Company Profile
ADVIK HI-TECH Private Limited (AHPL) is one of theIndia's

leading&global

automotive

component

manufacturers. We have been catering to the growing needsof a number of domestic and overseas customers across fourcontinents in the Design Development & Production ofEngine,
1

Transmission,

Break&Emission

Control

Mr. Aditya Bhartia (MD)Components from the past 23 years.
We Provide Custom Made solutions for our customer’s
design, keeping in mind their needs and specifications. Ourcustomerbase

includesleading

automotive

original

equipment manufacturers in India, Europe, UK, US and theASEAN region.
We are the preferred global supplier for a range of automotive components including Chain Tensioner,Oil Pumps, Fuel Cocks- Manual & Auto, Decompression units, Water Pumps, Combi Brake System,
Drum Gear Shifter, Starter Gears and many more.
ADVIK credit its success and growth to the areas of excellence, which include: State-of-the-Art research and development center, which is recognized by Government of India.
 Cellular manufacturing set-up for product engineering.
 Most advanced machines with latest technology.
 TPM- The Way to achieve Excellence.
 Testing and Metallurgical laboratory.

We have technical collaboration with German R&D company FMO Technologies (Trococentric) GmbHfor design, development & production of oil pump assemblies for passenger cars, commercial vehicles,
stationary engines and transmissions systems. We are committed to provide world-class products to ourcustomers in an effort to create a global footprint in world market.

Company History: ADVIK Hi-Tech PVT. LTD. has been established in 2000 at the chakan near Pune. We are leading
manufacturer of auto components supplying to globally renowned automotive original equipmentmanufacturer like Bajaj Auto, Hero Moto Corp, Honda Motors, Suzuki, Yamaha, etc..
We started a plant (P3) in Pantnagar, Uttrakhand in 2007, as a manufacturer of engine parts Like- Oilpump, Tensioner etc... We also started new plant in Bangalore, Manesar, Ahmadabad, one more plant
at Chakan and in Bawal near Gurgaon.
ADVIK PANTNAGAR

TPM – The Way To Achieve ExcellenceWe also started manufacturing our components overseas in Indonesia since 2014 and it is supplying toMagna, Daimler AMG, ZF, etc. & We have started a new plant in Vietnam also.
Currently the growth rate of the company is average 30% every year. Our Three plant are Awarded by
JIPM for Excellence award in category A, Now we (Pantnagar) have cleared both assessment of nextlevel award.

Business Acquisition

Customer BaseADVIK PANTNAGAR

TPM – The Way To Achieve ExcellenceOur Customers(EV Braking)Global Presence

ADVIK is Set to be the world’s
largest manufacturer of Tensioners,
Oil Pumps & Combined Braking
System in FY2018.
We supply oil pumps to Honda,
Yamaha, Suzuki and Kawasaki.
We used to earlier export to Honda
in Indonesia and we had a 25percent market share with them.

Customer Location

This was when we were exportingInternational Officeto them from India. Then we wentWarehouse

Manufacturing Footprints in India
ADVIK Hi-Tech PVT. LTD. has been
established in 2000 at the chakan nearPune.
We have 10 production Site in all overIndia and overseas also.

ADVIK PANTNAGAR

TPM – The Way To Achieve ExcellenceProducts port folio

Pantnagar Plant – Process and Material Flow system

ADVIK PANTNAGAR

TPM – The Way To Achieve ExcellencePantnagar Plant – Machining Technology

Management organization structure

ADVIK PANTNAGAR

TPM – The Way To Achieve ExcellenceStaffing Structure

2. Milestones on the Journey of Manufacturing Excellence.
2.1 Reasons for adopting TPM

ADVIK PANTNAGAR

TPM – The Way To Achieve ExcellenceTPM Journey

Our TPM journey started with declaration by top management in 2014. Subsequently we carried out 5S
activity as a base and Manager Model Line activity. Kick Off was done on 21St March, 2016 & TPM
activity was spread across plant. We started with trainings and carrying out 8 pillar activities.
TPM journey facilitated to get us various awards from our customers such as Best Development, GlobalSupplier, Quality Excellence Award & Delivery Excellence Awards and many more.
In 2019 -20 we also get TPM award by JIPM – EXCELLENCE IN CATEGORY A.
Now we have Successfully Completed 2nd Assessment for Award -Excellence in consistent TPM Commitment.

