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<strong>Raychem</strong> Customers Are Really Everything<br />

<br />

INTEGRATION<br />

<br />

<br />

...yet another milestone<br />

in the history of <strong>Raychem</strong> <strong>RPG</strong><br />

Inside


Happy Diwali<br />

Wishing our readers a very<br />

Happy Diwali & Prosperous New Year.<br />

May the sparkle never fade !<br />

<br />

<br />

<br />

<br />

<br />

Customer Toll Free Service 1800 209 9769


CEO<br />

SPEAK<br />

Dear Friends,<br />

I am delighted to be writing this column at the end of the first half of<br />

fiscal FY 11.<br />

As I look back, the last quarter has been very eventful in the history of <strong>Raychem</strong><br />

<strong>RPG</strong>.<br />

First, the very important and strategically significant integration of Tyco<br />

Electronics’ Energy business in India with <strong>Raychem</strong> <strong>RPG</strong> marked the next<br />

significant milestone in the history of <strong>Raychem</strong> <strong>RPG</strong>, after the JV was formed in<br />

1989. The integration leverages the combined strengths of the two organizations, and<br />

makes <strong>Raychem</strong> <strong>RPG</strong> a very potent force in Power Transmission &<br />

Distribution segment of the Indian Market. More details of this alliance is covered<br />

extensively in other sections of this Newsletter.<br />

I look<br />

forward to your<br />

continued support,<br />

as we push ahead in<br />

our quest to cross<br />

yet another<br />

important<br />

milestone, of sales<br />

revenues in excess<br />

of Rs 600 Crores<br />

in the current<br />

financial year!<br />

Second, the signing of the “Technology Transfer” with Hexaformer of Sweden<br />

provides a very vital differentiator for our range of distribution transformers. I am<br />

happy to announce that the machinery has arrived in India and installed at our<br />

Plant. The prototypes will be ready by mid-October and sales, both to the Indian<br />

market, as well as, exports to Europe through our partner, M/s Hexaformers, will<br />

commence in the next financial quarter.<br />

Our sales revenues in the first six months grew 18 % over last year and our profitability<br />

is as per budgets. We expect the second half to be stronger, both in terms of sales and<br />

profit growth. The SBUs are experiencing a strong flow of orders alongwith<br />

enhanced levels of customer enquiries for some of our new products introduced in the first<br />

two quarters of this fiscal.<br />

I look forward to your continued support, as we push ahead in our quest to cross yet<br />

another important milestone, of sales revenues in excess of Rs 600 Crores in the current<br />

financial year!<br />

As the festive season sets in, I take this opportunity of wishing you and your family<br />

all the best and happiness.<br />

Ramani Kasi<br />

President<br />

01


INTEGRATION<br />

Tyco Electronics' Energy Business in India<br />

with <strong>Raychem</strong> <strong>RPG</strong><br />

The foundation gets strengthened; foot prints deepened,<br />

as <strong>Raychem</strong> <strong>RPG</strong>, the existing Joint Venture of <strong>RPG</strong> and Tyco<br />

Electronics, embarks on a new journey of creating an<br />

industry-leading portfolio of products, technologies and<br />

solutions; and enhancing a larger team of talented and<br />

skilled professionals.<br />

This integration will help <strong>Raychem</strong> <strong>RPG</strong> to achieve its longterm<br />

goals and growth plans. As India embarks on its longterm<br />

initiative of Energy infrastructure investment, it will<br />

provide a key market to the integrated products and<br />

services of <strong>Raychem</strong> <strong>RPG</strong> and Tyco Electronics Energy<br />

