You are on page 1of 9

History

Lucas - TVS established in 1961 as a joint venture between Lucas UK and T V Sundram Iyengar & Sons
(TVS), India to manufacture Automotive Electrical Systems. Lucas-TVS is the Leader in Auto Electricals in India
today with 50 years experience in design and manufacturing. 4 out of 5 vehicles rolled out daily are fitted with
Lucas-TVS products.

Lucas - TVS is a TS16949 and OHSAS 18001 certified company. Lucas-TVS has bagged the Deming
application price in 2004 from the Japanese Union of Scientists and Engineers (JUSE).

Misson
To be a respected supplier of global auto industry, by developing innovative products and
solutions of value to customers using contemporary technologies and creative skills and
involvement of our employees, suppliers and other partners. Through these activities LucasTVS expects to contribute to auto industry and Indian society.

Vision
Dominant supplier of rotating electrical products to Indian industry.
Significant supplier of customized motors to specific non-automotive applications in India
Supplier to global car and commercial vehicle manufacturers.
Customer delight and employee's pride to build Lucas-TVS brand.
Sales turnover of 4000 crores [USD 800 Million] by 2015 and achieve stakeholder's
expectations.
"Vision without action is merely a dream
Action without vision passes the time
Vision with action can change the world"

The TVS Group traces its origin to a rural transport service, founded in 1911 in Tamil Nadu,
India. Today, this renowned business conglomerate remains faithful to its core ideals of trust,
values, service and ethics. The TVS Group is India's leading supplier of automotive
components and one of the country's most respected business groups. With a combined
turnover of more than USD 5 billion, the TVS Group employs a total workforce of around
25,000. Charting a steady growth in terms of expansion and diversification, it currently
comprises around 43 companies. These companies operate in diverse fields ranging from
two-wheeler and automotive component manufacturing to automotive dealerships, finance
and electronics. Uniting these multiple businesses is a common ethos of quality, customer
service and social responsibility.

People

Human resource is an asset never disclosed in a company's balance sheet. We at Lucas-TVS strongly believe that an organization's
most valued assets are its people who individually and collectively contribute to the achievement of the objectives of the business.
Keeping this in mind, Lucas-TVS's management style lays great emphasis on employee involvement and actively encourages
participation and commitment through Small Group Activities (SGA), Suggestion Schemes, Voluntary Work Teams and the like.

Culture

A highly visible culture of Commitment, backed up by Discipline & Positive Attitude prevails across the organization. We believe in th
equation:
Employee Performance = [Knowledge + skill] X [Will]

Trust, Value, and Service are the key words and beliefs practiced always internally and externally. Openness and transparency are s

leadership styles/ meetings. Internal customer- Supplier equations are extremely strong. SOP (Standard Operating Procedure-shop
SWP (Standard Work Procedure-office areas) are base points of DRM in line and staff functional departments. TEI (Total Em
Involvement) is the foundation of the organization. Learning culture prevails at all times and all places in the company. 5S is the first
every function. Approach and outlook of engineers / managers is always bi-focal (short term and long term). PDCA is the belief and t
Continuous improvement is the driver of growth. Systems and procedures are always put in place in reality to recognize an orderly w
Performance culture is encouraged and visible results are rewarded. Customer, economy in operations and Gemba are the basics o
culture. We take care of our employees and they in turn take care of our customers.

Education And Development

Human Potential is vast and requires the right amount of inputs to be utilized satisfactorily. Keeping this in mind, we invest significan
upgrading our employees and their potential. Training, Skill-building & Career Development are given primary importance as they all
round development.
Beyond all this, On The Job Training and Job Rotation are also practiced extensively to hone the skills of our employees.
Company operates a fully equipped training center, which features a multi-skill workshop, a product knowledge center, a CNC traine
computer facilities. Individual skills are fine-tuned through specialized courses, both within the country and abroad.
Lucas TVS employees in every part of India share ideas and learn from each other every day. This rich diversity and cultural experie
together to inspire new technologies, design ideas that meet the needs of all our customers.

Total Employee Involvement


SGA (SMALL GROUP ACTIVITY):

Quality Control Circles, named SGA (Small Group Activity) is a group of employees from the same or similar work areas who meet
voluntarily to identify, analyze and solve work related problems to improve not only quality, productivity and work methods but also th
quality of work life.
QIT (Quality Improvement Teams) :

Quality Improvement Teams is a forum for engineers/managers to solve their work-related problems. This works on a higher plane b
using advanced quality tools and techniques such as DOE Taguchi, Shainin etc and conducting experiments/deep analysis etc.
Suggestions :

Apart from the SGA contributing to the continuous improvement, we also have a suggestion scheme in our organization. Supervisors
engineers participate in continuous improvement activities called Quality Improvement Teams, Cross Functional Teams, Task Force
Work Teams etc.
The unique feature of the people involvement in Lucas-TVS is the co-existences of both the suggestions scheme -linked to Monetary
Awards and the SGA-with no monetary awards. It is to be noted that the SGA Teams are proud to present their case studies and de
immense satisfaction and pride when felicitated by the top Management.

