BMGI  OUTLINES  HIGH  IMPACT  AREAS  FOR  PLANT  LEADERSHIP  OVER  A  2-­‐DAY  PLANT  LEADERSHIP  CONCLAVE  

Being  the  Key  Knowledge  Partner  for  the  Plant  Leadership  Conclave  2012,  held  in  Mumbai  on  30  &  31st  August,  BMGI  highlighted  &  identified  key  areas  that  could  create  high  impacts  to  the  industry  thereby  leading  to  Plant  Leadership.  

The   event   was   organised   by   Yoogma   Business   Services.   The   event   comprised   of   thought  leaders  (speakers)  and  delegates  (senior  management)  from  across  the  country,  Middle  East  &   China   geos.   Key   company   executives   that   graced   the   occasion   included     Tata  Motors,  SAIL,   TVS  Motors,   Akzo  Nobel,   Tata   Power,  Whirlpool,   Bajaj   Auto,   Vedanta   Aluminium,  Reliance  Industries,  Honeywell,  etc  to  name  a  few.  The  event  was  well  attended  with  over  50+  C-­‐Suite  &  Senior  Management  executives  actively  participating  in  the  proceedings.  

The   Chairman   of   the  event,   Mr   Naresh  Raisinghani   &   CEO/  Executive   Director,  BMGI,  delivered   his   opening  keynote   address   on   the  topic   “12   Ideas   for   Plant  Leadership”  

Mr.Raisinghani   of   BMGI  talked   about   his   exposure  towards   thousands   of  improvement  areas  from  a  Manufacturing   &   Plant  perspective  on  the  basis  of  which   he   has   examined  &  collected   a   rich   repository   of   best   practices.   Further,   he   stressed   on   the   fact   that   a  substantial   chunk  of  manufacturing/   plant   set-­‐ups   in   India   have  not   yet   fully   exploited  or  realised  the  full  potential  of  these  prevalent  best  practices  &  hence  the  need  to  unlock  its  potential.    

Some   of   the   key   ideas   expressed   by  Mr.Raisinghani   included   reducing   variations   in   plant  processes   by   more   than   half,   increasing   batch   frequencies,   reducing   changeover   times,  creating   visual   factory,   Poka-­‐Yoke   (Mistake   Proofing)   concept,   Multi-­‐skilling   i.e   ability   to  upskill  an  existing  employee,  measuring  plant  yield,  ability  to  challenge  the  status  quo  w.r.t  process   &   product   design,   engaging   people’s   minds   in   carrying   forward   improvement  programs,   optimising   operations   via   Plant   experimentation   &   Evolutionary   Operations  concepts,  digitizing  processes  &  creating  a  “Pull”  based  supply  chain  to  help  liquidate  more  than  half  of  the  Inventory.  

Mr.Raisinghani’s   views   expressed   in   his   keynote   address   were   echoed   by   several   noted  speakers  later  during  the  course  of  the  day.  

Mr.   P   R  Mohanty   –   Outstanding   Scientist   and   Technical   Director   -­‐   Heavy  Water   Board,  focused   on   “Transformational   Leadership   –   Concepts  &   Practice”.  His   presentation   talked  about  aspects  of  Leadership  and  Innovation  and  insights  were  being  provided  on  the  Boron  Enrichment   Facility   and   the   experiment   conducted   at   their   Talcher   site.   Mr   Mohanty  

reiterated   that   being   a  Government   of   India   enterprise,  money  has   to   be   invested  wisely  and   the   right   places.   Reduction   in   cost   doesn’t   mean   poor   quality,   rather   it   gives   an  opportunity   to   challenge   yourself   to   better   your   product   and   be   more   efficient.   He   also  dwelt   on   the   fact   that   since   they   work   in   “non-­‐competitive”   space,   they   set   their   own  benchmarks.   In   fact,   their   operational   performance   is   better   than   several   equivalent  agencies  in  other  countries.  

“Managing  Key  Stakeholders”  was  led  by  Mr  Vijay  Kumar  Gupta  –  Asst  Executive  Director,  Dalmia   Bharat   Sugar   and   Industries   Ltd.  Mr   Gupta   spoke   about   the   presence   of   various  stakeholders  who  need  to  be  managed.  The  stakeholders  are  not  just  the  shareholders  and  directors   of   the   company,   but   include   Employees   and   their   families   (family’s   well-­‐being),  Vendors/Customers  (providing  a  win/win  situation),  Promoters  (Peace  &  Harmony,  Business  Growth,  plant  efficiency),  Investors  (plant  visits  /  give  right  business  perspective  to  investor),  Government  Agency  (legal  compliance  /  regular  liaison/  healthy  relations),  Local  Politician(s)  (regular  meetings  /  good  relationship  /  meeting  their  requirements),  Trade  Unions  (Constant  touch  /effective  dialogue  /  communication  /  fair  and  reasonable  approach)  and  the  Overall  Community   (corporate   social   responsibility   /   environment   management   /contribution   to  community  development).  

