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National Productivity Summit 2015

About National Productivity Summit

The continual need to reduce costs through productivity improvement measures is a challenge faced by most manufacturing companies. This quest and realization of attaining ever higher levels of productivity improvement enhances and sustains competitiveness in the Indian manufacturing industry. This is the culmination of innovations and improvements across varied aspects viz. highly productive manufacturing solutions through superior machining process, alternative processes, automation, out-of-the-box approach to challenges and the key differentiator: highly motivated manpower.

Indian Machine Tool Manufacturers' Association (IMTMA) has been in the forefront of championing productivity movement in Indian metal working industries by organizing the National Productivity Summit. This event showcases best productivity improvement projects in metal working industries from across India, which have excelled in achieving superior performance through sustained productivity improvements. The National Productivity Summit offers a unique opportunity to understand and learn from the experiences and best practices of other companies. National Productivity Summit brings together Productivity Champions and aspiring leaders on a common platform to share experiences, ideas and is an unmatched forum for networking with decision makers, experts, peers, researchers, academia, customers and suppliers of productivity equipment. The Summit addresses and demonstrates a wide variety of productivity improvements in metal working through Live Case study presentations, Keynote addresses and Plant visits.

National Productivity Summit 2015, 20 – 21 November @ Hotel Crowne Plaza, Gurgaon: 

IMTMA held successful Summits in the previous year’s 2006–2014. Key highlights of National Productivity Summit 2015 are:

  • 4 Plant Visits: (19 November 2015)
    Tour A: 1) Hero Moto Corp2) Sona BLW Precision Forgings
    Tour B:2) Honda Motorcycle & Scooters India2) Hitech Gears

    Along with the summit, will provide an excellent opportunity to delegates to witness productivity improvements on the shop floor.

  • 4 inspiring Keynotes:
Renowned industry experts will deliver Keynote addresses on various facets of productivity.
  • 'Ascent : A Practising Manager's Growth Mantra'
    Mr. Amit Chatterjee. Managing Director, Satorius India Group
  • 'Challenges in improving metal working productivity'
    Mr. M M Singh, Executive Advisor, Maruti Suzuki India Ltd.
  • 'Hitech's Journey in achieving productivity excellence'
    Mr. Rajesh Magoo, Chief Operating Officer, Transmission & Engine Component Business, Hitech Gears
  • 'Quality Route to Productivity'
    Mr.Rajeev Wasan, Sr. Vice President - Manufacturing, Honda Cars India Ltd.
  • 12 interesting case studies:
  • Ashok Leyland Ltd.
    Elimination of Hidden Energy Losses during non-Production Hours & Implementation of online monitoring
    Ashok Leyland found that the major contributor to their overheads was electrical power. Their case study highlights how they went about analyzing shop wise, line wise, and aggregate wise Energy monitoring with on-line single screen view, and further re-grouping of entire energy load. Mobile alerts for demand management was an added benefit. This resulted in huge savings and more so when machines are idling.

  • Bajaj Auto Ltd. - Chakan
    Productivity improvement & conversion cost reduction in Balancer Driven & Idler gear through alternate process & Yield improvement.
    Bajaj Auto, Chakan plant, achieved dramatic improvement of yield and cost savings by replacing forgings with sintered parts for balancer driven and idler gears. The sintered gears were near net shape with a yield of 95% against forgings with a yield of 70%. Process steps were also reduced, resulting in cost saving. The case study presentation will elaborate the approach used as well as the study carried out to address differences in the material properties of both processes.

  • Bajaj Auto Ltd. - Waluj
    Maximise overall equipment efficiency for Capacity enhancement with minimal capital Investment.
    In mass production every second saved is valuable. Normally to expect to save 20% of cycle time on a fully automated robotic welding line is quite challenging. However Bajaj Auto, Waluj, did just that! They looked at saving 0.1 sec for every spot that they were welding. Through their case study they will share how they went about doing very small improvements, which resulted in huge savings. In spite of 16% increase of spots to be welded, they maintained the cycle time.

