Excellence in Consistent TPM Commitment
ABI Turnamatics(A Division of ABI Showatech (India) Private Limited),Pulivalam.
1.Organization Profile
ABI Turnamatics (A Division of ABI - SHOWATECH (INDIA) PRIVATE LIMITED) is a 100 % Export
Oriented unit the company was set up in Pulivalam, in Vellore District of Tamilnadu. The Company wasstarted in the year 2000. The prime object which the company set up was to manufacture Turbo charger
Bearing housing for Passenger cars and Commercial vehicles at very economical rates and export
products to various countries.
"Dedicated precise cellular manufacturing cells for dedicated customers" is practiced to achieve Focused
Manufacturing. This helps to improve product quality and delivery performance. The mix of flexible CNC
machines and dedicated high productive SPM'S help in meeting the customer target costs and quality
requirements. This helps to achieve very low PPM levels at the customer end.
ABI is certified for IATF 16949 Quality Management System, ISO 14001 Environmental Management
System.
Total Productive Maintenance is being followed in all Machines to achieve Critical Objectives.
The company focusses to constantly upgrade technology and bring out products that meet global standards.
Qualified engineers and equipment are utilized for development of new products to meet the customer
requirements The company's in-house Computer Aided Design department, tool room, Coordinate
Measuring machine along with the well-equipped Standards room are used extensively to meet therequirements. The Marketing Office is located at Chennai, which is 120 kilometers from the plant.
Registered Name
Location
Established
Total Area
Total Built up area
TurnoverNumber of Employees
Location/ facilities
Nature of WorkTPM Kick off
TPM Excellence Award
Major SuppliersCasting supplier: ABI Turnamatics
A Division of ABI Showatech (India) Private Limited.
: 67, Chamiers Road, Chennai, Tamil Nadu, India.
: 2000: 8092m2: 2590m2: 2022-23 : 100.99 Crore.
: 2023-24 : 114.91 Crore.(Estimated): 230: Pulivalam,: Manufacture of Bearing Housing: 6th Nov 2014
: 2017:: Brakes India Private limited - Foundry division.
(TPM Special award company, DEMING award)
Various child parts suppliers in Europe

2.Milestone on the Journey to Manufacturing Excellence

2000

Established & Supply of Turbo Charger Parts to Turbo Energy Limited

2001Certified to QS 9000 Quality Standards

2003

Achieved QS 9000 Certification

2006

ISO TS16949 Certification

2006

Achieved ISO 14001 Certification

2007

EMS certification

2014

TPM Kick off (ABIT)2014

TPM approach in manufacturing area

2015

Six Sigma Activities Started

2012

ABI Soorai Green plant established

2017

IATF 16949 award

2017

TPM Excellence award – Category A

2018

OSHAS 18000 & ENMS 5001

2023

TPM - Consistency Award

3.Benefits Achieved
TPM Implementation at ABI Turnamatics (A Division of ABI Showatech India Private limited) not
only helped in improving business results but also brought drastic change in organization culture.
Increase in employee suggestion is one of the sample evident of involvement of highly motivatedemployees.
Further improvement in People attitude
Work environment improved further.
People “own” the machines.
Company wide participation.
Skill level increased.
House keeping improved.

Team approach has taken deeper roots.

4. TPM Award Assessment Achievement Sheet
Index
CategoryUnit(Calculation Formula)

Kick off 2014

Excellency Consistency
Targetaward 2017 award 2023

S

Number of workrelated accidents
requiring days off work

Cases/ year0000S

Number of workrelated accidents not
requiring days off work

Cases/ year

0000Parts/ hours

1219

2224%

69

83.8

84.15

85

87.9
95.4
99.42

88.2
95.9
99.5

90
95
99.99

123

118

5

425
2.38

584
2.33

778
1.60

10518
1.98

13

1

00

2.90

0.50

0.44

0.30

3.30

1.17

0.27

0.10

83.50

44.30

42.00

35.36

153.8378100

114.20
54
100

91.70
42100

88.64
36
100

00

00801

1662

2025

3000

PP
P

Productivity for main
products
OEE(or Overall Plant
Efficiency)
Availability
Performance RateQuality Products RateP

Number of breakdowns

PPMTBF
MTTR
Number of customer
complaints
In-line defect rate,scrap
In-line defect rate,
scrap and rework

PP

Q
QQC

Cost index

DD

Production Lead time
Delivery performanceS

Safety index

M

Number of Employee
Suggestions%%%
Breakdowns/months
Hour
Hour
Avg.
Number/months%%

Cost/Unit

5. Key to our Manufacturing Excellence

Pass.
Car
B/hsCD
B/hsg

Days%
Accidents per
1,000,000 operator
hours
Number/yearThe key to manufacturing Excellence lies in continual improvement activities and periodic re-view of
the results to meet the strategic performance and business results.
Future Plan Involving marketing to improve the turnover and profit
 Implement more kaizens to achieve zero losses
 To focus on tool cost and Energy cost
 Implement of IOT’s
 Focus on Aero parts
 Challenging Consistency award (silver) in 2025