10 Most Admired Companies in Manufacturing Industry

www.insightssuccess.in December 2018

10 THE

Company of the Month

MOST

ADMIRED

COMPANIES IN

MANUFACTURING INDUSTRY

Utkarsh Bansal Director Utkarsh India Limited

Sunil Duggal CEO

Representing India In Global Zinc-lead-silver Market

Hindustan Zinc - Zinc Of India

Editorial

M

anufacturing with a goal of optimizing concept generation, production, and product transaction has led to the birth of smart manufacturing. Smart manufacturing being the super set of manufacturing industry confides of multi-phase process of creating a product out of raw materials smart manufacturing aims to employ computer control and high levels of adaptability. Such technical process aims to enable flexibility in physical processes to address a dynamic and global market.

The emergence of the Industrial Internet of Things (IIoT) has created both hope and confusion among stakeholders responsible for operating industrial plants. Much of the early hype is focused on the impact of technological advancements on existing automation platforms. One of the biggest potential benefits of next generation IIoT systems which is the breakdown of enterprise silos. The technologies will allow for closer integration of production systems and Product Lifecycle Management (PLM) systems, Supply Chain Management and Customer Relationship Management (CRM) systems.

The Rise of Smart Manufacturing

As smart manufacturing enterprises start implementing smart enterprise control and asset performance systems managed by augmented operators, automation vendors will respond by implementing IIoT at all levels of the automation hierarchy. This will allow easy integration with next generation IIoT systems. In addition, with the increasing power of embedded electronics, connected intelligence will migrate down to the lower levels of the automation hierarchy – to the control level and to the sensors and actuators. As a result, operations technology (OT) systems will merge with information technology (IT) systems and the automation hierarchy will evolve to be a much flatter and more information-driven architecture.

Delivering smart connected devices that are IIoT ready means embedding Internet technologies like WIFI and web services natively into those devices. For example, Variable Speed Drives are essential to industrial processes by way of providing information on motor use and other devices like sensors and relays provide information on the device lifecycle. Embedded digital services also become critical to support process optimisation. For example the new series of Altivar Process drives with built in web technology standards, Ethernet connectivity, intelligence and asset management or energy management features deliver additional contextual information, including real time events, alarms, drifts, and historical data.

Shweta Priyadarshini Shweta Priyadarshini

Editor-in-Chief Pooja M. Bansal Managing Editor Shweta Priyadarshini Contributing Editors Rahul, Shruti, Sneha Art & Design Head Amol Kamble Associate Designer Poonam, Shweta Art & Picture Editor Rahul Kavnekar Co-designer Mayur Koli Business Development Manager Akansha Garewal Marketing Manager Dhruv Apte Sales Executives Rutuja, Vaishnavi Technical Head Swapnil Patil Technical Specialist Amar, Pratiksha Digital Marketing Manager Prashant, Rahul SME-SMO Executives Swati, Manoj Circulation Manager Tanaji sales@insightssuccess.com

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Representing India In Global Zinc-Lead-Silver Market Hindustan Zinc - Zinc Of India

36

16

Expert’s View

Utkarsh-A Diversied Infrastructure Conglomerate

Tech-based Innovations Revolutionizing the Manufacturing World

CONTENTS

CXO STANDPOINT

COMPANY OF THE MONTH

Cover er Story

Microsign Products A New Sight to the Manufacturing Arena

ARTICLE

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28

Editor’s Choice

42

Editor’s Choice

Predict a ‘Failure’ before it Occurs with the Power of ‘Predictive Maintenance’

Guerrilla Marketing: The New-age Marketing Technique To Create A Profound Effect On Targeted Audience

24 Cosmo Films Digitally Transforming the Manufacturing World

INTERVIEW 30

34 Cotmac Electronics Offering Wide Range of Cost Effective Engineering Services

40 Universal Robots

Mayur Uniquoters One of the Largest Manufacturer of Articial Leather

Pioneers of Collaborative Robot Technology

10

MOST ADMIRED

COMPANIES IN

MANUFACTURING

INDUSTRY

The Evolution of Manufacturing Companies that have Shaped the Way We do Business

T

he evolution of manufacturing has shaped the way we do business, as it’s always factored into what types of services we offer and what sorts of efficiencies we keep in place. The continued automation of manufacturing tasks paired with emerging smart technologies such as the Internet of Things signals that streamlining in manufacturing will play an even bigger role in 2018 and beyond. Toll manufacturing could become less of a practice as more facilities process materials and manufacture finished products on site, which is sure to impact logistical networks from resource to refinery to manufacturer and so on.

Manufacturing has long been a cornerstone of the modern economy, with advances in technology changing the processes and output volume drastically for all sorts of industries from food production to home goods, chemicals and electronics.

Herein we take an opportunity to feature such prudent and competent companies in our special issue of The 10 Most Admired Companies in Manufacturing Industry, in which we have signified 10 effective and the prominent manufacturing sectors.

The journey of our magazine begins with Cover story; Hindustan Zinc Limited is an integrated mining and resources producer of zinc, lead, silver and cadmium. It is India’s only and one of the world’s largest integrated producer of Zinc, Lead and Silver. The Company has its headquarter in Udaipur in the State of Rajasthan where it has its Zinc-Lead mines and smelting complexes.

In this issue we also have issued, Utkarsh India Limited, an ISO 9001:2015 certified manufacturing organization builds and innovates across seven major verticals - Steel Tubes, PVC Pipes, HDPE Pipes, Railway electrification, Poles, Towers and Crash barriers.

Cosmo Films Limited that is amongst the global leaders in speciality films for packaging, lamination and labeling applications. Cotmac Electronics is a leading solution provider, electrical panel manufacturer in the country and has interests in industrial trading, industrial automation, machine tools, chip and scrap handling conveyors, solvent extraction machinery, welding equipment, and welding automation, among others.

Universal Robots produce a robotic arm which is characterized by being extremely flexible and easy to use in the day-to-day production.

We have interviewed Microsign Products which is a leading manufacturer of plastic fasteners like cable ties, clips, clamps and markers in India.

Our in-house editors have written articles Predict a ‘Failure’ before it Occurs with the Power of ‘Predictive Maintenance’ We have also mention article Tech-based Innovations Revolutionizing the Manufacturing World, written by Ashok Rajpal,Managing Director of Ambrane.

10

MOST ADMIRED

COMPANIES IN

MANUFACTURING

COVER STORY

INDUSTRY

REPRESENTING INDIA IN GLOBAL ZINC-LEAD-SILVER MARKET HINDUSTAN ZINC - ZINC OF INDIA

Sunil Duggal CEO

Galvanized steel is one of the “originals” and it is found to be one of the best choices for most steel building construction projects

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industan Zinc, a Vedanta Group Company, is India’s only and one of the world’s largest integrated producer of Zinc, Lead and Silver. The Company has its headquarter in Udaipur in the State of Rajasthan where it has its Zinc-Lead mines and smelting complexes.

Proudly recognized as ‘Zinc of India’, Hindustan Zinc has provided Zinc sufficiency to India and represents India in the global Zinc, Lead and Silver market. As a market leader, Hindustan Zinc governs about 85% of growing Zinc market in India and produces almost 100% of India’s integrated Silver.

Sunil Duggal, the CEO of Hindustan Zinc says, “Awareness is the key to build a galvanized Indian economy. People do not understand the difference between ‘steel’ and ‘galvanized steel’. Galvanized steel increases the life of steel and gives life to not just industrial sectors but also house-hold sector. Galvanization is a layer of protection to safeguard steel from rusting.

Globally people are understanding that use of galvanized rebars can increase the life of their houses that can withstand many risks.

Infrastructure at coastal areas are at the maximum risk due to humidity and constantly changing climate. Galvanized rebars protect pillars and hold construction.

Galvanization of steel used in car body enhances the life of vehicle multi-fold – your recurring expenditure on repairs decreases and your safety increases. The new mega infrastructure development that is happening in India today, with the use of steel, should only use galvanized steel for strength and long life.”

Yashad Bhawan – Head Ofce of Hindustan Zinc in Udaipur

USD 3 Billion Investment in Expansions since 2002 Since disinvested in 2002, Hindustan Zinc has invested over USD 3 Billion towards its 4 phases of expansion programs to reach to the current metal production capacity of 1 million tonne per annum and expand the capacity to 1.2 million tonne by FY 2020 and eventually 1.5 million tonne in the next 5 years. Hindustan Zinc has a mine life of more than 25 years with reserves & resources of 411.3 million MT base, post depletion.