Pantnagar Plant
Pantnagar plant is the 2nd plant of ADVIK HI-TECH PVT.
LTD. It is a manufacturing facility established in 2007and it
is located at Plot No. – 7A Sector -09 I.I.E., Sidcul
Pantnagar, (Uttrakhand).
Pantnagar Plant manufactures Oil pumps, Tensioners, Fuelcocks, Drum Gear shifter, CGM, Starter Gear and De-compand supplying to various two wheeler manufacturers.

Plant’s Mile Stones

ADVIK PANTNAGAR

TPM – The Way To Achieve Excellence3 - Benefits Achieved
3.1 Pantnagar Plant- Tangible Results
 PBIT increased by 21% and sustained.
 Cost Index for Oil Pump reduced by 4.51 % from 2019 ( Excellence Category A) Cost Index for Tensioners reduced by 3.33% from 2019.
 OEE machine shop increased by 20.65%. - Sustained OEE assembly shop increased by 20.88% - Sustained Overall Inventory reduced by 5days from 2019...
 Safety index Sustained 0 to 0.
 Suggestions per employee increased from 1.5 numbers to 1.7 numbers from 2019.

3.2 Pantnagar Plant- Intangible Results
 Enhanced Teamwork approach for continuous improvement activities through TPM.
 Enhanced employee

Morale due to focus on Zero Customer Complaints, Zero in process

defects, Zero breakdowns and Accident.
 Employees have Sense of Pride so started thinking Widely and Deeply in their areas / section toImprove from existing condition to next level.
 Employees are now work as per the Flexibility of requirement and open for any changes.
 Sustenance of Improvements done by the operators.
 Enhanced operator ownership of equipment with understanding on importance of maintaining basic

condition i.e. “I Operate, I Maintain, I Control”.
 Repeated failures / defect are not happening due to corrective maintenance & development ofAnalytical Capability.
4. Key of Our Manufacturing ExcellenceWith the experienced gained through TPM activity, we intend to continue following in future.
• Total Employee involvement through active participation in TPM

pillar activities leading tosuggestions for continuous improvements.
• TPM methodology has improved analytical & logical approach at all levels. This is to be enhanced

through continuous involvement & trainings.
• Sustenance of 8 Pillar activities and go for award for excellence in consistent TPM commitment.

ADVIK PANTNAGAR

TPM – The Way To Achieve ExcellenceTPM Award Assessment Achievement SheetIndex(calculation Formula)

CategoryUnitKick off/TPM started (orlast time awarded TPM
Excellence Award

Actual Status
2022

Target2023

Category –A 2019-20)
S

Number of work-related accidents
requiring days off work
Number of work-related accidents not
requiring days off work ( First Aid Case)

Cases/year000

Cases/year

1290

Productivity for main product –M/CShop

Part/Operator

303

246

252

HourPart/Operator

332

372

391

Hour%

89.6

90.7

91

Availability%

98.71

98.14

98.30

Performance Rate%

92.45

93.84

94.00

Quality Products Rate%

98.23

98.56

98.50

OEE Assembly Shop(or Overall Plant Efficiency)
Availability
Performance Rate
Quality Products Rate%

94.8

95.16

96%%%

99.41
96.62
98.71

99.88
96.72
98.51

99.50
97.00
99.50

P

Number of Breakdown

332PPQQMTBFMTTR
Number of customer complaints
In-line defect
Scrap
rate
Oil Pump
Cost index
Tensioner
Production Lead time
Delivery Performance
Safety index(ex-Lost Time Incident Rate)

Breakdown/Month( Average)
Hour
Hour
Number/year
PPM

18600
1.3
2297

20474
1.07
114130712
10148

31.33 INR
38.45 INR
7100029.91 INR
37.18 INR
6.510002936.5
6100
0

1.5

1.7

2S
PP

Productivity for main product –Assembly ShopPOEE Machine Shop(or Overall Plant Efficiency)

PCDDS

Cost/Unit

Days%(Accident per1,000,000operator hours)
Number of Employee Suggestions
Number/year<Specify achievements not expressible in numerical terms>

M

Other
1.
2.
3.
4.
ADVIK PANTNAGAR

Do you have a program where all employees can participate in TPM? - Yes
Do you have a program allowing employees to be recognized their achievement? - Yes
Are top management involved in the audit/verification of completion of TPM pillar steps? - Yes
Are all pillar activity boards displayed and reviewed by top management? - Yes
TPM – The Way To Achieve Excellence