Division business in India.<br />

The Energy Division of Tyco Electronics ('TE') has a clear<br />

strategy for growth and, India is a key market that provides<br />

significant opportunity as the country embarks on its longterm<br />

initiative of energy infrastructure investment. This<br />

integration will provide a focused single business within<br />

India to serve Energy customers, increase the local<br />

development of TE technology-based energy products and<br />

services aimed specifically at the Indian market, improve<br />

operating efficiencies and result in more growth in India.<br />

Further, the integration will provide our Transmission &<br />

Distribution customers a large basket of products,<br />

increased local development of TE Energy technology-<br />

based energy products and services, specifically aimed at<br />

the Indian market.<br />

Presently, Tyco Electronics – Energy Division has its<br />

manufacturing plant in Bangalore, which in a phased<br />

manner, will shift to our new plant at Halol, Gujarat,<br />

currently under construction. The products that are<br />

covered in this integration are:<br />

“Simel” range of MV/HV/EHV connectors & fittings<br />

HVCS and transmission/distribution products<br />

“<strong>Raychem</strong>” & “Bowthrope” – polymeric surge arrestors<br />

and insulators<br />

“AXICOM” – Operating rods & insulating chambers<br />

“Utilux” – bimetallic lugs.<br />

Effective 1st October 2010, the entire range of Tyco<br />

Electronics' Energy Products in India are sold and serviced<br />

exclusively by <strong>Raychem</strong> <strong>RPG</strong>.<br />

There are great times ahead at <strong>Raychem</strong> <strong>RPG</strong>.<br />

Stay tuned! Stay connected!!<br />

02


Energy Transmission & Distribution SBU<br />

adds one more mini-SBU<br />

CFIP (Connectors, Fittings, Insulation & Protection)<br />

Post the merger with Tyco Electronics, a new mini-SBU has<br />

been created under Energy T&D SBU to market the entire<br />

range of products of Tyco Electronics – Energy India.<br />

We give a brief of the range of products under CFIP<br />

CONNECTORS AND FITTINGS<br />

Service Dead End Connectors<br />

A complete line of connectors and accessories for low,<br />

medium and high-voltage cable and overhead networks,<br />

substations, grounding applications, rail transport<br />

infrastructure, industrial applications and accessories for<br />

overhead optical fiber lines (OPGW and ADSS).<br />

Insulation Piercing<br />

Connector<br />

Wedge Connector<br />

Suspension Clamps<br />

Pre- insulated sleeves and Lugs<br />

Distribution Boxes<br />

“UHV Range” Aluminium High Voltage connectors<br />

03


CFIP (Connectors, Fittings, Insulation & Protection)<br />

Insulation & Protection<br />

An extensive range of products designed for use in<br />

distribution and transmission networks, qualified to IEC<br />

and ANSI standards.<br />

SURGE ARRESTERS<br />

Polymeric and porcelain surge arresters for distribution and<br />

transmission networks<br />

Low Voltage Outdoor Arresters<br />

Medium Voltage Outdoor Arresters<br />

High Voltage Outdoor Arresters<br />

upto 800 kV<br />

INSULATORS<br />

An extensive range of MV polymeric and porcelain<br />

insulators; insulation protection products for substations<br />

and overhead lines; housing components for composite<br />

hollow insulators and FRP components used in high<br />

voltage apparatus, as well as, for MV insulators and surge<br />

arresters<br />

RHINESTONE PROJECT<br />

<strong>Raychem</strong> <strong>RPG</strong>’s new manufacturing complex at Halol, near Vadodara - Gujarat<br />

The range of products (referred in our earlier article)<br />

manufactured by Tyco Electronics – Energy Division India<br />

at their factory in Bangalore will be transferred, in a<br />

phased manner, to <strong>Raychem</strong> <strong>RPG</strong>’s new plant at Halol, 50<br />

kms. away from Vadodara, Gujarat.<br />

The construction activities are in full swing with building<br />

foundation and surrounding road construction work<br />

completed. Specifications of various equipment and<br />

facilities are being prepared, scrutinized and procurement<br />

actions are in full flow. The factory is expected to be ready<br />

by the end of this calendar year.<br />

This facility will adopt the SMT (Self-Managed Team)<br />

model, similar to <strong>Raychem</strong> <strong>RPG</strong>’s manufacturing complex<br />

at Nalagarh, Himachal Pradesh.<br />

The project has been aptly named Rhinestone – like the<br />

gem stone, solid and sparkling, and for the river after<br />

which it is named ‘Rhine’ (in Europe) for its continuous<br />

flow passing through various countries and regions.<br />

Halol Plant<br />

04


<strong>Raychem</strong> <strong>RPG</strong> wins the <strong>RPG</strong> OE Award<br />

for 2009-2010<br />

3rd Year in<br />

Succe ss ion<br />

For the third time running, <strong>Raychem</strong> <strong>RPG</strong> was the<br />

