The background

1
The background

• Mostly started by an individual / group (4-5)
• Usually a technocrat (know- how)
• No peers only superiors (fear syndrome)
• Scalability
• Focus on manufacturing

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2
The background

• Expects return high and early
• Usually firefighting and
• Do not develop systems and procedures

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3
The policy

• Land Reforms
• Cluster
• Pollution
• Banking
• Simplification of procedures

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4
Indian Operational Case
Presentation by C. Sivakumar, CEO
Prabha Engineers
Reliable Friendly Creative Energetic
Young
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5
Whats the Magic?

• 4. Our Employee won the Uyarndha Uzhaipazhar
  Virudhu for the 3rd best suggestion of the year
  2004 from the Government of Tamil Nadu.
• Received the QCFI (Quality Circle Forum of India)
  5S Par Excellent Performance Award
• Received the Business Excellence Award for the
  year 2006 and Socially Responsible Organisation
  Award from our Hon. Governor of Tamil Nadu.
• 7. An ISO 9001 2000 certified company

We manufacture happiness
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6
Whats the Magic?

• Why are we Unique ?

We manufacture happiness
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7
Whats the Magic?
We loved to Question everything All
paradigms.. All established practices.. All
standards and norms.. All known methods and
customs.. all prevailing thinking and
thoughts.. All ideas and notions.. all wisdom
and wise men.. The questioning lead us along an
exciting road of discovery
We manufacture happiness
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Whats the Magic?

• Why have we survived ?

We manufacture happiness
Because the competitors allowed us
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Whats the Magic?

• Why did the competitors allow us to survive ?

We manufacture happiness
Because they found us
difficult to emulate
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10
Whats the Magic?

• Why did they find us difficult to emulate?

We manufacture happiness
Because we are creative
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Whats the Magic?

• Why are we creative ?

We manufacture happiness
Because we have passion
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Whats the Magic?

• Why do we have passion?

We manufacture happiness
Because we are a team with positive attitude
willing to break its own record, redefine its
goal and bring in changes to make the customer
say, Ah!
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Whats the Magic?
Men
Method
Material
People Centric Approach
Machine
We manufacture happiness
Money
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The Task
We manufacture happiness
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The Task

• How to keep employees

Motivated Excited Creative Committed Involved
We manufacture happiness
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The Way Forward
Faith
Fear
We manufacture happiness
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The Way Forward

• How did we do it at Prabha ?

Internal Enablers
External Enablers
Parents day Token of appreciation to
parents Spouse day Generation Next
Opening shots Trigger Fun at work Innovative
training through Magic
Theatre Outbound
Sports day Producers day
We manufacture happiness
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The Result

• The Transformation

To Management Workforce Team
We manufacture happiness
From Management Workforce Divide
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The Result

• The Transformation

To Impossible task possible
We manufacture happiness
From Possible task Impossible
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The Result
TEI
Mind
Technique
We manufacture happiness
Total Employee Involvement
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The Result

• Techniques Tools

3M Muda, Muri and Mura elimination 5S Seiri,
Seiton, Seiso, Seketsu and Shitsuke PY Poka
yoke Kaizen Kanban SGA Quality Circles
We manufacture happiness
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The Result

• TEI

P Q C D M S
We manufacture happiness
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23
The Result

• Today

Prabha has carved a niche for itself in the realm
of SMEs  1.      First SSI to venture in the
North by signing up with M/s. Ashok Leyland to
produce FES (Front End Structures) to their Alwar
Plant.   2.      First company to introduce
KANBAN system for FES supply to M/s. Ashok
Leyland thereby reducing INVENTORY of M/s. Ashok
Leyland from 15 days to 4 hrs.   3.      First to
Receive the Prestigious Platinum Award in the
Sheet Metal Category from Principal M/s. Ashok
Leyland acknowledging Excellent performance for
Quality, Cost Delivery  
We manufacture happiness
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The Result

• Today

4.      Not a single MANDAY lost in the last 25
years due to strike, lockout or any other
reason 5.      Never defaulted in its payment to
Bankers, Suppliers, Government agencies and
Employees   6.      Unique training methodology
resulted in improved Employer Employee
Relationship
We manufacture happiness
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We manufacture happiness
Reliable Friendly Creative Energetic
Young
THANK YOU
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