ALP Nishikawa Co.Pvt.LtdCompany ProfileAward for TPM Excellence, Category A
ALP Nishikawa Co. Pvt. Ltd.
Gurgaon-122015 (Haryana)Content
1) Organization profilei)

Brief History of group & Plantii) Product, process & Organization structure2) Milestone on the journey of manufacturing Excellencei) Why TPM
3) Benefits achieved.
i) Tangible resultii) Intangible result4) TPM Award Assessment Achievement Sheet
5) Key to our Manufacturing Excellencei) Experience & Future Plan
6) Contact DetailALP Nishikawa Co.Pvt.Ltd

1) Organization Profilei) Brief History & Company Profile
Introduction of ALP GroupALP Group is a USD 200 million Group, founded in 1985, is globally acknowledged as the pioneer inPolymer based products in India. The Group has been in the business for 35 years, having 7 state of the art
manufacturing units located in India & 2 across Africa and Australia. ALP group constitutes of 11companies with a presence around the globe and employs over 2,000 trained workforces & 200 expat
professionals.
ALP Group 11 companies are 1-ALP Nishikawa,2-ALP Oversease,3-ALP Aeroflex,4- Alp
Polymarpark,5-ALP OZ Auto Moulds,6-BTB touls,7- ALP Africa, 8-ALP USA INC
9-Gold Glass ALP,10-ALP GIEG Spain,11- ALP GIEG Germany
ALP Nishikawa is one of the leading manufacturers of TPE, PVC & EPDM weather strips and Seals inIndia. It’s a 50:50 joint venture with Nishikawa Rubber Co. of Japan (NRC). NRC is world leader insealing industry with operations in Japan, USA, India, China, Thailand, Indonesia and Mexico.
ALP Nishikawa First Unit Established in 1996 is located in Lalru, Punjab and is one of the leading
sellers of Rubber Profile, Windshield Rubber & Door Rubbers. And the Main Customer are PSA, Daimler,
TATA & Mahindra.
ALP Nishikawa Second Unit Established in 2003 is located in Gurgaon, Haryana and is one of theleading sellers of Rubber Profile, Windshield Rubber & Door Rubbers. And the main customers areMaruti & HONDA.
ALP Nishikawa Third Unit Established in 2018 is located in Sanand, Gujarat and is one of the leadingsellers of Rubber Profile, Windshield Rubber & Door Rubbers. And the main customers are Maruti &TATA.

ii)

Product, process & Organization structure

We are the manufacturer of Wind Shield Seal, glass runs channels, and flange mounted door seals,
door mounted door seal/sub seals, trunk lid & hood seals, edge trims, outer waist belt, inner waist belt,
double adhesive tape seal, dust seals, roof ditch & plenum applique seals.

PALP Nishikawa Co.Pvt.Ltd
Manufacturing Process Technology:
S. N

Manufacturing Process

1Extrusion

2Curing Oven

3Coiling

4Drilling & resizing

5Clipping

6Moulding

7

Coating

8

Packaging & Dispatch

ALP Organization Chart:

ChairmanI S Anand

ALP Nishikawa

M.D.
P S Anand
AVP - F&A
Devinder SainiCOOAnil Singh

Director- Mktg & BD
Koji Tokunaga

GM Operations Gurgaon
Amrendra Singh

GM Operations Lalru
Lakhwinder Singh

GM Operations SanandVinay Goyal

TPM Secretary
Divakar SinghALP Nishikawa Co.Pvt.LtdCOOAnil Sigh

GM Operations
Amrendra SinghAM Production
Vikramjeet SinghManager HR
Priyanka SinghAGM F&A
Manmohan SinghGM QA
Josheph. K

DGM Maintenance
Diwan Singh

Sr. Mgr. Training
Amit Zutshi

DM PE
Puneet Kaliya2) Milestone on the journey to manufacturing Excellence.