recipient of <strong>RPG</strong> Organization Excellence<br />

Award in the Manufacturing Category for 2009-<br />

2010.<br />

To continue on the organizational excellence<br />

journey, <strong>Raychem</strong> <strong>RPG</strong> had embarked on Mission<br />

well as, reach the 700 score by 2012 to achieve<br />

National Quality level of Organizational Excellence.<br />

Needless to say, this achievement was only possible<br />

with the support and co-operation of the entire<br />

team of <strong>Raychem</strong> <strong>RPG</strong>. Kudos to the team!<br />

A personal letter of congratulations by our<br />

700 journey in 2009, involving and sensitizing their Chairman, Mr. Harsh Goenka gives us the<br />

members in bringing excellence at workplace, as additional boost to excel further.<br />

05


<strong>RPG</strong> HOUSE<br />

Ceat Mahal, <strong>RPG</strong> Group’s Corporate Office at<br />

Worli is renamed “<strong>RPG</strong> HOUSE”<br />

The iconic building, standing tall at Worli for several<br />

decades, a building that is aesthetically and<br />

architecturally different from other buildings in the<br />

vicinity – Ceat Mahal was recently renamed <strong>RPG</strong> House.<br />

<strong>RPG</strong> House is the Corporate Office of <strong>RPG</strong> Group<br />

including Ceat Tyres, KEC International, <strong>RPG</strong> Life<br />

Science, KEC - <strong>RPG</strong> Cables and <strong>Raychem</strong> <strong>RPG</strong>.<br />

The changed name comes with a new welcome look<br />

of the lobby.<br />

One the move………………..<br />

<strong>Raychem</strong> <strong>RPG</strong> Sales Office at <strong>RPG</strong> House, Mumbai<br />

moves to Thane.<br />

For the last two decades, <strong>RPG</strong> House (formerly Ceat<br />

Mahal) was the Corporate, as well as, the Sales Offices<br />

for <strong>Raychem</strong> <strong>RPG</strong>.<br />

In the last five years, the company has grown in<br />

numbers organically and inorganically. <strong>RPG</strong> House<br />

was getting too small for the Sales Team of various<br />

SBUs. It was, therefore, decided to shift the entire<br />

Sales Office to Thane in the same office building<br />

where CPG - SBU is located.<br />

The new address is:<br />

<strong>Raychem</strong> <strong>RPG</strong> Limited<br />

Sun Magnetica, A - Wing, 101, First Floor, Near LIC<br />

Building, Eastern Express Highway, Thane (W) 400604,<br />

India. Tel: 022 - 64558484 - 85/86/87/88/89.<br />

06


New Business Unit of<br />

<strong>Raychem</strong> <strong>RPG</strong><br />

The Transformer Business, which was earlier part of Energy<br />

Tr a n s m i s s i o n & D i s t r i b u t i o n , i s n o w a n<br />

independent SBU, effective August 2010.<br />

operations and systems in place at Chakan, near Pune<br />

and Nalagarh, near Chandigarh and getting design and<br />

product approvals from various governing bodies.<br />

Many of our readers may be aware that <strong>Raychem</strong> Transformer SBU is now totally geared up to scale<br />

entered into the Transformer business in 2007. The greater heights in the coming years.<br />

formative years were focused on setting up world class<br />

<strong>Raychem</strong> <strong>RPG</strong> Transformers are here to stay!!<br />

Chakan Plant<br />

Nalagarh Plant<br />

Technological and Sub-Contract Agreement<br />

signed with Hexaformer AB, Sweden<br />

In our previous<br />

<strong>Raycare</strong>, of issue<br />

we had announced<br />

R a y c h e m R P G ’ s<br />

collaboration with<br />

H e x a f o r m e r A B ,<br />

S w e d e n f o r<br />

m a n u f a c t u r e o f<br />

Transformers under<br />

license in India.<br />

T h e f o r m a l<br />

a g r e e m e n t f o r<br />

technology transfer<br />

between <strong>Raychem</strong><br />

<strong>RPG</strong> and Hexaformer<br />

AB was signed in July this year.<br />

With this collaboration, <strong>Raychem</strong> <strong>RPG</strong> will manufacture Oil<br />