Hindustan Zinc’s mines are also expanding enormously. Hindustan Zinc’s two shafts, one each at Rampura Agucha and Sindesar Khurd mines, are all set to be commissioned in FY 2019.

The Company is also setting-up 2 new mills, at Zawar Mines and Sindesar Khurd Mine, with a joint capacity of 3 million tonnes of ore-treatment.

After the commissioning of new mills, the ore treatment capacity will increase to 17.7 million tonnes from the current 14.7 million tonnes per annum. Both the new mills are expected to start production in FY 2019.

To increase metal production through recovery process Hindustan Zinc is also putting-up three Fumer Plants out of which one is likely to be commissioned within the FY 2019.

This will help in recovery of metals - particularly Lead and Silver.

Globally people understand that use of galvanized rebar can increase the life of their houses that can withstand many risks about 550 tonnes of Silver, Hindustan Zinc is the 10th largest Silver producer globally and is aiming to produce 1000 tonnes of Silver in the next 3-4 years.

This will position Hindustan Zinc in the top 5 global Silver producers. The Company’s silver refinery at Pantnagar is recognized by London Bullion Market Association for its quality and the Company is among LBMA’s Silver Good Delivery List. Hindustan Zinc is ambitious to produce about 1500 tonnes of Silver in the next 5-6 years and be the 2nd largest Silver producer in the world.

Power Generation - Thermal, Wind and Solar Power The Company is self-sufficient in power with an installed base of 474 MW coal-based captive power plants.

It has green power generation of 309 MW including 274 MW of wind power and 35 MW of power through waste heat recovery process. Additionally, the Company has 16 MW of solar power and is investing in setting up Solar Plants in Rajasthan to produce 115 MW of Solar Energy.

development for future growth and partnering with research agencies and domain experts for adaptation of benchmarking technologies. The core development team is supported by well–equipped departments for Mineral Processing, Geo-metallurgy & Ore Characterization, Pyro-metallurgy, Hydrometallurgy and Analytical Services.

CRDL has been instrumental in bringing many process changes and utilization of waste which includes gainful utilization of 100% of fly-ash and slag.

Focus on Sustainability Environment, Occupational Health, Safety and Community Service Hindustan Zinc has been globally ranked 1st in ‘Environment’ and overall ranked 5th in Dow Jones Sustainability Index amongst Metal & Mining sector globally. The Company has a strong focus on sustainability.

The Company has strong focus on conservation of water and energy and all the plants operate on zero-discharge and moving steadily to zero-waste. The most friendly global environment technology has helped Hindustan Zinc to become one of the most admired Zinc company in the world.

Research and Development Hindustan Zinc’s Silver Renery at Pantnagar

Silver of India – India to become Top 2nd Largest Silver Producer Globally With current production capacity of

Hindustan Zinc has a state-of-the-art ‘Central Research & Development Laboratory (CRDL)’ which was established by the Company in 1976.

The principal focus areas include process improvements, developing quality assurance systems, research &

Development of local communities has always been the prime focus of Hindustan Zinc. The objective is to build a life of dignity for the rural poor.

The Company has always had strong focus on child care, rural women empowerment, agriculture & livestock

development, education, training of rural youth for gainful employment, to name a few.

Special Projects by Hindustan Zinc

Sewage Treatment Network in Udaipur Hindustan Zinc has set-up Udaipur’s first ‘Sewage Treatment Plant (STP)’ under Public-Private-Partnership model. Initially this STP had the capacity to treat 20 million litres of sewage per day which is now being expanded to 60 million litres of sewage treatment per day. With the expanded capacity, the Company expects to treat almost 100% of Udaipur’s domestic sewage.

inculcate the importance of safety at the very young age.

Additionally, through association with All India Radio – Rajasthan, the message has reached out to almost 100% of radio-listener population.

Honourable Union Minister for Road and Transport– Shri Nitin Gadkari Ji, along with a number of Rajasthan Ministers, Collectors, SPs and other government officials of Rajasthan Government have endorsed the message on Road Safety.

Through this project, Hindustan Zinc is making all efforts to propagate safety in the State and envisions the goal to make Rajasthan an accident free-State in India.

Shiksha Sambal - Bridging Gaps in Rural School Education

Football Academy – The vision to develop 10,000 Football Players in Rajasthan

Be Safe Zindagi – Safety Beyond the Business Boundaries Hindustan Zinc considers safety to be its utmost priority. Regular Town-Halls lead by senior management have brought safety as the prime focus area.

The Company’s safety project – Be Safe Zindagi was launched to drive safety in industries and also on the roads, particularly in Rajasthan. With the objective of imbibing safety through informal interactions with the employees, their families and the school children, the project has brought forward the value of life & belongingness towards one’s family & organization. A number of workshops have been conducted in schools to

whereby talented footballers from Rajasthan, both boys and girls, can get an opportunity to get trained and play for the Indian National Team. The Academy would provide international standard training facilities with ‘F-Cube’ Training and Assessment Technology, the world’s first intelligent and interactive device for football and fitness training, skill assessment, cognitive development, practice and also factor in important parameters like skills, nutrition, physical, psychological and mental development.

Hindustan Zinc has been associated with sports and has been promoting sportsmen for almost 4 decades when the company made its football stadium at Zawar in Rajasthan in 1976. Since the last 40 years, National Football Tournaments are being organized every year at Zawar Stadium. The company has also supported several athletes in the past who have brought numerous laurels for the country in international events. With this thought, Hindustan Zinc has set up India’s first, below 12 years, international level ‘Hindustan Zinc Football Academy’ in Zawar, near Udaipur.

Hindustan Zinc Football Academy is fully residential and world-class technology based Academy which provides a 360-degree holistic platform

Shiksha Sambal provides a platform that empowers rural students to pursue their dream of obtaining higher education and joining prestigious institutions to play an important role in development/ progress of the country in future. Shiksha Sambal is reaching out to more than 57 schools in 5 districts of Rajasthan - Chittorgarh, Bhilwara, Rajsamand, Udaipur and Ajmer. By now, more than 6000 students have been benefited wherein 150 teachers, 80 Field Instructors, 50 HZL employee-volunteers and resource persons from Vidya Bhawan Society are engaged in strengthening the quality of education.

Hindustan Zinc Mining Academy - Developing Skills in Rural Youth of Rajasthan To train ITI pass-outs in mining operations, Hindustan Zinc has set-up a state-of-the-art ‘Hindustan Zinc Mining Academy’ that is training rural

The new mega infrastructure development that is happening in India today, with the use of steel, should only use galvanized steel for strength and long life

growth – as billions are spent on replacement and maintenance due to corrosion.”

youth in Jumbo Drill Operations.

‘Hindustan Zinc Mining Academy’ and ‘Hindustan Zinc Football Academy’ are perhaps the first academies of their kind in India.

Sunil Duggal, CEO of Hindustan Zinc and the man behind the mission of galvanizing Indian economy says, “India’s potential is hidden under corrosion and Zinc can play an important role in sectors like railways, automobiles, energy network and coastal infrastructure, impacting GDP’s

“Zinc is the metal that is the backbone of several global economies fighting to erode the continuous losses occurring due to corrosion of infrastructure.

Western countries, which are far ahead of India in terms of infrastructure, mandate the use of galvanizing for the steel structures used for bridges, highways, airports, metro stations, railway stations, transmission etc.

If these vulnerable sectors mandate to address the issue of corrosion and related safety, it would lead to not just efficiency and savings worth millions of dollars for the Indian economy, but also build a long-lasting infrastructure.”

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A DiversiďŹ ed Infrastructure Conglomerate

UTKARSH

COMPANY OF THE MONTH

Utkarsh Bansal Director

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DECEMBER 2018

U

tkarsh India Limited is a label in the infrastructure domain.

This 30-year old conglomerate is uniquely poised attaining leadership in every area of their operation. They are driving the growth in Steel Tubes, PVC Pipes, HDPE Pipes, Railway electrification, Poles, Towers and Crash barriers. Constant evolution and innovation are the pillars of their sustainability in the ever-growing, competitive Indian infrastructure sector.