  • Bosch Ltd.
    To meet Customer demand through reduced throughput time & increased productivity with state - of - art modular machining centres
    Bosch Ltd through their case study have showcased how they moved from standalone machining centres to an integrated system using modular multi-spindle machining centres to meet their target in high volume and critical product. A KT analysis (Kepner Tregoe) was performed to decide upon on the type of manufacturing setup to be used i.e standalone machining centers or modular machining centers focusing on key parameters like capital investment, cycle time, output/day, manpower required, machine parameters like rapid rates, construction, automation etc.

  • Kiehinfie Pvt. Ltd.
    To increase capacity of Machining.
    Kiehinfie Pvt. Ltd. a carburetor manufacturing company with 70% Indian market share, had to increase manufacturing capacity by 89% in the shortest possible time, with zero investment, and without increasing floor space. Their case study presents how they accepted this challenge in their machine shop and the steps they took that included cycle time reduction in the existing processes without investment, new wood pecking cycle, combination of tools and clubbing operations.

  • Lucas TVS Ltd.
    RAMP-UP OF SGM-25 (Sundaram Gear Reduction Motor)
    Lucas TVS in their case study has presented their approach to increasing productivity by 100% in armature assembly of their starter motors due to a sudden increase in customer demand. Their approach consists of line balancing, improving MTTR and applying SMED principals to bottleneck machines, and reducing imbalance rejections during assembly. Wherever root cause was traced to supplier that too had to be tackled.

  • Mahindra & Mahindra
    Increase in productivity of 1.65 ratio hypoid ring Gear hard turning
    Mahindra & Mahindra were challenged to increase productivity in their hard turning operation by 50%. They converted a spring actuated chuck to a hydraulic operated chuck. By doing so they could increase the RPM of the chuck and proportionately increase feed rate during hard turning operations. The increased hydraulic pressure now compensated the increase in centrifugal force due to higher spindle RPM.

  • Maruti Suzuki India Ltd.
    Empty dunnage (Bin Packing) segregation System for space utilisation and inventory management.
    Maruti Suzuki has conceptualized and developed a patentable empty bin segregation system that helps collect direct online bins and bins on trolley of different sizes, there by eliminating manual segregation. This innovative empty bin handling system has resulted in manpower optimization, removing the non value added activity of manual segregation with improved availability of time, space, manpower and accuracy for maintaining Kanban system

  • SKF India Ltd.
    Productivity Improvement at Channel Group1 from 7000 Bearings/day to 12000 Bearings/day for 2 bearing types
    What does one do when competitors sell bearings below ones cost and market price is 30% below cost? SKF found this issue on two bearings that they sold. They analysed their cost structure in depth to identify the areas. Several steps were taken which included reducing labour cost, improving quality and optimizing parameters using DOE. All this resulted in nearly doubling the productivity on the machining lines and significantly reducing rejection. Their case study shares this journey.

  • Tata Motors Ltd.
    Merging the NANO - Front Door & Rear Door Cells into one common Cell (both LH & RH sides) to create the re-quired space for new 'KITE' Model Door Cells.
    Sometimes optimistic marketing targets are set and not reached while production capacity is geared up for that. This results in idle capacity and companies would like to use the idle capacity to introduce new products. This poses an interesting challenge for the engineering personnel; adapting idle capacity for a product not planned for. In robotic cells this can be daunting. The Tata Motors case study presents how this challenge was overcome on a robotic line, where welding, hemming, sealant application process, material movement was merged for right and left hand doors of their vehicles, Nano and Kite.

  • TVS Motor Company
    Productivity Improvement and flow manufacturing in machining fixtures and gauges through innovation and design standardisation
    Can one design and manufacture fixtures which do not use clamps, and no accumulation of chips and that too by creating standard elements? During new product development of machined parts often the longest lead time is design and manufacture of fixtures and gauges. TVS Motor has tackled through standardization of elements. They could achieve lead time reductions of 36% and have applied for a patent. Their innovative approach would be shared in their case study.