Filled Transformers upto 250 kVA with Delta Type<br />

Core Construction for supply to India, Bangladesh,<br />

Nepal, Sri Lanka, as well as, Hexaformer AB, Sweden.<br />

07


Energy Transmission & Distribution<br />

Energy T&D - Contracts expands its horizon<br />

What started 5 years ago as a service to our customers, T&D<br />

Contracts has now become a large enterprise with several<br />

projects implemented and many more under execution.<br />

Some of the recent projects are highlighted below.<br />

Erected and Commissioned 2 * 5 MVA , 33/11 KV Sub-<br />

Station at Kampasagar (Distt. - Koppal , North<br />

Karnataka) for M/s Gulbarga Electricity Supply Co. Ltd.<br />

(GESCOM).<br />

66 KV XLPE Cable Laying Turnkey Project for 4 different<br />

circuits from North Delhi Power Limited (NDPL)<br />

Erection and Commissioning of 66/11 KV Sub - Stations<br />

for Karnataka Power Transmission Corporation Limited<br />

(KPTCL - Bangalore) at:<br />

Dodahalahalli in Ramanagara District (Near Bangalore)<br />

Vanivilasapura in Chitradurga District (North Karnataka)<br />

Erection and Commissioning of 220 KV Class<br />

Sub-Station at Kashipur for M/s Power<br />

Transmission Corporation of Uttarakhand<br />

Limited (PTCUL), Dehradun. This is <strong>Raychem</strong><br />

<strong>RPG</strong>’s first project in the EHV segment of<br />

business.<br />

Customer Training<br />

At <strong>Raychem</strong> <strong>RPG</strong>, we believe that Training is one of the most<br />

critical and key elements to business success. Going by this<br />

belief, several training programs are held at various<br />

locations for customers and channel partners to give them<br />

hands on experience of our products and services.<br />

ENERGY TRANSMISSION AND DISTRIBUTION<br />

Technical Training<br />

on Cable accessories<br />

to Engineers &<br />

Technician of M/s<br />

Ceylon Electricity<br />

Board held at<br />

Colombo, Sri Lanka<br />

in August 2010.<br />

Technical Training on<br />

Cable Accessories for<br />

Jointers of Bokoro<br />

Steel Plant and other<br />

independent<br />

jointers.<br />

Product Training<br />

of entire product<br />

range to<br />

Distributors &<br />

Dealers at<br />

Kaman Plant in<br />

July 2010.<br />

Engineers and<br />

Jointers of Torrent<br />

Power Ltd.,<br />

Ahmedabad<br />

08


Infocom<br />

Key Features of R Racks<br />

Modular Design to ensure rigidity, high load carrying<br />

capacity and attractive aesthetics<br />

<strong>Raychem</strong> <strong>RPG</strong>’s Infocom Business Unit is known for its<br />

products and continual development to serve the<br />

requirements of their customers. Infocom has now<br />

become a one-stop solution provider for the passive<br />

network by adding R-Racks in its product portfolio.<br />

In a short span of time, Infocom has created a reputation of<br />

becoming a reliable partner for providing top-quality<br />

products in short lead times and at very reasonable prices.<br />

R-Racks have been installed in one of the best car<br />

manufacturing plant in Pune alongwith Asia’s largest car<br />

parking for hosting their valuable servers. Leading Telecom<br />

operators have also installed these racks for their critical<br />

telecom applications apart from being installed at<br />

Common Wealth Games site being hosted by India this<br />

year.<br />

R-Racks range of products include :<br />

Server racks – for IDC’s, Server rooms applications<br />

Optimum space availability as compared to other<br />

standard makes available with less overall height<br />

Reduced power and cooling requirement because of<br />

optimum design and space availability of enclosures<br />

Multiple doors, roof options for flexibility and<br />

ventilation<br />

Equipped with<br />

earthing<br />

arrangement<br />

Available in more<br />

than 40 plus size<br />

variants<br />

Roofs of racks with<br />

knock out blanking<br />

plate for ease of<br />

cable entry<br />

Network racks for Networking applications<br />

Wall mount cabinets for hosting small switches and<br />

routers<br />

Open Frame racks for telecom cabling<br />

Outdoor racks for telecom application<br />

Wall Mount Cabinets<br />

Open Frame Rack<br />

09


International Business (IBD)<br />

<strong>Raychem</strong> <strong>RPG</strong>’s footprints in Latin America<br />