Infrastructure is the backbone of any growing economy, and the same holds true for India, as well. There were many names and groups that formed, but a few survived in this competitive sector. Utkarsh, however, not only survived but also became a label in the infrastructure domain. The focus on innovation and expansion along with the commitment to quality and excellence helped them achieve this milestone in such a short span of time.

The Driving Force, The Guiding Light Behind Utkarsh Propelling the advancement of Utkarsh India Limited is the organisation’s vision and its dynamic, strategic planning. The ISO 9001:2015 certified responsive manufacturing conglomerate believes in “Life Demands, We Deliver” ideology. In this ever-changing, fast-paced culture, the philosophy of continually updating its methodology, technique, and products is helping them stay in demand. With new age technology and customer-driven approach, Utkarsh India Limited continues to remodel and reinvent itself. This approach, in particular, is the driving force behind their growth.

The Vertical, The Horizontal Successful Foray of Utkarsh It all started three decades ago when the present day Utkarsh India Limited DECEMBER 2018

was christened as Utkarsh Tubes and Pipes Limited. Embarking their journey with the production of MS and GI ERW pipes in 1987, the manufacturing roots of Utkarsh are traced back more than 30 years ago.

With an overwhelming market response, there was no looking back for Utkarsh India Limited. Year after year, decade after decade the company continued to grow and expand. In 2001, they became the first BIS License holder of IS: 2713 in Eastern India and first ISO: 9001 company as the pole manufacturer in India. After that in 2003, the company ventured into PVC pipes and fittings manufacturing, followed by production of Octagonal Poles and High Masts the following year. In 2006, it expanded its foray into the telecom vertical commencing the production of Telecom Towers, Transmission line Towers, and Substation Structures.

After stabilising themselves in the new areas of operations, they took another gigantic step in 2011 by starting the production of CORE approved Railway Electrification Structures for OHE and TSS. Two years down the line in 2013, the Power Grid Corporation of India Limited approved the supply of Transmission Line Towers and Substation Structures.

Then the year 2014 will remain special and memorable for the organization as they launched a world-class manufacturing facility at Gurap plant.

The use of state-of-the-art facilities and the latest automation makes this facility unique. In 2015, they also started “W-beam” and “Thrie-beam” Crash Barriers production. With the considerable growth and substantial expansion, the company rechristened from “Utkarsh Tubes and Pipes Limited” to “Utkarsh India Limited” in 2017. From being a pipe manufacturer, they became the leader of various infrastructural products, gaining a

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Contributing significantly in the development of better and robust infrastructure, and carving India's new image on the global foyer

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name in the industry as a critical player and setting their forte in several new arenas.

Innovative & Value-Based Product Line for New Age India by Utkarsh The revenue of Utkarsh India Limited is reaching 1000 crores in a span of 10 years. This formidable growth attributes to their innovative product line, customer-centric approach, and evolving technology. Almost every year in the last two decades, the company is expanding and launching new value-based products. Their innovative launches contribute significantly in the development of better and robust infrastructure, carving India’s new image on the global foyer. They are facilitating power transmission, its distribution, and rural electrification. In their endeavour to provide well-lit streets and roads, the range of Polygonal Poles and Lighting Masts is commendable. Likewise, for road safety, Utkarsh is striving for Crash Barriers par excellence.

To set new benchmarks is infused in everyone at Utkarsh. While their growth story mentioned above clearly implies it, their annual production capacity across the seven verticals and yearly increasing turnover are further reinforcing it. The annual gross turnover of the company reached INR 850 crore in 2017-18 and below is a snippet of their sectoral performance.

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• Steel Tubes: Utkarsh India Limited is into manufacturing of steel tubes for liquid, gas and sewage, structural purposes and conveyor belts. The annual production capacity of steel pipes is 120,000 MT. • PVC Pipes: Producing cPVC pipes and their fittings, column pipes, uPVC pipes, and ribbed strainers, they are known for producing quality and reliable products and one of the largest plant in the Eastern Region. The present annual production capacity is 30,000MT. • HDPE Pipes: Utkarsh India’s HDPE plant is equipped to manufacture pipes in diameters ranging from 20 mm to 315 mm. The total processing capacity of the plant is over 6,480 MT per annum. Pipes of pressure ratings ranging from 2.0 kgf to 20 kgf are manufactured.

Utkarsh India Limited has the capabilities to process all three grades of HDPE – namely PE 63, PE 80 and PE 100.

• Poles: There are different kinds of poles manufactured

by Utkarsh India. Among others include designer poles, lighting high mast, flag mast, signage mast, polygonal or octagonal poles, transmission poles, conical poles, solar and swaged poles. Designer and utilitarian, these poles go a long way in electrifying and adorning the modern day India. Utkarsh is a market leader in this sector and produces 1,00,000 Octagonal Poles and 12,000 High Masts annually.

• Transmission and Telecom Towers: Manufacturing transmission line towers, substation structures, telecom towers and facilitating rural electrification, Utkarsh India has been a part of bringing electricity in every nook and corner for years. Today, they manufacture 60,000 MT of Transmission and telecom towers annually.

• Railway Electrification: Producing OHE and TSS mast, they are the foremost manufacturers of this sector with 60,000 MT annual production.

• Crash Barriers: In the endeavor of road safety, the company is into manufacturing crash barriers and other road safety railing systems. It became a leader in this sector in a short span of time and has an annual capacity of 36000 MT. The Global Outreach, A Global Name A preferred and established infrastructure manufacturer in India, Utkarsh India Limited also enjoys a global presence with a vast customer base in various continents and countries. Their global outreach and export base extends to UK, Belgium, Germany, Australia, Canada, New Zealand, Poland, Lithuania, Northern Ireland, Iraq, Kuwait, Madagascar, Reunion Islands, and UAE among others.

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There are various bridges, houses, roads, buildings that stand tall for years, thanks to the beautifully engineered products of Utkarsh. It is their innovative and quality product line that makes Utkarsh a preferred infrastructure manufacturer in India and the world over.

The company strives to cater to its customer base according to the requirement in keeping with the best industry standards. Utkarsh doesn’t compromise on the resources and deliverables. Their quality products have stood the test of time over the last three decades. They have the CE certification for exporting to European Union from the United Kingdom, Dubai Civil Defence approval for exporting to Dubai, Qatar Ministry of Interior Approval for export to Qatar and UL Listing for exporting to Middle East Market.

Sustainable Solution, Always Headquartered in Kolkata, the company is sensitive to the cause of increasing environmental degradation and pollution. In their endeavor to provide a beautiful nature and mother earth to the coming generations, they maintain the highest standards of waste treatment. They are also accoladed with “Zero Discharge Plant” certification by the West Bengal Pollution Control Board.

The Leaders behind This Infrastructure Edifice Making Utkarsh India Limited what it is today, are the strong, relentless leaders who have given a purpose to many and had a vision of Make in India, three decades ago. Mr. Sunil Bansal, the Chairman and Managing Director, had launched Utkarsh Tubes & Pipes Limited in 1987. A seasoned leader, he had over 25 years of industry experience and laid the foundation of this organisation.

Taking it to new heights and making it relevant for modern times is the vision of Utkarsh Bansal. The Director - Business Strategies, he accomplished a Bachelors in Science in Industrial Engineering Operations Research from the University of California, Berkeley and a post-graduate in Business Administration from the Indian School of Business. He is the man behind the novel technology introduction and dynamic strategies that have seamlessly taken Utkarsh Tubes & Pipes Limited to Utkarsh India Limited. Mr. Utkarsh Bansal has shown exemplary confidence and facilitated the impeccable transition of the business’s core strengths and competencies to various new domains establishing it as a modern infrastructure firm with traditional values. He has the vision, the entrepreneurial skills that will leverage Utkarsh India Limited to greater heights and a new dawn.

DECEMBER 2018

INTERVIEW WITH INSIGHTS SUCCESS

MICROSIGN PRODUCTS A NEW SIGHT TO THE MANUFACTURING ARENA

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atering innovative solutions, one-stop shop for diversified manufacturing requirements; Microsign Products is one the leading manufacturing company. Mr. Nisheeth Mehta is the Founder and CEO of the company. He established Microsign Products with an approach to “Human Engineering” which enabled him to achieve maximum efficiency by mostly employing physically-disabled people. To get more details about the services and uniqueness which Microsign offer, we bring you an exclusive interview with Mr. Nisheeth.

1. Kindly brief us about your company.

Microsign Products is a leading manufacturer of plastic fasteners like cable ties, clips, clamps and markers in India. It is established in 1979 by Mr. Nisheeth Mehta.