  • Wabco India Ltd.
    Layout transformation and space productivity at for future business needs.
    In order to pursue a significant growth of 100% in next five years, it is but natural to envisage requirement of additional work space for manufacturing premises. However Wabco India Ltd. studied their operations in great depth. The entire project of space productivity in their site has not only involved the conventional way of creating free space by some Kaizens but also it featured a companywide approach to defragment the existing layout. This innovative approach to increase density in space utilization is truly worth understanding and learning.

About IMTMA-ACE MICROMATIC Productivity Championship Awards

Attaining a quantum leap in productivity is a journey that requires sustained efforts by the entire manufacturing industry at all levels and across industry sectors. It embraces several disciplines both technical and managerial. It requires the application of the latest techniques and tools, supported by learning from the best practitioners in the field. It requires a committed management to continually support and guide these efforts and committed professionals to explore ways to improve productivity and implement these measures in their operations. Several companies have already travelled on this journey and with significant levels of success.

Indian Machine Tool Manufacturers' Association (IMTMA) firmly believes that it is necessary to recognize those who have contributed to productivity improvement in Indian industries and to encourage more to emulate these pioneers. With this objective, IMTMA has instituted the Productivity Championship Awards, to be given to outstanding contributors to productivity improvement in the Indian metalworking industry.

ACE MICROMATIC has graciously come forward to sponsor the Productivity Championship Awards, to recognize and reward outstanding efforts and accomplishments in improving productivity in metalworking industries during the fiscal year 2014-15.

Participation from companies across India; sharing of experiences; recognition of achievers; and engendering an enthusiastic competitive spirit has contributed to the stature of the Summit and Awards, since its inception in 2006. These awards have become prestigious and symbolic of high productivity standards achieved by the Indian manufacturing industries.

The awards competition and how the champions are crowned

A competitive process is used to bring the highest objectivity in identifying and rewarding the productivity champions. Entries in the form of 1 page abstracts are called from professionals describing the productivity improvement projects implemented by them, the merits of these projects and the benefits realized.

An independent panel of experts screen these abstracts for suitability to enter the next stage of the competition. Selected entrants are then asked to submit a detailed case study of their project. These are examined critically for their intrinsic merits by the screening panel. Twelve short listed case studies are presented live at the National Productivity Summit. Based on the presentation and the interactions with the jury and the delegates, the awards are decided. Award winners are announced at the end of the National Productivity Summit. The standards are exacting, and the award winners are crowned as "Productivity Champions" at a glittering function at the National Productivity Summit 2015.

NPS 2015 Brochure NPS 2015 Brochure

Workshop on How Do I Make Digital Enhance my Business


Competition in the marketplace undergoes a distinctive change almost every five years, particularly true for cyclical industries such as capital goods including machine tools.

In 2005, the industry was just out-of-the-woods and began experiencing phenomenal demand – so plentiful were business conditions that most machine manufacturers were besieged with managing orders. Five years later, global recession took sails out of practically every-industrial ship – manufacturers were seeking every possible avenue to obtain orders. And in 2015, a picking-up economy is setting its own agenda on where business opportunities would emerge from, for the industry.


There has also been a precipitous transformation on the modalities of increasing business opportunities. The “DIGITAL” revolution has not just set-in amongst the emerging sectors as IT-ITES, BT, Electronics – but is making its foray into traditional brick-and-mortar businesses, including within hard-core manufacturing.

New marketing tools – unheard of in the last decade, are meant to take customer networking to a new pedestal. Neo shastras include digital media; ebusiness portals; web penetration; cyber-hub; apps; blogs; podcasts & webcasts; social bookmarking; and other formats of e-promotion – all engulfed under the broad contour of 'social and digital media'.