CEO presenting Suggestion Awards.


Voluntary Work Team (Sunday Club) :

Work Team is a unique concept conceived during 2001 (TQM promotion phase) to promote the Total Employee Involvement with a
sense of ownership of factory at workforce level .The movement started off with one team (Shop Floor 5S) of twenty members and
eventually grew over the last 5 years to 8 different teams (TPM, Enviro, Office 5S, Safety, Kanban , QCT , APS) to a membership of
625.The concept encourages the teams to create improvements in the above areas in different modules /offices of the factory on a
schedule on Sundays .
The fact that this is done as a voluntary act emphasizes the love the employees have on their respective workplaces. The improvem
as Kaizens bought about benefits by way of gadgets such as fabricated structures etc to maintain 5S, Safety Devices, Kanban enab
work elements, quick change problem solving etc all focussing on reducing wastage.
The members wear color coded T-shirts and are allocated into different teams to conceptualize and implement Kaizens. Full support
provided by the Management in the implementation of the same. The concept of Work Teams created over 7000 Kaizens besides
significant tangible savings to the organization. This great concept has sustained for over 6 years, thanks to the team efforts of the
members towards the same.

Kaizen Culture

The word Kaizen originates from the Japanese language. Kai means change and Zen means
better. Anything that is improved form the existing level can be termed as Kaizen. From the industry perspective, th
Kaizens can generally be classified into 3 levels, namely simple and first level Kaizens, medium level and high level Kaizens, which
innovations or breakthrough improvements.

In a nutshell, Kaizen is a way of life in Lucas-TVS at all levels of functions for sustaining the existing standards of performance and
continually improving the standards for better to cope up with ever increasing customer expectations and business competitiveness.
As a part of TPM implementation, we have created Kaizen circles. The circles focus on Kaizens in line with those nine pillars. Period
reviews are being conducted Pillar wise and the Kaizen done in each pillar are explained to all and this way the Kaizen culture is
implemented in all the departments.

Engineering
New product development by Engineering Research and Development is the
backbone of Lucas-TVS to meet customer requirements for their new vehicle
introduction programmes.
Over 70% of the current sales turnover is realised from new products developed by
in-house R&D.
Lucas TVS was awarded the Golden Trophy for Technology Excellence by
Automotive Component Manufacturers Association of India in 2007, among the
automotive component manufacturers. This stands testimony to the capabilities of
L-TVS engineering for development of new product and process technology.

Engineering center
The new product development is carried out through an integrated product and
manufacturing process development system. The product design, development,
manufacturing process design and technology development for new product
introduction are concurrently carried out through this integrated process, to satisfy
the customer requirements of applications.
The New Product Development Process of L-TVS is carried out on the
basis of concurrent engineering, design for manufacture and assembly, design to
target cost, design for reliability, meeting the requirements of TS16949. This NPD
process has been developed with the help of Japanese consultants to upgrade to a
world class level to ensure customer satisfaction.
The technical requirements of customers are transformed into new products by
the Engineering R&D teams . Product design is carried out using
3D software such as Pro/E, Catia, Unigraphics as required by the customers for
easy interaction and on-line design reviews, while designing LTVS products for the
engine and vehicle systems of the customers. Computer aided
engineering is extensively used for product design and development, through
computerized electromagnetic design, motor design, stress and fatigue analysis,
optimisation of design, reliability engineering, etc.

Teams of highly qualified scientists, engineers and technicians continuously keep


in contact with customers and ensure customer-friendly technology development.
Working together with the customer from the initial stages of vehicle development
is one of the major strengths of L-TVS R&D. This helps in ensuring that the
customers requirements are thoroughly understood and built into LTVS new
products at the early stages of design.
Engineering center has a full-fledged material and process development
lab, where research on the use of new materials, to improve quality and reliability
of products and add value to the customers in meeting their ever-increasing
demands. Manufacturing processes such as for enhancing electrical insulation,
improving corrosion resistance, metal joining, forging and casting etc are also
developed in this lab for the specific requirements of LTVS new products.
The Machine Tool Centre, part of LTVS Engineering function, design, develop
and manufacture special purpose machines, test rigs and single piece flow
manufacturing lines for meeting the stringent product quality and reliability
requirements of new products designed to the contemporary technology and lean
manufacturing systems of L-TVS.
L-TVS product proving and reliability engineering lab is one of the
best fully-equipped laboratory in this part of Asia. The purpose of this lab is to
facilitate improvement of the reliability of products manufactured by L-TVS
continuously to ever-increasing levels. This lab is equipped with test rigs and
facilities to prove L-TVS products to the test standards of Indian and overseas
vehicle manufacturers. The product proving process carried out by LTVS also aims
at reliability growth for LTVS products for Indian and overseas usage conditions;
for example, for Indian usage conditions, the products are subject to abuse tests
specific to Indian road and vehicle driving conditions. In this lab, testing
requirements of most of the international vehicle manufacturers are met
satisfactorily.