The company's manufacturing unit is located at Neswad, near Bhavnagar, Gujarat. It is state-of-the-art setup that includes injection molding equipment from world renowned manufacturer like BOY Germany and Fanuc Japan. The injection molds are bought from Taiwan, China and leading mold manufacturer in India with latest technology having features like auto trimming and auto ejection. The company has a clear focus on productivity and zero defect quality.

Microsign Products quality management system conforms and certified as per Automotive Quality management System Standard IATF 16949:2016 (International Automotive Task Force). It is certified by Bureau Veritas Certification for last two decades.

Microsign Products environment management system conforms and certified as per ISO 14001:2015.

Microsign Products has robust quality management system and there has been no system failure. Company believes in continual improvement in its approach. The improvement projects effectively implemented in the areas of quality, productivity and energy conservation

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clearly demonstrate the involvement of top management and entire team.

2. What are the different products and services provided by your company, which is setting you apart from your competitors?

Microsign Products is created by Mr. Nisheeth Mehta with clear focus in meeting automotive industries requirement of import substitution of plastic fasteners.

Even today most of the products are customer specific and are developed to meet their need.

The company caters to automotive, defense, aerospace, telecommunication, electrical, electronic and packaging Industries. Microsign Products also manufacture products that meets LCSO standard under JSS-54807 & JSS-54808 Ministry of Defense.

Products are made from Nylon 6, Nylon 66 or any other industrial plastic specified by customer and are available in various colors. Products are classified into following family; • Cable Ties (Releasable, Non-Releasable, Push Mount facility and Marking facility) • Clips and Clamps with or without adhesive back • Assembly Products • Customer specific Products 3. Brief us about the Founder/ Director /CEO, and what was the source of inspiration for your company to be in the Plastic Industry.

Mr. Nisheeth Mehta on completion of his engineering migrated from Mumbai to Bhavnagar, a then small town of Gujarat to start business. He founded Microsign Products in the year 1979 and started manufacturing plastic items for Indian Railways, Aeronautics establishment and Automobile industries.

In the year 1988 he taught of an innovative initiative of

DECEMBER 2018

Nisheeth Mehta Founder & CEO Microsign Products

DECEMBER 2018

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offering employment to deaf and mute people. On making them comfortable with industry environment and providing adequate training they were assigned to operate injection moulding machines which were little noisy due to high pressure hydraulic. The initiative was a great success and his belief was firmed up that such people are not the liability but assets to the organization. He continued experimenting people with other disabilities and started finding a work match for them in various processes of plastic injection moulding. Mr. Mehta asserted that he did it not for charity but gave them an opportunity to show that they are not different from others and they can do everything just fit them into your need. Slowly and steadily differently abled employees strength started increasing along with business. Today the strength of differently abled employees is around 60% which includes deaf and mute, mentally challenged and physically challenged people who work on machines and other various supporting activities.

Microsign Products under Mr. Nisheeth Mehta, CEO is deeply involved in CSR activities for last four decades.

The engagement of differently abled persons in factory is personally mentored by him. He is also heading a development centre in Bhavnagar. The key objective of centre is to identify and nurture the hidden youth talent and mobilize their energy in right direction.

Mr. Nisheeth Mehta for his tireless effort in society building has been appreciated, awarded and felicitated at national as well as at international level. National Presidential award to outstanding employer for the people with disabilities for the year 1999, The NCPEDP Hellen Keller award for the year 1999, FICCI outstanding achievement in empowerment of physically challenged for the year 2003 – 2004, CNN IBN Real Heroes award for the year 2009 are the few to name. A business case study on Microsign Products is registered at Indian Institute of Management, Ahmedabad (IIM-A) and is reviewed and analysed in their various forum and training program. Also case study on Microsign was awarded with 3rd Best Paper during International Conference on CSR and Sustainable Development for the year 2013 at Thailand.

Mr. Nisheeth Mehta recently during 2016 received appreciation for his CSR activity when he was invited for a talk show “Aaj Ki Raat Hai Zindagi” hosted by Mr. Amitabh Bachchan sponsored by Maruti Suzuki and Cadburys India on Star Plus. The program idea was

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adopted by Star Plus for Indian individuals contributing in nation building at personal level.

4. What are few of the challenges faced by the company in the plastics industry, today?

Cost competitiveness is the major challenge the plastic industry is facing today mainly due to import from China. To remain competitive one has to invest on multi cavity molds around five times more than existing capacity. To run these multi cavity molds a higher tonnage and bigger injection moulding machines are required which is again very expensive. The players who can invest can only sustain their position in market.

5. What is the technology used in manufacturing your products?

Microsign Products has state-of-the-art manufacturing technology that includes injection molding equipment from world renowned manufacturer like BOY Germany and Fanuc Japan. The machines are equipped with servo motors and latest controller. The company has inhouse product concept design cell. The injection molds are bought from Taiwan, China and leading mold manufacturer in India with latest technology having features like auto trimming and auto ejection. The company is well equipped with inspection and test facilities for dimensional inspection and performance testing.

6. Share with us how the company is contributing to its sector in the industry and what makes you a unique player in this field?

Microsign Products is unique in having a very large market segment like automobile, defense, aerospace, telecommunication, electrical, electronic and packaging Industries. Microsign Products also manufacture products that meets LCSO standard under JSS-54807 & JSS-54808 Ministry of Defense.

Microsign Products elite customer segments are Railways, Aerospace, Electrical and Electronics Equipments, Packaging, Ship Building and Defence.

7. Kindly explain us your advantages over your peers.

Microsign Products enjoys a very healthy business relationship with all its major customers. In many cases

DECEMBER 2018

. the relationship is more than three decades. Microsign Products is the preferred source by many customers for development of new products.

Microsign Products is strategically located at Bhavnagar, Gujarat which is in close proximity to automotive hub. The city is well connected by road to all major customers.

Microsign Products is well conversant with quality and dispatch requirements of all OEMs and other corporate sector.

8. What are the benefits gained by your clients while doing business with you?

Customers get zero defect quality at competitive price and quickest delivery. At few places stocks are maintained at transporter end and small batch deliveries are made to customers.

DECEMBER 2018

Microsign Products is proud single source to many customers. This is the result of many years of confidence building with customers.

9. How do you see yourself and the company in the future ahead?

Microsign Products is planning to enhance manufacturing capacity in existing customer – product base to three folds in a span of five years and also looking forward for entering into various other plastic injection moulding components like packaging seals, insert moulding components and any other areas where plastic complex components are required.

Microsign Products is also exploring for tie up with overseas business partner or investor who wish to invest in equipment and tooling. We would prefer to have business partner from our sector who is ready for investment and also willing to share customer base globally.

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10

MOST ADMIRED

COMPANIES IN

MANUFACTURING

Cosmo Films

INDUSTRY

Digitally Transforming the Manufacturing World

I

n India, the manufacturing sector is growing at a healthy pace and all the key economic indicators are predicting further improvement. It has become crucial for manufacturing companies to redesign and redefine the manufacturing process with the use of available technologies to sustain and grow in the market.

Established in 1981, Cosmo Films Limited is on a mission to redefine the manufacturing process by embracing cutting-edge technologies like IoT and Machine Learning.

It is a pioneer in BOPP film manufacturing, which introduced the country to commercial applications.

‘Engineered to Enhance’ is what best describes Cosmo Films. Currently, the company is among the global leaders in delivering speciality films for packaging, lamination and labeling applications. Its offerings include biaxially oriented polypropylene (BOPP) films as well as cast polypropylene (CPP) films. The company has successfully implemented CRM to enhance overall customer experience by providing complete visibility right from the order receipt to order dispatch.

setting up Cosmo’s first plant in Aurangabad in 1981.

Ashok has been on the board of several academic and industry institutions like IITs (Indian Institute of Technology) and FICCI (Federation of Indian Chambers of Commerce and Industry).

Along with Ashok, another significant persona in the core team is Pankaj Poddar, CEO of Cosmo Films. He is a qualified Chartered Accountant, who took charge of the company in 2011. Under his aegis, the company has achieved various milestones such as being felicitated as “Top 25 Value Creators in Fortune’s Next 500 Companies”, being recommended by experts in “Top Ten Multibagger Midcap Stocks To Buy in 2017” and marking a presence in the “Top 500 Companies List” published by renowned media publications. Association of Business Communicators of India has conferred Pankaj with the “Indian CEO of the Year Award in 2016” and recently he was also awarded with “Young Business Leader” by Zee Business in 2018”.