Concept and relevance of 'social media' in manufacturing industry marketing / positioning is rather underestimated. Simply put, 'social media' is not limited to exchanging messages, tweets or apps. Rather it encompasses the entire gamut of epromotion which could be effectively leveraged for brand promotions, even for core manufacturing sectors such as machine tools.


In order to better delve deeper into this element, your Association is scheduling a unique Workshop on "How do I Make DIGITAL Enhance My Business" on 04 and 05 December 2015 [Friday and Saturday] at "Waterstones" Hotel in Mumbai. Theme of the Workshop is 'Leveraging Social Media & ECommerce for Enhancing Market Share'.

The two-day brainstorming Workshop will enable the machine tool industry to be a 'first mover advantage' towards leveraging social media and e-commerce measures to increase business opportunities.

To be facilitated by leading experts as well as eminent industry stalwarts in the field of social and digital media, the Workshop would focus on the imperativeness of going digital for market supremacy. Industry would be educated on the significance of cross pollination between all forms of social media.

Highlight of the Workshop would be the release of an exclusive study report on "Leveraging Social Media for Machine Tools and B2B Segments. Global Scenario and Where India Stands? The Way Forward."

The Workshop is structured in a manner to make it informative as also stimulating, while being determinedly interactive.

Brief about the Sessions

Session One (1100 - 1200)
Inauguration by Chief Guest
Mr. Jamshyd N. Godrej
Chairman & Managing Director
Godrej & Boyce Manufacturing Company
Release of Research Paper : "Leveraging Social
Media for Machine Tools and B2B Segments,
Global Scenario and Where India Stands ? The Way Forward."

Videoclip : Socionomics
Modern world economy is in early stages of a profound change in the shape of business activity. Two centuries ago, dramatic shifts in economics of production precipitated the Industrial Revolution. An upheaval of even greater proportion is about to be triggered by unprecedented changes in the way we communicate, stay connected and most importantly, the way we do business. The power of IOT (Internet of Things) and Social Media are about to be unleashed.

Session Two (1200 - 1330)
  • Emerging global and Indian digital trends.
  • Why has digital become so important.
  • Change in human behaviour and its impact on business.
  • Introduction to digital ecosystem.

Videoclip : The Social Buzz
Going Digital is no longer an option. It has become an imperative as it impacts all aspects of business from Production to Sales, from managing supply chains to managing people, keeping track of cash to inventory control, after sales service to new product development. It will redefine business models and corporate structures.

1330 - 1430 Networking Lunch

Session Three (1430 - 1600)
  • Importance of website and best practices for great web presence.
  • Search engine optimisation.
  • Search engine marketing.
It is surprising to witness how many businesses actually do not have online presence. We spend precious time & money to search out customers and yet forget that website facilitates customers searching us! This applies equally to those who do set up a website and then forget about this most revolutionary tool.
Cost effective, 24 x 7, accessible from anywhere, from multiple devices, with high score on credibility and a visible link to sales & bottom line.

1600 - 1630 Networking over Tea / Coffee

Session Four (1630 - 1800)
  • Social networks.
  • Identifying relevant social network.
  • Power of targeting on social media.
  • Social bookmarking.
Interactions – the searching, coordinating and monitoring that people and firms do when they exchange goods, services or ideas pervade all economies. Such interactions exert a potent influence on how industries are structured, organised and even how customers and markets behave. Any change in their level or nature, would trigger a new dynamic in economic activity. Simply put, Social Media is an umbrella term that defines various interactions that integrate technology, social issues and construction of words, pictures, videos & audios. A whole new vocabulary. Zillions of conversations people are having 24 x 7 is akin to 'word of mouth' on steroids! They can make or mar brands, affect business prospects, influence opinions and all these at speeds that can rival that of light or sound, on click of a mouse!

