiating systems. Below mentioned are some of the key products are:•Industrial Explosives:

BULK Explosives

Packaged Explosives

Initiating Systems•Defence Explosives:

TNT

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COMPANY PROFILEPRODUCTION SYSTEM:
Given below is the production process followed at SIIL Chakdoh. It starts with the order
initiation by customer followed by its production planning by the SCM team. After this,purchase dept. procures required Raw Material & Packaging Material for the actual production.
At SIIL, along with the actual production, several lean practices are also taken care like 5S,
TPM with an objective to make all the processes waste-free. After this, finished goods arepackaged and dispatched to the customer or to the site of actual consumption.

1. OrderInitiation• Reciept of Sales Plan from marketing.
• Provide Schedule for delivery• Meet delivery dates for dispatch
2. Production • Manage In-bound & Out-bound LogisticsPlanning• Quality Testing of incoming material
3. RMPM • Managing alternate vendors for RMPM
Procurement

4. ActualProduction.

• Completing Day-wise production plan
• Reducing In-process rejection• Sustain Safety, Quality, Reliability
5. Production • Implementing Lean practices
Control• Safer packaging & handling of products
6. Packing & • Reduction of PM cost
Dispatch

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PLANT ORGANIZATION:

STAFF:
There are currently 3445 number of employees out of which 1167 number of employees areOn-Roll while the rest are on contract basis. Considering the various departments, the charts
below show the department-wise allocation of employees.
Staff Details

Total Employees

3756

Male / Female

OnRoll / Contract0%

MaleFemale

3062

694

On-RollContract

1220

2536

20%

40%

60%

80%

100%

Number of Employees

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Employees work in four shifts. The detailed shift times along with working hours are given
below:
ShiftG

From
09:30 hrs
10:00 hrs

To
18:00 hrs
18:30 hrs

A

06:00 hrs

14:30 hrs

B

14:30 hrs

23:00 hrs

C

23:00 hrs

06:00 hrs

2. MILESTONES ON THE JOURNEY OF MANUFACTURING EXCELLENCE:
Solar management decided to adopt TPM as companywide policy to address followingchallenges:
••
•
•
•
•
•
•
•

Machineries and Equipments were not available in basic condition
Machine Operators were mainly responsible for only production activities with theconcept of “I Operate, You Maintain”
No practices applied for maintaining equipment at optimal condition
Maintenance activities carried out only when machines were not available for
production
Majorly Breakdown maintenance was followed
Target & analysis for reducing breakdowns were not recordedStandard practice for breakdown management was not documented
Primary information and knowledge transfer about basic conditions of machineries andequipment’s, types of losses & analytical tools were not implemented
Systematic method for cost and loss reduction was not followed

TPM Journey started through plantwide launch on 22nd May 2018. Initially to start with TPM
was initiated on selected Manager Model Machines. TPM implementation is a continuous
process now and since May 2018 it is horizontally deployed.

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COMPANY PROFILETPM Kick Off: Based on the results achieved on MMM, the plant “kicked-off” the program.
MD & CEO along with other Management team officially kick off the program for deploymentof all eight pillars in all divisions of the plant on 21st January 2019.

JIPM Assessment’s–
1st Stage Assessment TPM Excellence Award – Category A was held on 2nd Jun’2023
Assessed By – Prof. Tetsuo MIYAMURA San & Kimio ISHIKAWA San
2nd Stage Assessment TPM Excellence Award – Category A was held on 23rd Nov’2023
Assessed By – Prof. Tetsuo MIYAMURA San & Kimio ISHIKAWA San

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COMPANY PROFILE
3. BENEFITS ACHIEVED:➢ Cultural Change:o Workmen have started owning responsibility for operating and maintaining theequipment.
o Team working culture is inculcated by breaking down departmental barriers.
We have CFT’s working effectively.
o Culture of waste elimination is getting inculcated. Reduction in breakeven pointfor off highway was achieved on the back of Kaizens implemented on the shopfloor.
o Improvement in skill level of the operators in terms of multi skilling.
o Review mechanisms set up for tracking performance parameters.
➢ 5S activities improved shop floor. This gave a positive image about the company tovisiting customers and has resulted in more business enquiries to our company.
➢ S-D-C-A cycle has started due to formulation of checklists. This has resulted inbenchmarking of key indices for further improvement.
➢ Disciplined approach to problem solving is demonstrated by use of Why-Why analysis,
10 step methodology, etc.
➢ KMI-KPI-KAI connect enabled to harness the efforts of everyone to goal of Zeroaccidents, Zero defects and Zero break downs.
To improve the total employee involvement & promote TPM activities, management has
prepared R & R policy to recognize & motivate the people who are actively contributing into
the TPM implementation.
4. KEY OF OUR MANUFACTURING EXCELLENCE:
Aim of manufacturing excellence is to implement the best practices for improving key resultsin terms of PQCDSME. SIIL involved all employees to work for manufacturing excellence.
Continual improvement activities and periodic review of the results are enablers to meet thekey strategies and Business parameters. Following are few highlights noted herewith:
➢➢
➢
➢
➢
➢
➢
➢
➢

Development of proactive approach to address break down, accident & defect incidences.
Strong condition base maintenance approach for enhancing equipment's reliability.
Continual focus on Quality Management System through ISO 9001.
Continual focus on Environment Management System through ISO 14001.
Continual focus on Occ. Health & Safety Management System through ISO 45001.
Green energy focus through uses of renewal energy and improving Green Belt area.
Focus on improving knowledge and skill of people through competency development.
Emphasis on 5'S principal.
Low-cost automation to eliminate losses in product realisation process.

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5. ACHIEVEMENT RECORD:

Category

Index

Unit

BM(TPMStarted)

PPPPPPPPPPQQQOEEOEE: AvailabilityRate
OEE: Quality Rate
OEE: PerformancerateOPE
Manpower Efficiency
Breakdown due toweak JH
BD Hrs -A
BD Hrs -B
BD Occurrence-A
BD Occurrence-B
MTTR- A
MTBF- A
MTTR- B
MTBF- B
Customer Complaint
In-process rejection
Defects due to weak
JH

Actual
FY 23-24(April'23 Nov'23)
84%

68

FY 23-24(April'23 Nov'23)
85%

79

90

88.54

%

100

100

95.10%

86

100

99.64

%
%

76
84

90
99

8699

Nos.

132

00Mins
Mins
Mins
Mins
Nos.
PPM

91
31.68
5335
102.6
771
54.3
1152
6
250

0100140
3500
40
2500
00910.18
1316
42.87
3094
38.18
2520
142Nos.

5900April '19 June'19PTarget

HrNos

Cannot be disclose due to Defence related items

C

Cost index---SS

Major Accident
Minor Accident
Accident due to weak
JH

Nos.
Nos.

040000

Nos.

000Kaizens

Nos.

-500

689

Nos.

50

546

550

%

6485

83

Cum No

01300

1280

S
M
M

M

M

Employees recognizedthru R&R
Skill level of
Production &MaintenanceworkmenEquipment Competent
Operator

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Other

1. Do you have a program where all employees can participate in TPM?
Yes, Through trainings, Quiz, Suggestions Scheme, Kaizen
implementation, etc.
2. Do you have a program allowing employees to be recognized theirachievements?
Yes, there is scheduled "Rewards & Recognition" program to facilitate
employees for achievement.
3. Are top management involved in the audit/verification of completion of
TPM pillar steps?
Yes, Top management holds, review and monitors the progressperiodically.
4. Are all pillar activity boards displayed and reviewed by top management?
Yes, Boards are

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