Cosmo Films – A Perfect Example of Distinctiveness

Cosmo Films’ sheer determination and unified efforts is what positioned it amongst the largest exporter of BOPP films from India. Today, it is also one of the largest producers of thermal laminating films in the world. Apart from the widest portfolio of speciality BOPP and CPP films, customers recognize Cosmo Films for its customized innovation that it provides them by successfully maintaining strategic relationship with a customer-centric approach. Over the years, the company has effectively spread its wings and developed five state-of-the-art manufacturing facilities globally and built a strong customer base across more than 100 countries.

“We at Cosmo Films have always focused on speciality segments and increasing its occupancy in the products baskets through continuous product innovation,” asserts the core team.

The company is consistently working on product innovations as well as tech-based innovations in order to stay ahead in the game. It believes in taking advantage of technological advancements and has adopted digitization, automation and robotics in its manufacturing facilities to increase productivity. Cosmo has converted every challenge into opportunity with its unique approach that showcases:

Meet the Industry Veterans Ashok Jaipuria, Chairman and Managing Director of Cosmo Films is a visionary entrepreneur and philanthropist.

He pioneered BOPP Films manufacturing in India by

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Leading through Innovation – The company primarily focuses on recognizing customer’s unmet needs and then customize innovation to fulfill that need. Its experienced and dedicated R&D team works tirelessly towards DECEMBER 2018

’’

Cosmo believes in creating symbiotic relationships with its clients to enrich mutual growth at its best

’’

Pankaj Poddar, CEO

only in terms of its product expertise but also recyclability.

Acknowledging the industry trends and complexities, the company has been working aggressively with brands to provide them with structure rationalization solutions for recyclability.

The strategies that the company follows to stay competent and move in the right direction include:

improving the product portfolio and is now working more hard to improve its speciality films portfolio. Recently, the company has set up a state-of-the-art R&D lab to complement its efforts. Now, it has R&D labs with most sophisticated equipments, one in India and the other one in the US.

- Focus on speciality films growth - Constant review of cost on zero budgeting basis - Diversification in related areas - Consistently expanding R&D base and bringing product innovation to the table

Digitization of Business Processes – Cosmo has been way ahead in adopting technology to increase business productivity. It has successfully completed SAP Database Migration from Oracle to HANA. The company has adopted cloud technologies like - SAP HANA Enterprise Cloud for mission critical applications and advance data processing, SAP Success Factors (HCM) for empowering and improving employee experience, and Salesforce (CRM) for enhancing customer experience.

Future Prospects

Customer-Centricity – It starts from creating customer classification clusters. For key customers, Cosmo has account management teams comprising of cross functional representatives. Focus on quality, sampling experience and constant communication with the customer are some of the other factors making Cosmo customer-centric.

Cosmo intends to become a packaging solution provider with variety of film substrates to offer. It has already ventured into the production of CPP films and has announced plans to install a speciality biaxially oriented polyethylene terephthalate (BOPET) films. It keeps upgrading the film capacity and in order to add value-added capabilities, a new coating line is soon to be installed.

Additionally, Cosmo is on its way to expand speciality sales.

Inclusive and Sustainable Growth – Growth at Cosmo has always been inclusive and sustainable in nature. Being a focused polypropylene player has helped the company not DECEMBER 2018

Cosmo Films Limited brings to the table excellent governance, management skills along with technology, quality products and historical industry knowledge qualifying ability to service the future growth of the industry. Implementation of AI for forecasting, robotics for process automation and machine learning for maintenance are already in process.

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EDITOR’S CHOICE

A

PREDICT

‘FAILURE’ BEFORE IT

OCCURS WITH THE

Power OF

‘PREDICTIVE MAINTENANCE’

M

achines need maintenance, and there are two popular techniques which everyone has heard of- preventive maintenance and corrective maintenance. However, there is one more innovative technique that is recently gaining attraction across manufacturing vertical, i.e. predictive maintenance. It is one of the most innovative methods to repair a machinery part before some failure occurs.

Predictive maintenance system diagnoses the real condition of components using vital performance metrics and predicts the failure in advance. This system work in tandem with IoT technology and help manufacturers to better understand the health of their machinery parts and also tell them when a particular machine will fail. However, there are countless benefits which a manufacturer can reap by installing a predictive maintenance system, but before moving forward, it is vital to understand the critical difference between preventive and predictive maintenance, which many people often get confused.

Preventive maintenance is based on time, events or meter readings and not on the actual condition of the

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machine. For example, the maintenance of our cars is an example of this time-based maintenance approach.

When its service triggered, it does not calculate the actual condition of the component (all the times) and thus leads sometimes to unnecessary maintenance fixes and costs. Contrary, predictive maintenance trigger maintenance based on the real working condition of machinery. It only triggers maintenance when there is a need with the help of innovative techniques like Vibration Analysis, Oil Analysis, Infrared Thermography/ Thermal Imaging, Ultrasonic Monitoring and Wear Particle Analysis. Such methods provide multiple benefits to the manufactures as described further.

Reduce Maintenance Cost When a machine gets defected or some parts become faulty then the company not only burdened with extra cost required for replacing/repairing those parts but their total maintenance cost get inflated since it depends upon many factors like maintenance department overhead, tools needed to maintain the equipment, labor cost, and the actual cost of replacing/repairing that machinery past. Many studies

DECEMBER 2018

reflect that by using predictive maintenance technique, an organization can reduce the maintenance cost up to 50 percent, sometimes even more than this.

Sharp Drop in Component Failure When organizations keep a strong vigil on the health of their equipment’s based on their actual condition, then the probability of unexpected catastrophic failure of machine parts reduce significantly (by approximately 55 percent). Before installing the predictive maintenance system, technicians check the frequency of failure of each part and then consistently monitor the failure rate for the next two years. Doing so helps the company to know the machine failure in advance in almost all the time. Studies reflect that such a system can reduce machine failure in nearly up to 90 percent of the times.

be the trigger point for servicing a component rather than old traditional methods. Doing such can increase the life of individual components and improve the service life of industrial plant machinery by an average of 30 percent. Moreover, it also avoids severe damage to the equipment as well as the other attached plant systems.

One extra benefit of using predictive maintenance system is its ability to calculate mean-time-betweenfailure (MTBF). It provides the vital statistics that determine the precise time to replace machinery and thus helps in increasing the service life of the machinery. Moreover, predictive maintenance automatically reduces the MTBF, and when it reached a point where maintenance cost exceeds replacement costs, it gives the sign to replace the machinery itself.

Enhance Workers Safety

Reduce Downtime In the event of any catastrophic failure not only do the machines come to a halt but productivity also gets impacted to an extreme level. Downtime ultimately affects sales and leads to significant revenue losses to the company. According to one report published by Information Technology Intelligence Consulting- 98 percent of the organizations incur a loss of over $100,000 due to a single hour of downtime. This is quite large and disappointing but no need to worry anymore as predictive maintenance system is there to help you out.

In one research it is found that predictive maintenance reduces the mean-time-to-repair (MTTR) by whopping 60 percent. Moreover, thus result in increased productivity with keeping loses as minimum as possible. Many manufacturers are thus using this system to leverage its benefits in reducing the downtime.

The Manufacturing industry is huge and diverse which work through the assistance of countless big machines. Many times sudden fault in the devices impact the safety and security of human lives who work inside the plant. A predictive maintenance system gives an early warning related to a specific device and thus significantly reduces the risks of destructive failure which can many times lead to injury or death at large. This is the reason; nowadays many insurance companies also offer extra benefits to factories that have installed a condition based predictive maintenance system in their manufacturing plant.

The overall benefits of installing predictive maintenance systems are enormous. Mostly, it increases the overall operational efficiency of the manufacturing and processing plants and, therefore, this condition-based innovative system is getting immense recognition in the manufacturing vertical.

Enhance Service Life of Components Each machinery component has its own life which requires maintenance throughout its life that too in regular intervals. However, doing untimely maintenance cannot help much in the long run.

