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Company Profile

Name: Champion Components (P) Ltd.

Location: Faridabad, India

Established: 1967

Current size: 85 employees

Products: Sheet Metal Components &

Engineering Fabrications for

automobile, construction and

agricultural sectors

Customer: Earth moving equipment for OEM’s

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Sustaining Competitive and Responsible Enterprises

Enhancing Work Place CooperationEnhancing Work Place CooperationEnhancing Work Place CooperationEnhancing Work Place Cooperation

Management Vision

Champion Components (P) Ltd is a family owned

business founded by Mr. SC Bhatia in 1967 as a small

scale unit to produce fabricated engineering

components. With his fortitude and determination, he

turned the small company into a leading light

engineering industry of Faridabad.

Today the company is producing sophisticated

engineering components for automotive, cement and

agricultural farm equipment sectors. The company has

the distinction of delivering quality products to its

customers since last four decades. Today the company

is managed by a team of three young directors who

are having good experiences & qualified professionals.

The young management is genuinely interested in

bringing world class manufacturing (WCM) practices.

Before subscribing to SCORE program, for a year, they

participated in the LEAN cluster program run by

National Productivity Council (NPC) and made

sufficiently good improvement. With the introduction

of SCORE program in India, Champion’s management,

thoughtfully examined the range & scope of SCORE

program and enthusiastically enrolled for the SCORE

Modules.

Workplace Challenge

Starting from a small workshop, company now produces voluminously big

fabricated parts’, as a result, face day to day challenges of work place space

constraint as also mix up of parts & components.

Growing from a small organization to a light engineering industry, the

employee strength grew to 85 people and with heavy part fabrication,

workplace occupational safety and organizing workplace became a big

problem. Employees had no voice in how work is organized.

With large size of the product and variety of fabrication processes, it was

real difficult for the employees and management to organize the

workplace. Though worker would be concerned about his output but the

prevalent work place practice(s) became a hindering factor for worker

efficiency. Many times worker was not aware of product & company

concerns; as a result, factory would result in disorganized work place,

leading to safety issues and lot of unwanted material stored here & there.

“With increase in business and product range, space was becoming a

constraint and so accommodating varied parts fitting into limited space,

was becoming a challenge of its own kind”, mentions PK Verma, the

Quality Manager.

Concrete flooring has made the workplace neat & easy to

move

Champion’s management heard about SCORE from Faridabad Small

Industry Association (FSIA). “After LEAN, I was looking for an

improvement program that would help us to address our challenges and

become more competitive” explained the company’s Director, Manish

Bhatia.

Page 2 For further information please see www.ilo.org/score or contact ILO New- Delhi Office | ILO Country office for India | Indian Habitat Centre | Core 4B, 3

rd Floor| Lodhi Road| New Delhi – 110003 | INDIA | Tel. +91-11 2460-2101-03| Email: bhadra@ilo.org

Interview with the Director of Champion Components:

Before

Cluttered and disorganized area of factory.

After

Clean and tidy Lunch area for workmen

Meeting the Workplace Challenge

After the Training of Enterprise (TOE) of SCORE program, an Enterprise

Improvement Team (EIT) was formed which started meeting regularly for about 3-4

times in a week. The EIT consisted of 3 workmen and 5 management cadre staff,

including the Director.

Initially it was confusing, where to start, but as workers involvement grew,

1S & 2S initiative started gathering momentum in every nook & corner of the

factory. 1S & 2S initiative in the company led to freeing space from different areas of

the factory. “We are still sorting many old inventories of goods and tools &

deciding about them” mentions Manish, Director. “In fact a proper dining space

had come out for workers to properly rest and take food, once the space was

freed”, he added. Workers are now shedding old stored junks, which was kept for

years.

Weekly EIT meetings were held on every Tuesday. 10 minute daily meeting

brought the whole shift in the involvement of workers, as daily sharing of

production targets and concerns not only improved the Management-Worker

dialogue but also boosted workers morale in enhanced participation.

Thrilled with the response, Director of Champion, once gave complete

liberty to workers to red tag all items in respective work area so that appropriate

decision could be taken to decide about the old inventory. In this process,

approximately 0.6 Million Rupee worth of material was scrapped.

Employee Suggestion scheme in its renewed vigor is prompting worker to

suggest improvement in workplace practices. “Workers are now excited and

wondering their participation in the whole initiative whole heartedly as they are

being talked of day to day problems”, says Dalbir (Worker). “Daily meeting has

immensely helped to know our daily targets”, adds Dalbir.

ILO: Mr. Manish, What was the biggest gain from the SCORE training?

Mr. Manish: Freeing the space from clutter, that was stored for years,

thereby bringing more space for work in a safer manner. We sold about

0.6 Million Rupees, worth of old inventory. With daily communication, our

workers have now started getting involved in the improvement initiative,

which was not driven in earlier initiatives of LEAN. I think it is a good start

and I am happy for my team to take it forward. We are still evolving.

Our Partners:

Stake Holder Benefits

Employee • Improved Morale

• Clarity of Targets

• Feel Included

• Safety

• Job Satisfaction Management • Improved

Communication between workers & Management

• Motivated work force Company • Organized Work Place

• Recovery from Scrap

This case study is written by Piyush Kumar of PMG Consultants. Many thanks to the management of Champion Components for sharing their experiences. Many thanks to ILO’s Ms. Sudipta Bhadra for reviewing the draft of this case study and nurturing the SCORE program in India.