Advance Engineering
L-TVS continuously monitors the requirements of international customers for Auto
electrical products. To meet the requirements of OEMs in the next 3 5 years,
several new breakthrough products are under development in Advance
Engineering section. Teams of engineers in Advance Engineering continuously
innovate and develop new products to delight the customers and end-users. The
basic requirements of such developments are based on continuous interactions
with customers and end-users to understand their unfulfilled needs. This team also
continuously reviews the usage of L-TVS products by the end-users and identifies
the new requirements and design add-on features and functionalities to these
products, in advance of the requirements proposed by OEMs.
Also the teams have developed contacts and access to the contemporary
technology under development in our range of products, in other parts of the world,
so that new innovations and breakthroughs can be created further for
implementation in the near future.

manufacturing
Gear Reduction Starter Flow Line

Manufacturing
Products are manufactured using State-of-the-Art facilities organised in Product Units, Modules, Nagare Cells
and Assembly Cells and incorporating Quick Change Tooling, Poka Yoke, Chakku Chakku (Auto Unloading). The
condition of machines is monitored and maintained by TPM techniques and the schedule adherence is monitored
by DRM (Daily Routine Management) while Process & Product Quality is sustained and improved by ZED-Q
(Zero Defect Quality) activities. The Manufacturing system is competently backed up by an advanced Tool Room
and an inhouse SPM/ Process Plant manufacturing facility. The entire organisation is firmly entrenched in the
change process and committed to CIP (Continuous Improvement Programme).

Our Journey Towards Manufacturing Excellence


Products are manufactured using State-of-the-Art facilities organised in Product Units, Modules, Nagare Cells
and Assembly Cells and incorporating Quick Change Tooling, Poka Yoke, Chakku Chakku (Auto Unloading). The
condition of machines is monitored and maintained by TPM techniques and the schedule adherence is monitored

by DRM (Daily Routine Management) while Process & Product Quality is sustained and improved by ZED-Q
(Zero Defect Quality) activities.

Total Quality Management (TQM)


Lucas-TVS, believes that quality begins and ends with the customer. This means identifying customer needs and
comprehensively meeting them. For the company, quality is not just conformance to drawings or specifications
but ensuring customer satisfaction. This belief forms the basis of its approach to Total Quality Management
(TQM). Quality Assurance methods like Advanced Product Quality Planning, Statistical Process Control
Techniques, Effective Tool Management System, Process Capability Improvements, Preventive Maintenance,
Producer Control and Small Group Activities form the backbone of the system approach adopted.
In its continuous pursuit of both technological as well as methodological excellence, Lucas-TVS has scripted yet
another new dimension to manufacturing by not only adopting the Cellular Manufacturing System / JIT but also
extending the same to its Suppliers. By the implementation of this system components from its suppliers are
delivered on a pull basis with First In First Out concept supported by simple visual controls and supplied to the
line on an hourly basis with KANBAN system.

Manufacturing
Organisation

Methodology

Manufacturing
Journey

Journey Towards
Excellence...

Customers
The TVS Group, with a turnover of over one billion dollars, is the largest manufacturer of automotive components
in India. The group produces autoelectricals, diesel fuel injection systems, braking systems, automotive wheels
and axle fasteners.

Gene
Hyunda
ral Fiat
i
Ford
Moto Indi
Motor India
rs
a
India
India

Honda
Motors

Tatra Motors Swaraj Mazda Eicher Motors

HMT

SAME

Swaraj

Mahindra
Renault

Maruti Udyog

Tata Motors

Escorts

Hindus
Tata
Force
tan
Motors
Motors
Motors

Ashok Leyland

TAFE

Mahindra
&
Mahindra

Mahindr
a
&
Mahindr
a

Man Force Truck


PVT. LTD

Johndeere

Mahindra
& Mahindra

Standar
Mahindra
d
Indofar
Gujarat
Combin m
Tractors
es

Kirlosk
Lombar Greav Cummi
Bharath
ar Oil
Birla
Tata
Simpsons Caterpillar
Indofar
dini
es
ns
Earth
L&T Komatsu
Engin Yamaha
Cummins
& Co
India
m
India Cotton India
Movers
es

Kinetic
Engineering

LML

Yamaha
Motor India

Honda
Motor
Cycles & TVS Motor Bajaj
Hero Motors
Scooter
co
Auto
India PVT.
LTD

Mahindra &
Mahindra

Royal Enfield

Export

Arctic Cat
- U.S.A

AUSTRALIA
DUBAI
KOREA

Commercial
Denso
Vehicle
IVECO Manufacturing
Group
Italy
- Italy
- U.S.A

AUSTRIA
EGYPT
KUWAIT

BANGLADESH
ENGLAND
LIBYA

Proton Malaysia

BAHRAIN
GERMANY
MALAYSIA

Wabco
- Germany

BELGIUM
GHANA
MAURITIUS

Cummins Motori Minarelli - Italy


U.S.A

CHINA
IRELAND
ROMANIA

DOHA
ITALY
RUSSIA

SERBIA

SEYCHELLES

SWITZERLAND

TURKEY

SINGAPORE

SOUTH
AFRICA

SPAIN

SRILANKA

SULTANATE
OF OMAN