Deming Drill
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Iipm Industry Visit to Rane Engine Valves Pvt. Ltd., Chilkur, Hyderabad
After a brief security check, the group was escorted to the training hall, where the Manger and Deputy Manager-HR addressed them on the company’s business and many interesting facts about the factory site. It was noted that the site lies in a catchment area, and hence no major constructions are allowed. Environment protection is a major concern. Rane is ISO-14001 certified.
The 350 workers, who work in 2 shifts, generally come from nearby villages. There are also about 50 ITI technicians and engineers. The group is engaged in manufacturing valves for engines, mainly used in automobiles. There were manual as well as automated operations, and the use of CNC (Computer Numerical Control) technique is common. Operations include forging, turning, milling, boring, drilling and grinding with heat treatment, annealing and normalizing. Soap-water is used as coolant to prevent melting of tools, due to the heat generated in high friction operations. It was a marvel to see such a neat and clean mechanical workshop. Students also got a practical example of project scheduling, line balancing and statistical quality control; on charts displayed on the walls of the workshop.
70 % of the products are exported, as products so manufactured is of world class, pertaining to stringent quality and workman norms. Western Europe and Japan are the prime markets for Rane. Volkswagen is one of the major clients. Rane has won the prestigious Deming award and many other international accolades.
It was noteworthy that accident rate was very low. As per the Factories Act, if a worker is absent for more than 48 hours, it becomes a “reportable” accident; otherwise an accident is “non-reportable”. There were few non-reportable accidents from time to time for e.g. eye-glares, cuts, burns, etc. but no major reportable accident has happened in last 2 years. Rane has successfully implemented 5-S in housekeeping. It focuses in implementing TQM & TPM, and has been awarded JUSE (Union of Japanese Scientists and Engineers) award for their efforts.
The canteen was huge and students relaxed there before attending a final interaction with the managers. This followed a photo-session outside the workshop. It was a learning day and students returned to campus, bubbling with enthusiasm.
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