Award for Excellence in Consistent TPM Commitment
Lumax Auto Technologies Limited
Gat No.156/1, Mahalunge Ingle
Chakan-Talegaon Road
Chakan, Pune, Maharashtra-410501
India

1. Organization profile:
Plant Details
Lumax Auto Technologies Ltd, Chakan plant was established in 1995, with Fabrication parts like Silencers,
Chassis for Two-wheelers, and Forks. From 1995 Lighting parts were introduced to plant products. In 2011,
Metallizing facility was introduced. LATL, Chakan plant is situated in a Plot area of 10800 sq. mtrs, and witha built-up area of 5048 sq. Mtrs. The connected load is 1000 KVA with backup DG set capacity – 400 KVA.
This plant has a total permanent manpower of 90 employees i.e. 41 staff and 49 Associates and approx.
150 contractual workers. At present the plant is manufacturing 100% Lighting products for 2 wheeler and 3Wheeler and has Bajaj Auto Ltd as a major Customer with > 85 % of SOB and the rest for Mahindra andMahindra 2 Wheeler and Piaggio Vehicle Pvt Ltd through Lumax Industries Ltd.

Lumax strives for continual improvement of manufacturing processes with emphasis on consistent qualityand cost effectiveness Lumax signifies LUMINOSITY MAXIMA for today's demanding automobile users.

We at Lumax in the new millennium are committed to retaining excellence in the quality of our products
and services, with a focus on customer satisfaction and market leadership we vow to remain a responsible
corporate citizen contributing to the lives of our people and the preservations of our Planet's eco-balance.

Under the umbrella of “ DK Jain Group has 2 Listed companies named as Lumax Industries Ltd and Lumax
Auto Technologies Ltd.and 37 manufacturing plant along with 6 R&D centres.

Lumax Auto Technologies Ltd Chakan Plant achieved the Award for TPM Excellence - Category B in 2017and is now ready for a challenge next level award i.e. Award for Excellence in Consistent TPM
Commitment
1 of 5

Plant Product Range: Head Lamps, Tail Lamps, Blinkers, Reflex Reflectors, Rear Fender assembly, Leveller
Motors, Warning Triangles.
Plant's Key manufacturing processes: Moulding, Metalizing, and Assembly

Key Processes
Product Range

Molding

Surface Treatment

Assembly

There is approximate 240 nos. of manpower out of those 6.3% managers, 7.3% engineers, 5.6%supervisors, & rest 81.5% are associates.

2. Milestone on the journey of manufacturing excellence.
LATL Chakan in line with philosophy of the company and the group has always been conscious of its product quality& services aiming to maximize shareholders value & services to all stake holders.
Quality is a never ending journey at LATL Chakan plant, which continuously improve all key performance parameters
Major challenges, during quality journey, include improving equipment reliability and employee competencies at alllevels.
In today’s competitive scenario it needs team work and TPM is one of the best manufacturing practices followed by,LATL Chakan plant.
TPM journey started in Dec. 2012 with one manager model machine. LATL plant launched TPM activities on 28 June.
2013 with formal Kick-Off ceremony held in guidance of customer.i.e Bajaj Auto Limited. And then in 2017 Plant
successfully challenged and achieved Award for TPM Excellence - Category B

For Quality Front Lumax Auto Technologies Ltd Chakan plant achieved and sustained Zero Customer
Complaints from last 3 Years and also Sustained all the KPI result achieved during Award for TPM
Excellence - Category B
The Main Customer Bajaj Auto Ltd awarded Quality Bronze Award in 2013,Quality Silver Award in
2014,Quality Gold Award in 2017,Quality Gold Consistency Award in 2019 and 2022
2 of 5

3. TPM Journey: -4. Process Flow:
As per Typical automotive lighting manufacture industry Lumax Auto Technologies Ltd,Chakan Plant having
6 Injection Moulding Machines, surface treatment process i.e Aluminium metalizing and Hard Coat andthen Assembly Lines.

3 of 5

5. Benefits achieved:

4 of 5

6. Key of our manufacturing excellence:
The key to manufacturing Excellence lies in continual improvement activities and periodic review with Top
Management of the result to meet the strategic performance & business results.

With the learning’s of improvements made in existing equipment’s and plants, we will install new
equipment’s/ facilities by incorporating all improvements.
4.1 Lowest manufacturing cost
4.2 Deskilling of all processes
4.3 100% Poka Yoke for defect free systems
4.4 100% FIFO in all storage systems
4.5 Indigenisation of development activities for reducing cost and lead time
4.6 Development of suppliers with TPM learning to provide cost benefits
4.7 Proficiency in new technology products
CSR activities:a) Adoption of School for Swatch Bharat Abhiyan and provide basic amenities and improve
infrastructure of the school.
b) Support nation building mission of “Sarva shiksha abhiyan” in which Encouragement provided to key
communities for education.
c) Lumax Ki Nanhi Chhan (For Girl Child of Employee)d) Adoption of school for juvenile diabetes care center and provide basic health check up .

5 of 5