Business Unit – IBD<br />

participated in Latin<br />

America's biggest Oil &<br />

Gas Exhibition - RIO Oil<br />

and Gas 2010 held in Rio<br />

De Jeneiro in the first<br />

week of September 2010.<br />

The exhibition met with a<br />

lot of success with<br />

prospective distributors<br />

visiting the stall.<br />

Expanding Geographies<br />

through Channel Partners Worldwide<br />

Business Unit IBD has been strengthening their territories around the world with a wide Network of<br />

Distributors in different countries.<br />

Canada<br />

USA<br />

Denmark<br />

Netherlands<br />

Belgium Germany<br />

Luxemburg<br />

Spain<br />

Turkey<br />

Russia<br />

Egypt<br />

UAE<br />

Singapore<br />

10


Jawaharlal Nehru Stadium (JLN) was the venue for the<br />

opening and closing ceremony alongwith many events of<br />

CWG 2010.<br />

JLN Stadium consisted of 88 structural steel columns(10,000<br />

MT) upto 45m<br />

a b o v e t h e<br />

ground level,<br />

s u p p o r t i n g<br />

600 MT(2,200<br />

km) of cables<br />

and casting.<br />

CORCON 2010<br />

CORCON 2010 was held in Goa in September 2010. It was a<br />

good opportunity for OWG to display their products and<br />

services, as well as, interact with several dignitaries from Oil &<br />

Gas Industry, as well as, Governor of Goa, Dr. Shivinder Singh<br />

Sidhu.<br />

C O R C O N 2 0 1 0<br />

provided an excellent<br />

platform for exchange<br />

of information on<br />

corrosion and its<br />

prevention through<br />

It formed the<br />

world's largest<br />

tensile fabric<br />

Double success!<br />

Heat Tracing Team at University 201<br />

CPG has been renamed OWG (Oil, Water & Gas)<br />

The new name captures the gamut of services that are<br />

being catered by this sector business.<br />

It goes beyond corrosion protection!<br />

Commonwealth Games (CWG) - 2010, New Delhi, India<br />

roof system of 14 steel ramps around the periphery which<br />

ensured that the stadium of 60,000 seats be evacuated in just<br />

six minutes.<br />

The steel bars carrying the entire weight of highly engineered<br />

roofing required the best corrosion protection method and<br />

<strong>Raychem</strong> <strong>RPG</strong> provided that support to the client.<br />

We supervised the installation of anti-corrosive tubular<br />

sleeves, especially imported from Belgium for this project.<br />

The magnitude of this project can be seen in the pictures of the JLN Stadium.<br />

technical programs, open sessions & exhibition. It was well<br />

participated and attended by professionals from the industry,<br />

academic and R&D institutes, defense and students from all<br />

over the world.<br />

Berry Plastics, our<br />

business partners in<br />

corrosion protection,<br />

also participated in the<br />

exhibition. Their stall<br />

was located next to<br />

<strong>Raychem</strong> <strong>RPG</strong>.<br />

Tyco Thermal Controls Organized an Industrial Heat Tracing Mr. Jim Beres - VP Technical<br />

Training Program - University 201 for India and Middle East Mr. Vincent Amy - Director Sales - India / ME<br />

representatives. The four-day program was held in October at Mr. Ajit Raghavan - Director Marketing - India/ME<br />

Hyderabad.<br />

The program included<br />

Senior members<br />

s e s s i o n s o n l a t e s t<br />

from Tyco Thermal<br />

technologies and new<br />

Controls, across the<br />

p r o d u c t s . I t a l s o<br />

globe, were present<br />

included advance level<br />

at the workshop.<br />

training for the existing<br />

range of products.<br />

11


VASAI<br />

Celebrations at Vasai Plant<br />

Engineers’ Day<br />

<strong>Raychem</strong> <strong>RPG</strong> being an engineering company with 80% of<br />

