Over 90% of the shop floors at Anand’s manufacturing facilities are manned by knowledge workers –‘Operating Engineers’

The origins of the Model – Early ‘90s

The Operating Engineer model pioneered by Anand is today an Industry benchmark recognised across the board as a unique model, which has remarkably captured the essence of the concept of using “knowledge workers” in a manufacturing environment. The ‘Operating Engineers’ as they are popularly known as are a shining example of what innovative HR thinking can achieve.

Today the Anand Group has over 4,000 Operating Engineers in 39 plants spread over 8 states in India. The success of this “knowledge worker” model is clearly visible from the fact that all these plants have complete flexibility and agility to meet the ever increasing expectations from the customers while maintaining a young and dynamic workforce in the age group of 22-24 years. These knowledge workers have a minimum educational qualification as diploma engineers.

Such a happy and unique situation can trace its origins back to the early 1990s when Gabriel was setting up a plant in Ambad, Nashik. Characteristically, Anand was in the process of introducing another ahead of its time and first – in - class initiative of “Cellular manufacturing” in India at this plant. This simply put, meant single operators would operate multiple machines, rather than the usual practice of one operator per machine.

Some of the ‘Cells’ proposed to be installed at this plant were expensive – about Rs.10 million a piece, and hence it was imperative that people who operated them should have the requisite capabilities and education to handle

THE ‘ANAND OPERATING ENGINEERS MODEL’ :AN INDUSTRY BENCHMARK

them well. This is when the idea of hiring diploma engineers took birth with a view to moving away from the practice of hiring simple matriculates, as was the norm until then.

A group of Diploma Engineers was hired on an experimental basis. However, the delivery of the machinery to the Nashik plant was delayed by around six months. The Plant Manager at the time, who also happened to be a retired Officer from the Indian Army, was well versed in the methodical training of work force and took it upon himself to use this fallow time in effectively developing his team. Special training modules were created that taught the operators about attitude, responsibilities to their tasks and towards the machinery and shop floor discipline. He further advanced their technical skills by teaching them the 7 Tools of Quality, how to read engineering drawings and a whole host of other practical applications that would be really helpful. The training took these ‘freshers’ to a much higher level in terms of knowledge and the discipline of working on expensive and sophisticated machines. When the machinery arrived and was installed, the employees were already familiar with their jobs and rearing to get started.

Such was their enthusiasm and skill level that the plant achieved its rated output in a matter of two months rather than the typical timeline of a year!

This is how the “Operating Engineer” model was born and became the inspiration that saw its replication in every location of Anand and has further evolved over the years to have taken the shape it has today.

A Training and Development process that creates seasoned Operators It is indeed a tremendous sense of satisfaction that envelops management and operators alike. OE’s are put through a minimum 40 hour training and are also encouraged to complete their graduation/further education alongside their jobs. Typically, the OE at the end of his tenure turns out to be a seasoned operator fully capable of taking up higher responsibility within the company or moving out to jobs of a higher level in the industry at large.

The ensuing benefits of this model are largely evident in terms of the company having a continuing pipeline of a young educated work force resulting in heightened customer confidence; a ready and valuable talent pool for the company as well as the industry at large besides generating a substantial amount of goodwill all around, as this army of lifetime brand ambassadors of Anand moves ahead.

It is commendable to say the least, that today three Anand plants are headed by people who started out as Operating Engineers; 7% (about 30) of Anand Managers are ex-operating engineers and over 200 are today working as first line management staff (Asst Managers/ Shift supervisors).

This model also actively includes the employment of female Diploma Engineers as well.

Today there are nearly over a 1000 female operating engineers working at Anand locations. They are hired from across the country with nearly 300 being hired every year. Over 95% of the workforce on the shop floor of Takata India comprises of women – total testimony to the success of the women operators concept. Working on an Anand shop floor has emerged as an excellent employment option for young women diploma holders as the advantages are many as well understood by them.

It is hardly surprising that this ’Knowledge Worker’ Model pioneered by Anand is regarded as a Benchmark by companies within and outside the industry all keen to study and understand its intricacies.While the Force moves on.

A Successful Outcome – The ‘Operating Engineer’ Model is born

The Unique advantages of the model

Women Engineers on the shop Floor

THE ANAND ‘OPERATING ENGINEERS’ MODELAN INDUSTRY BENCHMARK