Special Evening Session (1900 - 2000)
"Leveraging Digital World – The Haas Way".
A company, more e savvy then most. Benchmark with the best in class.

2000 - 2200 Networking Dinner

Session Five (0900 - 1030)
  • Content marketing.
  • Email marketing.
  • Podcasts and webcasts.
  • E-books and videos networking.
Internet Marketing refers to leveraging web, email and social media to drive direct sales and generate leads. Various on line tools are being used. Viral Marketing, Internet Explorer, personal internet communicator or marketing blast ... to name a few. The most cost effective marketing effort even for B2B products.

1030 - 1100 Networking over Tea / Coffee.

Keynote Session (1100 - 1200)
"LinkedIn – as a Platform for DIGITAL Strategy for the Indian Machine Tool Industry".
Facilitation by "LinkedIn".

Special Noon Session (1200 - 1300)
“Leveraging Facebook in B2B environment to achieve Business Goals”.
Facebook's more than one billion users make it a social, cultural and economic phenomenon. With an entire interface designed for businesses, complete with business profile, an advertising system that allows marketers to target specific group of information users, it creates opportunity for businesses to reach out to their target audiences in most economical and effective way.

1300 - 1400 Networking Lunch

Session Seven (1400 - 1515)
  • E-business – creating own presence.
  • Leveraging existing E-business portals.
  • Reverse auction.
E-commerce is the buying and selling of goods and services or the transmitting of funds or data over an electronic network, the internet. Other terms are eBusiness, eTail (Retail), NetBanking etc. After trail blazing the b2c path, eCommerce is now set to revolutionise B2B scene as well. Tech-savvy companies are leveraging this tool to open up new segments, new markets, new geographies, with new and dedicated strategic frameworks.

1515 - 1530 Networking over Tea / Coffee.

Session Eight (1530 - 1645)
  • Leveraging digital for other stakeholders {HR, procurement, etc.}.
  • World of mobile apps.
  • Social listening and customer life- cycle management.
The speed, reach and efficacy of digital mediums make it suitable for other spectrums of business activity as well. HR (e-recruitment, webinars, employee engagement), procurement (other side of marketing) are closely linked to an effective e-presence of corporates.

Concluding Session (1645 - 1715)
  • Which five actions will I take in my organisation?
  • What next?
Drawing up an Action Plan:
  • For participating companies
  • For IMTMA

'Modena' Hall
“Waterstones” Hotel
Sahar, Andheri (East)
Mumbai - 400 059.

{Conveniently located – five minutes of driving distance from Sahar International Airport (T 2) and 20 minutes from Santacruz Domestic Airport}.

“Waterstones” Hotel is offering Special Tariffs for
participating delegates at the Workshop, and comprise:
Single Room - Rs. 6,000 + Taxes [per night]
Double Room - Rs. 6,500 + Taxes [per night].


“UDAAN” - Rs. 9,500 + Service Tax.
SME Members - Rs. 10,500 + Service Tax.
Large Members - Rs. 12,000 + Service Tax.
{Charges includes conferencing; F&B; course materials and defrayment of expenses for organising the Workshop}


Prospective participants are requested to register their kind presence at the Workshop on “How do I Make DIGITAL Enhance My Business” on 04 and 05 December 2015, through the enclosed 'Registration Form', and have it sent to IMTMA Secretariat in Gurgaon on or before 20 November 2015.

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Workshop Registration Form

Upcoming Events

  > Workshop on How Do I Make Digital Enhance my Business
4 – 5 DECEMBER 2015
Waterstones Hotel, Mumbai
  > National Productivity Summit 2015
19-21 NOVEMBER 2015
Hotel Crowne Plaza, Gurgaon
  > International Seminar on Forming Technologies
20 JANUARY 2016
Bangalore International Exhibition Centre, Bangalore
  > IMTEX FORMING 2016 &
Tooltech 2016

21-26 JANUARY 2016
Bangalore International Exhibition Centre, Bangalore

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