Timely maintenance based on real condition should

DECEMBER 2018

29

INTERVIEW WITH INSIGHTS SUCCESS

MAYUR

UNIQUOTERS ONE OF THE LARGEST MANUFACTURER OF ARTIFICIAL LEATHER

1. Kindly Brief us about your company Mayur Uniquoters, has been a resounding success in the field of superior synthetic leather in India, replacing genuine leather in many markets. Mayur was borne out of high level of competence, commitment, stringent quality control measures and value addition.

Mayur is the largest manufacturer of synthetic leather/ PVC vinyl, using the ‘Release Paper Transfer Coating Technology’ in India. This state of the art coating line from Italy has special features like electronic thickness & coating weight controllers and double ventilation covers for precision. Company has come a long way in the past two decades from a meager production of 0.25 million linear meters per month, to an astonishing 3.05 million linear meters per month, through our 6 state of the art coating lines mostly from Italy in two plants situated at Jaitpura and Dhodsar near Jaipur.

Mayur is the first company in this sector in India with an ISO 9001:2015, ISO 14001:2015,OHSAS 18001:2007 & IATF 16949 : 2016 certification, which was very important if you were looking to cater to the automotive segment.” (IATF 16949 is an international technical specification for quality management systems in the automotive industry.)

• • •

•

With his leadership, the company has received following Awards and Accolades: Forbes Asia Top 200 Best under a Billion Company Award” in the year 2012-13 World Wide Achievers – Business Leadership Award 2014.

THE SECOND INC. INDIA innovative 100 – Certificate of Excellence” for being ranked amongst 30 Most Innovative CEOs, 2014 & smart innovation.

Institute of Economic Studies “UDYOG RATTAN

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AWARD to Chairman” and “ EXCELLENCE AWARD to company” – 2015.

2. Brief about the CEO/Founder of the company: Organization : Mayur Uniquoters Ltd Designation : Chairman & Managing Director Native Place : Fatehpur (Shekhawati) Birth Place : Jaipur, Rajasthan Place of residence : Jaipur, Rajasthan Mr. Poddar entered the Artificial Leather trade and distribution business in 1968, when he was 22 years old as a commission agent for the National Leather cloth Company. At that time, he used to supply to Hindustan Motors and Bata. Bata was a professionally managed company and so they had a very well defined procurement system for the raw material. Mr. Poddar with his visionary effort and suggestions led them to cut the inventory level to 1/4th and thereby increasing the profit margins. By 1976, he got distributorship for eastern India. In 1987, he started another business and laid the foundation of Mayur Leather Products Limited, for making industrial shoes to be worn by shop floor workers for a German company.

Mr. Poddar is planning to make all children of this area as to educate proud world citizens by investing in promoting top school facilities, higher learning tools, better hygiene, good health, nutrition meals, and playgrounds for sports in 100 schools of Jaipur district in coming 3 years with an aim of uplifting lives of 32,000 students.

3. Share your point of view on the current scenario of the Industry The growing demand of artificial leather is due to its appearance and flexibility in using lightweight product.

DECEMBER 2018

Poddar

Chairman & MD

Rising environmental concern along with discontinuation of animal species which are killed to obtain leather has led to shift the production to artificial leather. Hence, the global artificial leather market is expected to grow at 38.2 billion with CAGR of 7.9% from 2016 to 2022. PU based artificial leather is made up of coating cotton or soft polymer which makes it ideal for garment manufacturing. PVC is second faster growing segment.

These leather is made up of adding plasticizers and dyed to PVC so that fabric are made softer. Bio based artificial leather is growing market owing to strict regulations of government of using eco-friendly products.

4. What are the few challenges faced by the company?

Main challenge is competition from China. In India we manufacture PVC coated fabric for making artificial leather. In China most of the products are from PU coating which is very close to leather look like and very light weight and more eco friendly than PVC. MUL DECEMBER 2018

decided to go for making PU leather for which 25 acres land has been bought in Gwalior, MP. Construction is going on and if everything goes well, production will start in 2019.

A number of materials such as ocean leather, microfiber, cork leather, canvas, or textiles can be used as substitutes for synthetic leather. Therefore, the threat of substitutes is expected to be moderate as these substitutes have not witnessed large-scale production.

5. What are the innovative strategies that you are working on to thrive in the competitive market?

Expanding the customer base After forging strong relationships with leading domestic original equipment manufacturers and footwear manufacturers, company began working with global auto OEMs. Today, Mayur Uniquoters generates a big chunk of its revenues from overseas markets—it is one of the

31

biggest exporters of synthetic leather to competitive automotive markets like USA, where conformance to customer specifications is a must. In fact, the company is the only one from India to supply synthetic leather directly to American carmakers—Ford and Chrysler Corporation. That apart, Mayur Uniquoters exports its products to Belgium, Russia, Sri Lanka, Saudi Arabia, South Africa, UAE and UK. Keeping abreast of time Mayur Uniquoters’ foothold in the market is attributable to its world-class quality control systems (that comprise testing equipments) and its R&D wing that has the best engineering minds. Manufacturing is undertaken in compliance with domestic and global standards to ensure that the end product is of outstanding quality.

6. Which strategies do you follow to stay competent?

How are you shaping yourself to become a expertise in capital markets, technology, and trading platforms?

• Customer friendly product presence & penetration into the market has changed the presumption of people to utilize the benefits of our products suitable to their needs which was not the case before. MUL could achieve this by offering various innovate products which can be used for multiple purposes.

• Our great Focus on Research and Development:Rapidly progressing technological revolution has also created the need for the industry to focus on R&D and market intelligence to offer the right product mix to the market. Conducting R&D is woven into the DNA of our company as it will be the platform for innovations to flourish • Environment friendly approach:- Synthetic leather/textile industry consumes large amount of resources. Hence it becomes much more important to adopt the ‘green way’ for growth. The first step we have taken is building an Environmental Management system.

• Implementation of standard systems & processes: Implementation of standard systems & processes and lean manufacturing systems reduced/eliminated waste of the source thereby increased efficiency, better quality of products and resource optimization.

7. What are the benefits and support your clients is getting from your company in this fastest growing competitive world?

We are aligned with our buyers and treat them as partners to experience higher success rates, decreased risks and enhanced collaboration and innovation. By the efforts of our top marketing teams successfully aligned with their key buyers have resulted improved buyer capabilities of innovation, quality, reliability and costs/price reductions and agility to reduce risk factors.

Greater value has been achieved for both businesses, something that would be difficult to achieve if operating independently.

8. Kindly brief us about your strategies to tackle the competition in your sector. What steps are you taking to ensure that you continue to grow and develop MUL is concerned, we have always focused on new products in respect of quality, durability and new invention keeping in mind the requirement of customer.

In my view there are 2 important things in any business that is to be able to identify the customer’s requirement and satisfy the customer with required product. We have very strong marketing and R&D team.

We are very keen in quality control which has been achieved by way of keeping world class quality control systems having complete range of testing equipments of the world standards and has very good engineering team of R&D. Just to elaborate we are the only company from India who is supplying directly to US automotive companies – Chrysler and Ford & maintain very good quality. Last year, we had exported to automotive more than Rs100 crores worth business.

9. What can be expected from your company in the upcoming years?

The Key goals of MUL are to supply automotive OEM all over the world. This will happen gradually. We are in the process of venturing more and more in to automotive market and opening up European market. We have very good growth in sales for 3 years since we are selling to USA and going well in European market. Our motto is to keep our customer happy and act as soon as possible in case of problem or any development or any need for support. In MUL, every customer has to be treated like a “GOD”- no matter whether he is right or wrong. So our first principle is customer satisfaction.

We have business set up in USA & Mexico to cater to demands of customers promptly.

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DECEMBER 2018

10

MOST ADMIRED

COMPANIES IN

MANUFACTURING

INDUSTRY

Cotmac Electronics Offering Wide Range of Cost Effective Engineering Services

W

hat does a river lock system in Egypt have in common with a vegetable oil refinery in Ukraine, a hot briquette iron plant in India or a pharmaceutical Silicon Carbide plant in China? They all run smoothly on automation solutions from Cotmac Electronics.

Cotmac Electronics Pvt. Ltd (CEPL) incorporated in the year 1992 is one of the leading Solution Providers in the field of Industrial automation, Electrical systems. Cotmac offering includes designing customized solutions, systems engineering, manufacturing, development, installation and commissioning up to the complete satisfaction of customers. Pralhad Hage is the Managing Director of CEPL under whom the company has received many awards and accolades which includes The top 25 Innovative Organizations” from CII, ET NOW – “Leaders of Tomorrow Awards”, ‘D&B’-“ SME Business Excellence Awards”, SKOCH Achiever’s award, All India No1 award from Siemens, The Inc. India Innovative100 award.