A  Panel  Discussion  on  “Workforce  Management  -­‐  The  Future  of  Workforce”  was  chaired  by  Mr.   S.  Vijayan   -­‐   Principal   Consultant  Ramco  Systems,  Mr.   S.  Hariharan   -­‐   Joint  Managing  Director   –   Solaris   Chem   Tech,  Mr.   Vijay   Kumar   Gupta   -­‐   Asst   Executive   Director,   Dalmia  Bharat  Sugar  and   Industries   Ltd  and  Mr.  G  S  Uppal  –  Head  of  CS,   IR  &  Administration  –  Tata  Motors.    

Mr.S   Hariharan   of   Solaris   Chem   Tech   talked   about   Workforce   Management   -­‐   Gen   Y  Imperative.  He  echoed  the  points  raised  earlier  by  Mr.Raisinghani  on  the  topic  of  Employee  engagement  as  he  stated  that  today’s  Gen  Y  has  different  expectations  

Mr.  Hariharan   provided   an   interesting   perspective   by   providing   a   comparative   analysis   of  people  born  before  1950,  after  1950,  after  1970  and  after  1985  on  various  aspects  such  as  Ethics,  Leadership  Style,  Communication,  and  Work  &  Family  Life.  He  also  provided  a  view  on  What  Gen  Y  can  bring  to  the  table  and  how  one  can  try  to  engage  them  in  today’s  world.  

Mr.   G.S.   Uppal   of   Tata  Motors   through   his   presentation   threw   some   light   on   Employee  relations.   He  made   a   very   valid   point   stating,   ‘There   are   no   good   or   bad   employees,   just  good  or  bad  managers.’  There   is  a  general  perception  about  Employee  Relations  -­‐  Narrow  Minded,  Negative,  Reactive,  Conflict  Resolution,  Ad  Hoc,  etc.  Mr.  Uppal  provided  an  insight  on   the   changing   profiles   of   workforce   in   India   at   three   levels   –   Yesterday,   Today   and  Tomorrow.  

Mr.   Gupta   of   Dalmia   Bharat   Sugar   and   Industries   Ltd,   who   presented   in   the   previous  session,  shared  his   insight  on  Young  Leaders  and  how  can  one  manage  young  leaders.  Mr.  Gupta  provided  certain   important   traits  on  both   the  aspects   including  Talent,   Impatience,  Work  Life  balance,  Quick  results,  Energy,  etc.  

The  panel   discussion   provided   an   opportunity   for   others   to   ask   questions   and   learn   from  experiences.  122  

 

An  Open  Discussion  on  Plant  Leaders  -­‐  Challenges  &  Solutions  was  being  led  by  Mr.  Sanjay  Kurup  –  Director  (Manufacturing  Operations)  West  –  Pepsi  and  Mr.  Naresh  Raisinghani  –  CEO   and   Executive   Director   –   BMGI.   They   gave   insights   about   important   aspects   on  Management,   Manufacturing,   Operations   &   Technical,   Supply   Chain   and   Logistics.   Mr.  Kurup  spoke  about  importance  of  Balanced  Scorecard  and  how  it  helps  to  drive  results  once  the  annual  goals  are  fixed.  Mr.  Raisinghani  also  provided  insights  on  having  the  staff  to  gel  together  during  distress  and  how  it  helps  to  come  out  of  any  situation.    

Mr.Eddy   Anwar   of   MDPV,   a   software   firm   providing   solution   around   MES     made   a  presentation  on  Manufacturing  Execution  System  (MES)  for  Plant  Sustainability.  The  various  System  used   by   companies   (ERP   such   as   SAP,   etc.)  manages  manufacturing   operations   in  factories.  Real   time  data   can  be   the  eyes  and  ears  of  manufacturing  units   and  hence   it   is  imperative  for  organizations  to  look  at  systems  that  support  their  manufacturing  operations  for  better  results.  He  provided  insight  on  how  this  system  helps  various  functions.  

Mr.Krishna  Rao  –  Sales  Director,  ASIA  PAC  -­‐  Stratus  technologies  spoke  about  Continuous  Servers  Availability  for  24/7  Manufacturing  Plants.  Stratus  Technologies  provides  servers  to  protect  mission  critical  systems  from  downtime.    In  today’s  world,  manufacturers  are  using  lot  of  systems  for  better  productivity  which  requires  continuous  availability  of  servers.  

A   panel   discussion   on   “Good   Maintenance   Practices”   was   chaired   by   Mr.   S.   Vijayan   -­‐  Principal  Consultant  Ramco  Systems  &  participated  by  experienced  Plant  Leaders   such  as  Mr.  Anil  Malik  –  Shutdown  and  turnaround  Manager  Qatar  petroleum,  Sudhir  Agrawal  –  VP   Reliance   Gas   Transportation   Infrastructure   –   Engineering   and  Maintenance   and   R   K  Vijayavergia  –  ED  (OPS)  –  SAIL.  

