Endurance tech. pvt. Ltd. 1 Industrial visit report ENDURANCE TECHNOLOGIES PVT. LTD.

ENDURANCE was established in 1985 as Anurang Engineering Co. Pvt. Ltd. to manufacture Aluminium Die Casting products at Aurangabad, Maharashtra (India). The Endurance Group is a global force in Aluminium Casting (including Alloy Wheel), Suspension, Transmission and Braking products with an annual sale of €251 Million (RS. 1634 Crores) from domestic operations and approx. €104 Million (RS. 674 Crores) from overseas operations for the year 2008-2009. Endurance Group has 19 Plants across India, Italy & Germany. Name: ENDURANCE TECHNOLOGIES PVT. LTD. Established: August 1985 (As Anurang Engineering Co. Pvt. Ltd.) Corporate Office: E-92, MIDC Industrial Area, Waluj,Aurangabad – 431136. Telephone: +91-0240-2554902 URL: Chairman: http://www.endurancegroup.com Mr. Naresh Chandra

Managing Director:Mr. Anurang Jain Business Area and Main Product: Casting : High Pressure Die Castings, Low Pressure Die Castings , Gravity Die Castings, Alloy Wheels Suspension : 2/3 Wheeler Shock Absorbers, Motorcycle Front Forks, Hydraulic & Gas charged Dampers, Macpherson Struts, Gas Springs Transmission : 2/3 Wheeler Clutches,Continuous Variable Transmission (CVT), Friction Plates Braking : Hydraulic Disc Brake, Tandem Master Cylinders, Hydraulic Drum Brakes, Brake Shoes, Caliper Components

Submitted by Kunal Bansode

Endurance tech. pvt. Ltd. 2 Industrial visit report

A total of 16 plants at prominent locations in India & 3 overseas plants. Manufacturing Plants: India: 7 Plants at Aurangabad, Maharashtra, 5 Plants at Pune, Maharashtra, 1 Plant at Manesar, Haryana ,1 Plant at Chennai, Tamilnadu, 2 Plants at Pantnagar, Uttarakhand Overseas: 2 Plant at Massenbachha- usen, Germany,1 Plant at Torino, Italy. R&D Centers: 3 R&D Centers at Aurangabad, (for Suspension, Transmission & Braking) 1 R&D Center at Pune, (for Casting) Maharashtra. Report : An Industry visit was arranged for students of FY MBA(2009-11 batch) ENDURANCE TECHNOLOGIES PVT. LTD.(Machining Division)B-20, MIDC Area, Chakan,Village: Nighoje, Taluka: Khed (Rajgurunagar),Pune - 410 501. India. This is aHigh Pressure Die Casting and Machining Plant. This plant having 71 High Pressure Die Casting Machines (250 To 1400T) (BUHLER, ITAL PRESS, UBE, TOSHIBA, YOTA, HMT, IDRA ZITAI) ;Melting: - 30000 M. Tonnes Per Year. And CNCs (LMT) – 72 Nos, VMCs (ACE) – 83 Nos ,HMCs (MAKINO, DECKEL MAHO) – 7 Nos ,SPMs (HMT, EMT) – 47 Nos, 3 Paint Shops. This plant is having 800 employees and the major products are High Pressure Die, intricately shaped castings with weight per piece ranging from 400 gms to 8.5 kgs.

Observations: 1.This company has got perfect situation exactly nearer to highway . 2. So ease of transportation. 3. From the nearby city company can get technicians and engineers easily. 4. No problems of electricity, water and man power. The company is having TPM (Total Productive Maintenance) system which is invented in Japan. Why TPM needs: lowest cost, excellent quality, zero losses and zero accidents. Benefit of TPM: zero breakdown, zero losses, zero accident, zero defects, zero customer complaints.

Submitted by Kunal Bansode

Endurance tech. pvt. Ltd. 3 Industrial visit report

Pillars of TPM: 1. Kobtsue Kaizen: all the losses are captured and improve them 2. Jishu Hozen: it’s a Autonomous maintenance : I do, I operate and I maintain its total operator ownership 3. Quality maintenance: its for zero defects 4. Planned maintenance: its support operators, for zero breakdown & maintain cost 5. Safety Health & Environment: echo-friendly environment, employee health, accident. 6. Education & Training: Hazardous areas are identified with help of this. 7. Office TPM: for take proper decision, identifies office losses and material procurement.. 8. Initial Control: (development management): Design inspection of product and find out defects & complaints and achieve zero breakdown. Plant layout: Plant layout is a very important feature in today’s industries. It is arrangement of the desired machinery and equipment of a plant established in the way which will permit the easiest flow of material at lowest cost and with the minimum handling in processing the product from the receive of raw mater Departments : 1. Research and development department. 2. Machine shop. 3. Store department. 4. Sheet metal department. 5. Production planning & control department. 6. Inspection department. 7. Assembly section. 8. Coloring and packaging department. Work Environment:

Submitted by Kunal Bansode

Endurance tech. pvt. Ltd. 4 Industrial visit report The work environment of the unit was very impressive. Many notice boards and cell activity boards and different notices could be seen. The company had displayed its messages, goals, rules, policies, strategy, daily plans and finally, the past results on the notices all around the workspace. It was very interesting to see the different kinds of methods that the workers applied for completing their job. Quality Maintenance methodology Display board shows: component study, final inspection, rejection control, inspection improvement, inspection sustenance and results. Planned maintenance display board shows : initial cleanup, customer for hard to access & source of contamination, prepare temper standards, general inspection, autonomous inspection, standardization and autonomous maintenance. Main goals : • • • Leader in casting industry Achieve $ 675 Million sales Rank in top 3 company in India

Mr. Yogesh is production engineer in machining plant and he was giving us very important information about production unit, Mr. Yogesh said that the plant produce crankcase for Bajaj , C.C. covers, cylinder heads and cylinder block; alloy wheels. The main customer of the plant is BAJAJ auto. We were seen the casting process which is done in the following manner: Shot blasting (for shaping) then for improving the life of the product pretreatment process is there then product goes to paint shop( 2 wheeler shop & 4 wheeler shop) then product goes to machine shop and last product goes through production lines i. e. CNC machine, HMC & VMC and turning center for block. The HR person of the company is very good and helpful person, he was giving us very important knowledge about HR system like how dispute act, employee act and industrial act are works in the company. And also giving some knowledge about core HR and industrial HR system. He show us that the company having Yearly Performance Appraisal System. The company giving training for employees every month for four(4) hr/month/employee. And they are having Performance Reviles Discuss Process.

Submitted by Kunal Bansode

Endurance tech. pvt. Ltd. 5 Industrial visit report It was a wonderful experience for us all as we saw the production process. The students gained an interesting insight regarding the management tools like Six sigma and Kaizen used by the company for managerial effectiveness. The industrial visit was an enriching experience as the students could relate the theory taught in classroom to the realities of the corporate world. As we see the company works on the following principles: Continuity and innovation, hands on experience, know-how and technology and growth. The students were given a warm welcome on arrival and refreshment towards the end of the visit. An undoubtedly benign hospitality and insight understanding of a business organisation made the visit a huge success!

Submitted by Kunal Bansode