A Persistent and an Ardent Leader Mr. Pralhad Hage is a graduate from College Of Engineering Pune, in the year 1988, in Electronics and Telecommunication Engineering. After having a short experience with Advani Oerlikon ltd, he started own manufacturing of Uninterruptible Power Systems and Industrial electronics equipment and joined Cotmac group to established Cotmac Electronics Pvt ltd.

Mr. Pralhad Hage has demonstrated his commitment towards society and environment by initiating various CSR activities in organizations. The few CSR activities initiated by him are: working to resolve water problems of farmers from remote villages, working for the cause of socially and financially deprived people, blood donation events, tree plantation events, distribution of laptops & study material to police children, financially support to people affected by natural calamities like drought, flood etc.

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Today Cotmac Electronics is a leading solution provider, electrical panel manufacturer in the country having annual turnover of more than Rs 250crores with manpower in excess of 550 people. Under the leadership of Prahlad, the turnover of Cotmac Group has been 300 Crs. It also manufactures all types of Control Panels which includes UL approved and CE certified panels. The organisation has also developed innovative product such as on-site Gas Generator (Hydro-Oxy gas) for various industrial application like cutting, soldering, brazing.

Finding its Strength in Industrial Customer The UPS manufacturer market became crowded and most of the customers were from non-industrial sector. The company realized its strength in serving industrial customer so looking at the strength and upcoming growing requirement of automation & electrical solutions in industries, CEPL eventually diversified into Electrical & Industrial automation business.

Till early 2000, the panel manufacturing and system integrator business was treated as proprietor owned business. CEPL took major leadership initiatives to transform proprietor owned culture to professionally managed business with focus on branding. It developed and established local branches as well as international operations for Cotmac Electronics in USA, Dubai, Singapore and Canada.

Finding the Perfect Balance To handle growth, it has implemented many system & procedure for strict control including the SAP implementation. The company has excelled in managing the perfect balance between controls and flexibility and has converted the challenge into company’s USP. “Large enough to be resourceful and small enough to be flexible” is one of the USP of CEPL.

DECEMBER 2018

’’

The Cotmac Group of Companies combines strong business ethics with global best practices to consistently deliver excellence

’’

Pralhad Hage, Managing Director

The managing director believes that the extensive industry experience of promoters in the industrial industry and diversified customers bases have resulted in revenue grew at above industrial average and maintaining the operating margin percent.

The company has forged strong relations with prominent customers, resulting in a stable order flow. Furthermore, company has benefitted from its established supplier relations, which ensure stable supply of raw materials at competitive prices, and at significant credit. Today with a strong all India branch network and few overseas branches, COTMAC is being looked as an Indian MNC and gained the status of “Trendsetter” in the segment and now looked as a role model by others.

Innovative Strategies Moving up in value chain by shifting from Electrical and automation system provider to “total solution provider” it realized that to overcome low entry barrier and price competition, the company needs to improve what it is offering. It has worked on below strategies to overcome these challenges.

It has come up to strategies where it focuses on developing technical capability to offer total solution i.e. design, engineering, development, project management, commissioning, training and after sales services. It has DECEMBER 2018

developed innovative product “On site gas generators” that generates oxygen/hydrogen gas from water for various application like soldering cutting, brazing. It is replacement of highly pressurized fuel gas cylinders (LPG and DA).

CEPL has also added new division to offer end to end solutions such as projects division to cater big projects, repairs and service to offer after sales services, engineering division to support out client from bidding stage, Robotic and vision system division to cater total requirement.

Mr. Pralhad says, People in Cotmac never take innovation as just a buzzword but it is part of their culture.

Innovation- A Part of Culture The organisation has taken continuous efforts to have an innovation encouraging culture by having flat informal organization structure. By encouraging all employees to come out with creative ideas, opening and strengthening communications between senior executives and the customers to get a better of sense of market trends, becoming more tolerance for mistake.

As the technologies and industries are revolutionizing, COTMAC today is poised for a big leap in the new era.

With focus on new technologies the organisation wishes to offer the latest solutions to the customers like intelligent panels and IOT enabled products which will benefit them by delivering extra value to solution. The Cotmac vision is “To be preferred industrial Electrical & automation solution provider globally and reach a global rank of top 10”.

As the trend in the industry is anticipated to shift towards IT based solutions. Anticipating future trend, company has started associating with companies who have developed IT based solution for manufacturing and process industries.

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EXPERT’S VIEW

TECH-BASED INNOVATIONS

REVOLUTIONIZING THE

MANUFACTURING

T

echnology has transformed and influenced virtually every aspect of our life. The pace of technological development has changed the way we live and work. One of the major industries that have undergone a revolutionary change due to technology is the manufacturing industry. Rapid technological changes are shifting the manufacturing process to a mechanised one.

While this definitely spells growth, it also incorporates and inspires a change in way we deal with and understand technology. Moreover, it brings about a complete evolution of the entire production process.

Industrial robotics has evolved and so has its role in the process of manufacturing. Today, robots accomplish simple tasks such as welding, painting and even more complicated tasks. With efficient and technologically advanced programming methods, robots are trained to do much more than simple tasks. A varied number of industries today are harnessing the power of industrial robotics and reaping its benefits.

Along with industrial robots, another trend that has picked up in the recent times is 3D printing. The capacity to produce a tangible object based upon a 3D image has left the world awestruck. More and more manufacturers are trying to tap into this unique and customisable technology in the recent times.

Micro-manufacturing has impacted communication technology in a commendable way. Allowing for the creation of minute and tiny components in various devices, micro-molding goes hand in hand with micro-manufacturing.

WORLD

also helps in the simplification of processes and gets the product in the market quickly.

These technologies have significantly changed the way the manufacturing industry functions and also influenced the different stages of the production process. Most of these technologies have yet to reach their maximum potential.

Major technological giants are heavily investing in these technological advancements to improve the quality of their products.

Some of the steps that need to be taken in this direction are training the workforce, readiness to adopt technologies and deal with cyber security.

Overall, these digital technologies have altered the value chain. Converging technologies will pave the way for a workforce which is more digital and resource-efficient. In the future, digital technologies will be used to plan, create and optimize the product development process. Data will thus remain at the heart of the production process and technology will lead to greater productivity.

Automated workflow processes, advanced robotics, technologically advanced analytics are here to stay and dominate the manufacturing industry and increase its efficiency. Centralised manufacturing processes aided by technological advancements will lead to the creation of unique products for the consumers. The modernisation of the manufacturing process will then pave way for greater growth and economic development.

By manufacturing products digitally with the help of cutting edge technology and methods, many industries are able to cut down on costs and simultaneously increase efficiency. It

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DECEMBER 2018

About The Author Ashok Rajpal, Managing Director of Ambrane A skilled entrepreneur possessing great air for leadership and a powerful persona, Mr. Ashok Rajpal is the Managing Director of Ambrane, which has carved a niche for itself in the power bank sector in India.

Consistently setting new benchmarks and leading the company towards an upward growth trajectory, his entrepreneurial expertise and vision have always been his strengths.

Ashok Rajpal MD

DECEMBER 2018

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10

MOST ADMIRED

COMPANIES IN

MANUFACTURING

INDUSTRY

Universal Robots Pioneers of Collaborative Robot Technology

I

ndian manufacturers increasingly strive to adopt newer and more efficient practices to optimize their automation processes, and compete on a global scale.

Cobots, which are a part of Industry 4.0, therefore, fit hand-in-hand with what the Indian manufacturing market needs, and supplementing the growth. The demand for cobots in India is increasing as Indian manufacturers are looking forward to inculcating latest technologies in their production processes. The ease of use of cobots is unparalleled and we feel this product is an incredible fit in the Indian market. They are not meant to replace labour but collaborate with them. Universal Robots are looking to actively facilitate manufacturing activities across industries in India aligning its vision with various government initiatives.

The fact that the robot can be used as an extension of the human arm, cobots can be used for dangerous applications, where the human workforce might be at risk. The collaborative robots can also be incorporated in all manufacturing processes. The Universal Robots’ robotic arms can automate virtually anything; from assembly to painting, picking and placing screw driving, labelling, packing, polishing, gluing, dispensing, deburring, grinding welding, palletizing, machine tending and injection moulding and whatever other tasks you can think of and thus can be implemented virtually in any industry, by any operator without special robotic training.