Gurgaon Plant

TPM Secretary
Divakar SinghALP Nishikawa Co.Pvt.Ltd
We were always looking to optimize Overall Equipment Effectiveness (OEE). However, this crucial
business goal involves a difficult balancing act between maximizing equipment performance and the riskof incurring machine failure and lost time. Leveraging the benefits of digital, data-driven solutions, TPM
empowers us to effectively maintain our production lines through heightened visibility and workforce
transformation.
i)

Milestone

Dec 2022 Star Champion Kaizen Award by CII
Nov 2022
May 2022

Platinum Award in Kaizen by CII
Overall Performance Award by MSIL

Apr 2019
Feb 2019
June 2018

Honda Bronze Award for Cost
Implementation of DM, QM, SHE, OTPM
Implementation of AM, PM, KK & EnT

May 2018
Mar 2018

TPM Kick Off
Certificate of Appreciation Delivery Award from Honda

Jan 2018

TPM Declaration

Oct 2017
Jan 2012
June 2010

IATF 16949:2016 Certification
Certificate of Incoming Quality Improvement from MSIL
Nishikawa Production Supply Implemented

Dec 2008
Nov 2004

OHSAS 18001 & ISO 14001
TS 16949 Certification
Gurgaon Operations Started

June 2003
3) Benefits achieved.
i)

Tangible Business Result & PQCDSM Result

TPM Implementation at ALP Group companies not only helped to improve the business result but alsobrought drastic changes in organization improvement culture. Increase in Suggestions /Kaizens & Project
implementations is one of the samples evident for highly engagement motivated Employees. And also
team bonding increased with the help of Cross Functional Pillar Involvement.
Below are the few tangible benefits in key business results in terms of PQCDSM.

ALP Nishikawa Co.Pvt.Ltd4) Achievement Sheet (Index Table).

ii)

Intangible Result

After Implementing Total Productive Maintenance, Skill of our employee improved in every area,
Employee started using the Problem-Solving tools, Why-Why Analysis, Brainstorming, Cause & Effectdiagram, Pareto, Cp/Cpk & TPM Circle activity, which improve their analytical skill & motivated them.

ALP Nishikawa Co.Pvt.Ltd
With the help of Total Productive Maintenance, we were able to involve our employee in improving thebusiness result, which result 5 times improvement in Kaizen & Suggestion activity, 100% involvement inJH Circle activity & Created ownership of Machine as well as every area of plant.
Some of the Initiative in last 4 years as:
Total 14 Six Sigma Yellow Belt Project Done.
Total 11 Six Sigma Green Belt Project Done.
Total 1 Six Sigma Black Belt Project Done.
Total 49 Quality Circle Project Done.
Apart from this every Pillars have done multiple loss reduction project & 29 Major Cost saving projects.
5) Key to our Manufacturing Excellence

Data is the key to making informed decisions and is the foundation of Operational Excellence.
And TPM teach us the methodology how to record and play with the data & Continual review by top
management is also one best key to achieve Manufacturing excellence & Employees are the mostimportant asset of any organization, but they can also be a liability if they don’t understand how to work
effectively with others. And our Employee have learned this best technique from TPM Methodology.

TPM Declaration Date: Jan-2018
TPM Kick Off Date: May-2018i) Our Experience
Implementing TPM in our plant was a roller coaster ride as initially it was difficult for everyone tounderstand the concept of it. But when we started Manager Model Machine activity & spreaded theknowledge of TPM to everyone than it become the way of life.
Our people too enjoyed the TPM learning & implemented wholehearted which resulted in overallimprovement. Our team have learnt about improvement methodology & implemented multiple projects asALP Nishikawa Co.Pvt.LtdQuality Circles, Six Sigma Yellow Belt, and Six Sigma Green Belt & Six Sigma Black Belt. We have also
implemented Lean Projects & VSM Projects.
ii) Future Plan
After gaining multiple results with TPM, we are very confident to go to the next Level of TPM Awards.
The Same experience we are implementing in our other plants too. & in coming years, we will be able toapply for JIPM awards for our other plants.
TPM Excellence Category A Award for Gurgaon Plant: Dec’ 2023
Consistency Award for Gurgaon Plant:
Dec’ 2026
Special Award for Gurgaon Plant:
Dec’ 2029
Advance Award for Gurgaon Plant:Dec’2032
World Class Award for Gurgaon Plant:Dec’2035