its employees, engineers, it is only apt that significance be<br />

given to Engineers’ Day.<br />

On September 15, Engineers’ Day, the Engineering<br />

Department of Vasai - EOU unit celebrated the occasion<br />

with cutting of the cake by our President, Mr Ramani Kasi.<br />

Mr. Deepak Kumar, Head – IBD was also present at the<br />

felicitation.<br />

World Ozone Day<br />

World Ozone Day was celebrated on September 16.<br />

It was a day to pay homage to the ozone layer that saves<br />

our earth from harmful ultra-violet radiation of the Sun<br />

that impacts plants, animals and human health.<br />

Safety Campaign<br />

Safety campaign was organized in September.<br />

It included fire fighting and first aid mock drills.<br />

12


VASAI<br />

W<br />

RLD ENVIRONMENT DAY<br />

On the occasion of World Environment Day on June 5, EHS-<br />

Vasai arranged a month- long celebration of events and<br />

activities involving staff and operators of Vasai Plant.<br />

Environment Education<br />

Environment Conservation Oath<br />

Tree Plantation<br />

Rewards and Recognition<br />

Project SAMBHAV<br />

Everything is Possible<br />

As wisely said, ‘Space is Gold’ and ‘Time is Money’, Vasai<br />

plant which currently holds two separate manufacturing<br />

operations in two buildings, took a decision to consolidate<br />

the entire operation of both buildings into one building,<br />

thus providing<br />

Additional space for new business opportunities<br />

Optimize existing resource utilization<br />

Increase output size-wise and person-wise<br />

Reduce operating expenses.<br />

Creating platform for LEAN Manufacturing<br />

The project should be completed by December 2010.<br />

13


Visitors at Vasai Plant<br />

Several members from <strong>RPG</strong> Group companies visited Vasai<br />

in the last quarter to observe our operation systems and<br />

processes. The visits were extremely interactive and visitors<br />

took back a lot of learning from it.<br />

KEC – <strong>RPG</strong> Cables Team<br />

<strong>RPG</strong> Life Science Team<br />

Nalagarh Plant had a spate of visitors in the last quarter.<br />

This new plant of <strong>Raychem</strong> <strong>RPG</strong> has generated a lot of<br />

interest because of its wide range of new products and<br />

SMT Business Model adopted (Self-Managed Teams).<br />

Visitors at Nalagarh Plant<br />

Senior members of Tyco Electronics<br />

State Labour Minister, Kishan Kapoor & B. R. Verma, Labour Commissioner<br />

Team from Dr. Reddy Laboratories<br />

14


NALAGARH<br />

<br />

August 15 - Independence Day celebrations<br />

Integration of the Nation,<br />

Integration at Work!<br />

<strong>Raychem</strong> <strong>RPG</strong> has signed an agreement with Chitkara<br />

University, located in Himachal Pradesh, to conduct a series<br />

of programs in a phased manner for our SMTs that will lead<br />

to awarding of B.Tech Degree in Electrical & Electronics .<br />

Organizations adopting SMT business model takes upon<br />

Proud to be a RRLite!<br />

and opportunity to complete their degree in engineering.<br />

Chitkara University<br />

i s l o c a t e d i n<br />

District Solan,<br />

Himachal Pradesh.<br />

the responsibility of giving academic, as well as, practical The campus is 32<br />

training to young students who have completed Std XII (A<br />

k m s f r o m<br />

Levels) and prepare them to work on various functions of C h a n d i g a r h .<br />

operation. During their tenure, they are also given training<br />

Signing of Agreement<br />

<strong>Raychem</strong> <strong>RPG</strong> and Chitkara University collaborate<br />

Chitkara School of<br />

Engineering &<br />

Technology offers<br />

p r o g r a m s i n<br />

Computer Science<br />

E n g i n e e r i n g ,<br />

E l e c t r o n i c s &<br />

Communication<br />

Engineering and<br />

Civil Engineering.<br />

(R) Brig Dr. R. S. Grewal, Vice Chancellor<br />

- Chitkara University<br />

(L) Varinder Kanwar, Registrar<br />

- Chitkara Univesity<br />

15


KAMAN<br />

Kaman traffic intensifies!<br />

As part of a strategic move, IED Operations (which was<br />

earlier based at Rabale) was shifted to our existing Kaman<br />

Plant in September.<br />

With this move, IED members will get an opportunity to<br />

move and mingle with other SBU members.<br />

Kaman is large, a very happening plant and buzzing with<br />

activities. Currently it has the following operations for<br />

Energy T&D, Infocom, OWG and IBD.<br />

Customer Care Centre (Sales Order Offices)<br />

Kitting operations<br />

Wazoo Operation (for expansion of tubing)<br />

IED Operations<br />

Product Management Group<br />

Corporate Operations – TPM & Quality Assurance<br />

One large joint family of <strong>Raychem</strong> <strong>RPG</strong>!<br />

16


KAIZENS<br />

Way of life at <strong>Raychem</strong> <strong>RPG</strong> !<br />

At <strong>Raychem</strong> <strong>RPG</strong>, Kaizens have been in practice for over 10<br />

