So how many quality checks does the ElectroMech shopfloor have? "Each process has different requirements for quality checks. We have well defined quality plans for each process and depending on the process either the process owner or the quality inspector carries out checks as per these quality plans." To make this happen requires complete engagement of the employees in the actual operations. "The self correcting system that we have put in place throws up a lot of instances where we realise we need to ramp up on the capabilities of our resources - men as well as machine.

When it comes to upgrading the employees' knowledge, during periodical management reviews we analyse the problem areas and then provide training to enhance the employee's knowledge of the process," shares Tushar. These reviews are done together with the process owners, the respective departmental heads and the top management. Hence everyone gets involved in determining the course of corrective action so that the quality issues can be eliminated.

Capabilities

The ElectroMech plant at Pirangut near Pune is one of the largest manufacturing facilities in the country for industrial cranes. Spread over 20 acres of land, it has a manufacturing area of 23,000 sq m. "We have implemented a piece flow process within our plant that enables us to have a capacity to manufacture easily in excess of 1500 cranes. This year we will be manufacturing in excess of 700 cranes and thus can claim to be the largest manufacturer of cranes in terms of volumes. Our semi-automated stacker crane system in the stores enables us to store all components in a systematic palletised manner and enables quick retrieval.

The plant is equipped with state of the art CNC Plasma cutting machines with an innovative vertical plate storage system that enables fast and precise cutting of steel used in fabrication of the cranes. We have semi automated welding systems that ensure a consistent and top class welding quality. We can also boast of one of the largest paint booth in the industry having a length of 50m and a width of 8m. This is a down draft type paint booth that allows us to paint multiple crane components at the same time. Our dispatch area is also unique and is serviced by a giant 42m span single girder gantry crane with a SWL of 20t that speeds up the dispatch process."