Appealing Approach to the Manufacturing Industry The idea is for humans and robots to be inter-dependent and achieve what each of them does best, safely. The aim behind cobots is such that they are easy to operate and require human interaction ensuring the productivity of the employees, the quality of the products, making the production efficient and quick on a larger scale. This approach is particularly appealing to the Indian manufacturing industry because labor-intensive conditions and cobots together can help the Indian market achieve the

40

best of both worlds by making precise use of this distinctive technology.

Universal Robots is the leading manufacturers of advanced user-friendly and light industrial collaborative robotic arms (cobots) from Denmark. It entered the Indian market in February 2016 and since then it has been successful in deploying 400 cobots majorly in the automotive industry and its ancillaries, followed by FMCG, Electronics, and R&D centers.

Introducing Online Learning Platform Universal Cobots firmly believes that technology makes people more competitive and productive long term. So it wants to make this technology accurate for as many people as possible. The company is one of the 1st robotic companies who have started UR+ Academy. Universal Robots introduced the online learning platform to ensure that everybody with a desire to learn the concepts of cobots get the introduction necessary to master basic programming skills. If one logs into the website, UR Academy is there and it is basically free. More than 14,000 users from 132 countries have joined the Universal Robots Academy to become robot programmers.

The easy online training modules are built to deliver hands-on learning via interactive simulations to maximize your engagement. UR Academy is a completely free and interactive training program, which delivers hands-on learning that allows you to become a cobot programmer in only 87 minutes. The nine Universal Robots Academy modules are available in English, Spanish, German, French and Chinese. 43,000 courses have now been completed on the online training platform.

The Universal Robots’ robotic arms can automate virtually anything; from assembly to painting, picking and placing screw driving, labelling, packing, polishing, gluing, dispensing, deburring, grinding welding, palletizing,

DECEMBER 2018

’’

The Universal Robots Academy is a new online self - training program which provides engaging, handson experiences, simulations and interactive robot animations which helps acquire skills to program and operate a UR cobot without further assistance, which is available 24*7.”

’’

Pradeep David, General Manager

machine tending and injection moulding and whatever other tasks you can think of and thus can be implemented virtually in any industry, by any operator without special robotic training.

The Collaborative Robots The fact that the robot can be used as an extension of the human arm, cobots can be used for dangerous applications, where the human workforce might be at risk. The collaborative robots can also be incorporated in all manufacturing processes. Universal Robots currently hold 60% of the world’s collaborative robot market share. The company expects to continue having this strong hold on the market, staying ahead of competitors with our innovations.

The Commencement of Universal Robots The inception story of Universal Robots is incredibly interesting. In 2003, the three Founders of the company, Esben Østergaard, Kasper Støy and Kristian Kassow, together came up with the idea of creating a light robot that is easy to install and program as they could see that heavy, expensive and unwieldy robots where dominating robotics and there was a huge market for a more user-friendly option. In 2005 they officially founded Universal Robots, with the aim of making robot technology accessible to small and medium-sized enterprises.

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In 2008, the company sold its first product through distributers in Denmark and Germany. Within a year the company expanded its business in the entire European markets. In 2011 Universal Robots entered the Asian market with a local office in China and in next two years, Universal Robots established two subsidiaries, one in New York and the other one in Shanghai and also established a distributor network in South America and Oceania.

Making a Difference by Giving Back Universal Robots believes in giving back to the employees and thus, collaborative robots function as a helping hand to the workforce and not a replacement. Cobots function to increase the productivity of the workforce as they are accessible and easy to use, the employees too, are excited to work side by side with their robotic co-workers increasing efficiency along with the quality and quantity of production.

While being the very pioneers of collaborative robot technology already gives us the edge in this market, our other innovative ventures include Universal Robots+ and Universal Robots Academy. UR+ is also a unique platform, and functions as an online store showcasing UR certified products from around the globe, all of which are designed to equip our cobots to work flawlessly for your application/requirement. This includes everything from end-effectors and accessories to vision camera and software. This results in a fast, smooth, and low-risk integration for a reliable and easy operation.

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GUERR I MARKE LLA TING

THE NEW-AGE MARKETING TECHNIQUE TO CREATE A PROFOUND EFFECT ON TARGETED AUDIENCE

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dvertisements are not new for this world; it is in use since 4000 BC. In the ancient times, business persons use advertising medium to express their sales messages, product information and

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special offers through wall posters. Time changes so thus the marketing techniques, in 1960’s; businesses started using different mass media channels such as radio and print to promote their products and services. It was late 80’s and early 90’s when advertising industry saw a gigantic change when television started promoting businesses through its TV screens. Now in the current times, deep penetration of internet and mobile technology into the remote pockets of the world, social media has emerged as a king of advertising vertical. Marketing persons now-a-days using social media platforms like: YouTube, Facebook, Twitter and others to promote their services/products.

Among many marketing techniques, guerrilla marketing is a way to connect to the targeted audience in no time.

Promoting a brand/product/service with an unconventional tactics that too in a small budget is what makes it unique and popular among marketing agencies. The main goal of this technique is to do whatever it takes to gain customer’s attention and educate them regarding the products and services in an engaging manner, way apart from the conventional means of advertisement. This term: ‘Guerrilla Marketing’ was first coined by ace marketer Jay Conrad Levinson in 1984 and since then it has been a favourite medium amongst the marketing teams to yields maximum results.

This marketing technique relies heavily on creativity, high energy, and imagination where every effort leads towards creating something unique that can surprise the consumer.

Guerrilla Marketing makes an indelible impression on the consumer’s mind and creates copious amounts of social buzz in all arenas. This technique is touted to be one of the finest form of advertising amongst all due to the fact that most guerrilla marketing campaigns aim to connect the consumer at a more personal and memorable level.

Experiment of Coca-Cola: If one can look into the history of Guerrilla Marketing, it is quite obvious that why this technique is hugely popular. From smaller companies to multinational giants, everyone has got attracted towards it and gained immensely by this this means of product promotion.

Soft-drinks giant Coca-Cola did an experiment in 2010 to promote its product. The company with the assistance of one marketing agency crafted a “Happiness Machine”.

They placed this machine on St. John’s University in Queens campus in New York. The marketing agency also placed five different cameras to capture the immediate response from the end-users in an unscripted manner. What DECEMBER 2018

was new in this machine was that- it dispenses a way lot more than just a cold beverage.

When students saw this machine, they got benefitted with multiple coke’s, fresh flowers, and other mouth-watering eateries, which was obviously a surprise for everyone.

These other stuff, apart from cold beverage surprised many and garnered widespread attention in the whole campus.

Everyone was amused with the dispensation of multiple items from the vending machine. In fact, that video went viral on YouTube and till date it has garnered 4.5 million views with the greater penetration in Brazil, Mexico, Japan and Russia region. This staggering number of view count took everyone on surprise in the top management and after witnessing an amazing ROI, Coca-Cola decided to continue with that ‘Happiness’ theme by releasing numerous other videos using the same idea.

Experiment of UNICEF: Millions of people have no access to clean water and thus they have no option but to drink filthy water to survive. Every year, millions died across the world by suffering through water borne diseases like Cholera, dysentery, dengue, typhoid amongst other.

Every government is doing something or the other to provide its citizens access to clean water, but unfortunately, millions are still seems unlucky. The two things that are blocking the access of clean water to the people are necessary funds and other is the awareness regarding the disadvantages of filthy water. To alter this scenario and to provide some smile on those unlucky faces, UNICEF (The United Nations International Children’s Emergency Fund) developed an interesting idea. They thought to use Guerrilla Marketing technique to highlight this alarming issue. What they comes up with an idea to sell dirty water for a 1$.

Yeah! You heard it right. This what UNICEF did on the busy streets of New York to increase the awareness, raise funds and change perception regarding unclean water. They used a very touching campaign where they installed a filthy water vending machine and told end-users to buy unclean water. Although, no one bought filthy water but many donated a dollar or more to help those in need. That campaign was a huge success which not only raised money but also helped in increasing awareness, and changes the perception concerning unclean water.

Just like these examples, Guerrilla Marketing can also do wonders for your business if use in an innovative way and can potentially help your organization/product to earn a reputation for being different.

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