years, and through this process of continuous<br />

improvements, it has brought to the shop floor work<br />

efficiencies and remarkable reduction of costs and energy.<br />

We give below two Kaizens that were recently put into<br />

practice.<br />

KAIZEN 1<br />

of 11kW was drawing more power than other machines<br />

because of weak design.<br />

Idea Implementation<br />

Improvement in the<br />

design and providing<br />

Molding Machine Motor<br />

of 5 KW<br />

Theme<br />

Reduce Energy consumption by 50% 5 0 % E n e r g y<br />

Team<br />

consumption<br />

IBD Operations, Vasai<br />

Analysis<br />

Using the ‘5 Why’ technique and energy mapping, the<br />

analysis revealed that the existing Molding Machine Motor<br />

Benefits<br />

H o r i z o n t a l<br />

Deployment<br />

Implement this approach<br />

on all equipments<br />

Before<br />

After<br />

KAIZEN 2<br />

Theme<br />

Increase customer satisfaction and customer delight by<br />

providing error free kits from CARS Kitting.<br />

Horizontal Deployment<br />

This Kaizen is getting horizontally deployed at other SBUs<br />

as well.<br />

Weighing Scale for detecting missing components<br />

Team<br />

CARS Operations, Kaman<br />

Analysis<br />

After collating the past data on missing components, using<br />

the ‘7 Steps of Structured Problem Solving’ methodology,<br />

the team was able to reduce and eliminate the problem.<br />

OVER-WEIGH<br />

UNDER-WEIGH<br />

Solution Implementation<br />

Team explored different counter measures and finally<br />

decided on implementation of Weighing Scale with data<br />

capturing software with special features like Andon (Audio<br />

visual indicators) for monitoring and highlighting defects.<br />

Each product (Kit box) had specific number with weight<br />

measured and stored in the software to ensure all the<br />

components as per BOM are included.<br />

Benefits<br />

Zero Customer complaints for missing components<br />

Packing Line Weighing Scale Packing Line<br />

17


CHAKAN<br />

Visitors at Chakan Plant<br />

Chakan plant also had a<br />

spate of business visitors in<br />

the last quarter to assess<br />

the operation systems and<br />

set-ups for manufacture of<br />

various types and sizes of<br />

Transformers.<br />

- Converteam of U. K. and<br />

India<br />

- T a t a C o n s u l t i n g<br />

Engineers<br />

- CESC Ltd., Kolkata<br />

- Tyco Electronics - Energy<br />

Directors (of <strong>Raychem</strong><br />

<strong>RPG</strong>)<br />

- A. A. Bin Hindi, Kingdom<br />

of Bahrain<br />

These visits were a great encouragement to the Chakan<br />

team members for the tremendous improvement and<br />

progress made in the last 3 years.<br />

A true motivation for further excellence!!<br />

C e l e b r a t i o n<br />

As done each year, Chakan Day was celebrated on August<br />

12. Chakan plant had a festive look and members were in<br />

true spirits of celebration. Moreover, members were<br />

enthused in participating in competitive games like<br />

Carom and Chess and other activities.<br />

18


Aabha Awards – “Gems of <strong>Raychem</strong> <strong>RPG</strong>”<br />

Team CARS-Kaman was declared "Gems of <strong>Raychem</strong><br />

<strong>RPG</strong>" - June 2010 for initiating a new process - Counting<br />

by Weighing at Cable Accessories Kitting facility at Kaman.<br />

(refer Kaizen Section)<br />

The team included:<br />

Pradeep Godse, Deputy Manager - Quality CARS<br />

Pravin Shirke, Manager - Corporate Engg<br />

Hemant Raorane, Sr. Manager, Operations CARS<br />

Nelson Lopes, Executive, Operations CARS<br />

Nambi Ramanujam, Manager - EOU Operations, Vasai<br />

was declared "Gem of <strong>Raychem</strong> <strong>RPG</strong>" - June 2010 for<br />