Mr.  Malik  who   is  based   in  QATAR  spoke   regarding   the   important   issue  of  plant   shutdown  and   stressed   on   importance   of   reliability   and   availability   of   plant   unit   and   the   associated  maintenance  requirements.  He  posed  relevant  questions  on  avoiding  Emergency  Shutdown.  He  stresses  on  the  need  for  constant  readiness  and  review.  

Mr  Sudhir  Agarwal  spoke  on  how  to  prevent  breakdowns  and  highlighted  use  of  framework  such   as   “Failure   Modes   and   Effects   Analysis”   and   “Failure   Modes   and   Effects   Criticality  Analysis”.  

Mr  Vijayavergia  spoke  about  Troubleshooting  and  Problem  Solving  with  focus  on  providing  solutions   to   enhance   productivity   of   the   plant/machinery,   increasing   plant’s   operational  efficiency,  reducing  unplanned  shutdowns  and  lowering  costs  attached  to  maintenance  and  repairs  of  the  plant  and  machinery.    

The   panel   discussion   provided   an   opportunity   for   others   to   ask   questions   and   learn   from  experiences.  

A  joint  presentation  on  Flexible  Manufacturing  System  was  made  by  Mr  Bharat  Shah,  Head  Operations,  Pidilite  Industries  Ltd  and  Mr  Dinesh  C  Sinha,  COO,  Kalyani  Carpenter  Special  Steels  Ltd.  

The  presentations  talked  about  aspects  of  driving  improvements  such  as  Quick  Changeover,  improving  quality,  cycle  time  reduction,  greater  labour  productivity  and  shorter  lead  times.  Some   of   the   topics   discussed   such   as   Quick   Changeover   were   being   talked   about   by  Mr.Raisinghani  in  his  earlier  keynote  opening  address.  They  spoke  about  the  critical  factors  of  production  including  Machinery,  Raw  Material,  Labour,  Capital  and  Land.  They  also  spoke  about  how  companies  can  use  tools  such  as  Six  Sigma  for  improving  OEE.    

   

The  keynote  speaker  of  Day  2  was  Mr.  Kulbhushan  Gupta,  Head  Of  BE  &  Six  Sigma,  Jubilant  Life  Sciences  Ltd.  He  gave  an  overview  on   the  Business  Excellence   journey  at   Jubilant.  He  then   shared   insights   on   how   the   deployment   has   been   successfully   managed   in   the  organization.   He   talked   about   challenges   faced   and   actions   taken   for   driving   success.   He  shared  some  cases  on  problems  solved.  

A   3   hour   Post-­‐Conference   Master-­‐Class  session   was   conducted  by   BMGI’s   Senior  Principal   Consultant  Mr.Ambarish  Raj.    

Important   points   related  to   deploying   Innovation  &   Growth   Projects   was  also   covered.   The  underlying   4   key  principles   to   Innovation,  Innovation   Processes,  and   Tools   &   Techniques  such   as   the   D-­‐4   TRIZ  methodology  was  also  covered  &  discussed.    

The   overall   session   was   highly   interactive   with   participants   being   provided   with  multiple  exercises/  games/videos  to  gain  a  practical  perspective  towards  Innovation  as  a  concept.  

Mr.   Shree   Phadnis,   Country   Deployment   Champion   &   Master   Black   Belt,   SKF   India  continued  further  with  the  Innovation  agenda.  He  started  with  some  concepts  on  breaking  psychological   inertia   at   the  work   place.   He   concluded  with   case   study   demonstrating   the  application  of  TRIZ  to  solve  a  critical  problem  at  the  workplace.  

The  event  ended  with  the  event  organizer  Ms.  Jyoti  Shau  thanking  the  speakers,  delegates,  knowledge  partner  and  sponsors.  

About  BMGI  Breakthrough  Management  Group  International  (BMGI),  a  global  consulting  firm  with  a  strong  focus  on  delivering  results,  partners  with  organizations  in  various  stages  of  their  business  life  cycle  to  transform  their  business  performance.  BMGI  is  recognized  as  the  world  leader  in  harnessing  the  power  of  cutting  edge  techniques  in  the  area  of  Innovation,  Strategy,  Problem  Solving  and  Business  Transformation  for  achieving  tangible  business  results.  BMGI  enables  businesses  drive  growth  and  improve  profitability.  Headquartered  in  the  US,  BMGI  has  offices  in  13  countries  around  the  globe.  BMGI  has  delivered  cumulative  benefits  to  its  clients  worth  several  billion  dollars  with  an  ROI  of  5:1  to  20:1.  

For  More  Information,  Contact:  

Jaspreet  Singh,  BMGI  Phone   :  +91  22  4002  0045,  Email:  jaspreets@bmgindia.com