successfully launching the Cost Reduction drive 'Sankalp' at<br />

Vasai.<br />

Nambi was instrumental in putting together the plan for<br />

launching Sankalp across all the departments of EOU. His<br />

approach, sensitivity on cost awareness, leadership skills<br />

and team spirit led to 100% participation of members in<br />

Sankalp. The drive also gave opportunity for team<br />

members to create innovative ideas in reducing costs.<br />

Rupesh Pawbake - Associate CARS<br />

Nambi Ramanujam<br />

The process of Counting by Weighing at CAR kitting<br />

improved productivity and accuracy. Moreover, it helped<br />

in detecting missing components during the kitting<br />

process.<br />

As a result of this method introduced in Kaman six months<br />

ago, Customer Care Team has not received a single<br />

complaint from their customers regarding missing<br />

components, which has further increased the satisfaction<br />

level of Energy T&D customers.<br />

With the success of Sankalp, EOU was able to improve the<br />

bottom line significantly.<br />

Implementing Sankalp successfully at Vasai, Nambi has<br />

exhibited the following Core Values:<br />

Focus on Customers<br />

Demonstrate passion for performance through<br />

anticipation, speed and flexibility.<br />

With the success of this initiative, CARS Kaman Team has<br />

exhibited the Core Value:<br />

Focus on Customers<br />

19


Aabha - Appreciation & Recognition Policy<br />

Relaunch ed!<br />

Aabha, the Appreciation & Recognition Policy at <strong>Raychem</strong><br />

<strong>RPG</strong> was introduced two years ago.<br />

However, with the ever-growing number of members<br />

coming on-board, opening of new offices and plants, it<br />

was imperative that the awareness be recreated to recall<br />

the Appreciation & Recognition Policy of the Company.<br />

Aabha was relaunched on July 23 this year. Corporate HR<br />

kick-started the initiative and made arrangements for<br />

Location HR and Champions to take forward various<br />

activities for the relaunch. One week prior to the relaunch,<br />

teasers were sent out via email to whet the interest of RRL<br />

members.<br />

On the day of the relaunch, all the offices and factories of<br />

<strong>Raychem</strong> <strong>RPG</strong> carried a festive and colourful look. The<br />

relaunch ceremony included:<br />

Opening Ceremony by SBU Head/Location Head<br />

Cricket Match<br />

Unveiling of Aabha Manual<br />

Awards distribution<br />

Screening of the film, Lagaan<br />

Distribution of Aabha Manual<br />

High tea and closing of ceremony<br />

The ceremony was a grand success, members were<br />

charged-up with their favourite game and there was a lot<br />

of camaraderie amongst members.<br />

There was excitement, there was awareness, making it a<br />

great beginning to the relaunch of Aabha.<br />

C HE E R<br />

S !!<br />

!<br />

20


Aabha Recognition<br />

a a o t n<br />

A bh Rec gni io<br />

Keep the Appreciations flowing!<br />

21


Ramani Kasi, our President, turned 50 this year!<br />

To celebrate the golden milestone, the office<br />

of our President, Mr. Ramani Kasi at <strong>RPG</strong><br />

House (formerly Ceat Mahal) had a festive and<br />

colourful look on June 22.<br />

In his own words, as he stepped into his office,<br />

“I feel like a small boy having a birthday treat!”<br />

At the Commonwealth Games<br />

New Delhi October 2010<br />

The Rayline team, Pankaj Kumar, Gurvinder Singh<br />

and Laxman Singh Rana were involved in the<br />

electrical infrastructure set up of CWG 2010 in New<br />

Delhi. Moreover, the organizers appointed Pankaj<br />

Kumar on their Management team at CWG 2010.<br />

Pankaj was truly delighted and felt extremely proud<br />

to be given this opportunity in providing his services<br />

for this prestigious event. He is humbled by the fact<br />

that this opportunity has come through his services<br />

at <strong>Raychem</strong> <strong>RPG</strong> to serve his nation in its true colours<br />

and finery.<br />

Sports Day at Nalagarh<br />

Prideful moment indeed for our Rayline Team!!<br />

Nothing is more enjoyable than a healthy, competitive<br />

match amongst colleagues.<br />

Nalagarh team took time off from their busy schedules to<br />

participate in a variety of sports and games.<br />

RRL bonding at its best!<br />

Extremely participative and very enjoyable!

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