Format for Presentation of Best Practices (VLMi/VLCi)

1. Title of the Practice

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Visionary Learning Community of India (VLCi):

In order to facilitate the small & medium enterprises (SMEs) enhance productivity, the

Confederation of Indian Industries (CII) in collaboration with Japan International Cooperative

Agency (JICA) & by leadership of Anand Group of Industries launched a special programme

called Visionary Laghu-udyog Mitra Mandal (VLMi), which would see the CII and Nutan

Maharashtra Institute of Engg & Tech (NMIET) collaborating in training sector. The VLMi programme would see the faculty of NMIET being trained, who in turn, would train

the batch of SMEs in the area & college students.

2. Objectives of the Practice

The principle objective of VLMi is on Make in India for Indian manufacturing industries, so this

ambitious drive to succeed, the base of Indian manufacturing viz. MSMEs has to be

strengthened. VLMi is looking forward to make this happen in the involvement of educational

institutes with manufacturing transformation journey. The NMIET College would be offering the

subject as an open elective for its engineering students.

Objectives:

1. To introduce the concepts, principles and framework of contents of Toyota Production

System (TPS).

2. To acquaint the students with various productivity enhancement techniques.

3. To acquaint the students with different aspects of Production Planning and Control and

Standardization.

4. To introduce the concepts of material flow, tier structure as applied in industries.

5. To acquaint the students with different aspects of industries shop floor activities and

Industrial Safety rules.

Principles:

1. The industry transformation journey is based on Toyota Production System (TPS)

which comprises its management philosophy and practices. The TPS organizes

manufacturing and logistics for the manufacturer, including interaction with suppliers

and customers.

2. The VLMi transformation is based on Fish Bowl Principle by Prof Shoji Shiba. The

fish bowl principle is as follows:

The different genus of fish jump into common fish bowl & they follow their own

intuition to dive. The different fish swim mutually in fish bowl & then jump away to

see the new region after getting conversant with unknown area by learn & practice.

3. The Context

VLMi Transformation appearance is self–initiated bustle & it consists of four basic modules like

3S (Safety, Shorter Distance & Space), Vmap(Visual Map), Hei-junka(Leveling) & Standardized

Work which are supported by community based learning & college faculty involvement to

achieve the transformational outcome.

In order to have Industry ready students, NMIET Pune & GIT Belgaum have started working on

curriculum based VLMi tools for Engineering students. There will be an elective course—

Modern Manufacturing Concepts starting in 2nd semester. Basic outline of the curriculum has

been developed jointly by both the institutes under guidance of Mr. CS Patel. First content of

Semester 2 elective—Basic Observation Skills—Safety & Cleanliness is also developed. It will

help students to get familiar with observation skills using examples from home & public places.

VLMi Focus on following Practices:

1. Leadership Development

2. Skill Building

3. Learn-Apply-Learn Technique

4. Tools & Technique (3S, Vmap, Hei-junka & Standardized Work)

VLMi Transformation Model:

The VLMi 2016 batch consists of following community members (Industries) which are from

different regions of Pune such as:

1. COSMOS Constructions.

2. COSMOS Mechanical.

3. Shilpa Machinery.

4. Malhar Industries.

5. Nikhil Industries.

6. Gaurav Enterprises.

7. Mask Polymer

8. Manas Automotive

9. Dran Engineers

10. Abhijeet Engineers

11. Deepesh Pressings

12. NMIET(Academic Partner)

The VLCi(VLMi transformed to VLCi) 2017 batch consists of following community members

(Industries) which are from different regions of Pune such as:

1. COSMOS Constructions.

2. Shilpa Machinery.

3. Ultra Engineering

4. Venketesh Industires

5. Padmatech Industries

6. Shilpa Machinary Pvt. Ltd.

7. NMIET(Academic Partner)

8. PCCOE Ravet(Academic Partner)

9. PCCOE Akurdi(Academic Partner) 10. MM Polytechnic(Academic Partner)

4. The Practice

The VLCi transformation model is based on Learn-Apply-Learn Technique. The following are

the brief description of the transformation model tools:

1. 3S (Safety, Shorter Distance & Space) - The principle of the 3s map is to optimize the

material movement, formation of space by identifying possibility of space economy &

things to see the safety related issues. This tool focuses on material flow on shop floor. It

also includes the flow of measurement tools, information flow.

2. Vmap (Visual Map): The principle of V map is to understand & create the basis of Tier

Structure flow, create controlled flow in tier to build productivity & quality in to line or

cell. This map visualizes the flow of material in tier; visualize the facts & data, its

evaluation & productivity with flow improvement.

3. Hei-junka(Leveling): The Hei-junka is Japanese word which means leveling. The

principle of Hei-junka module is to optimize/minimizes the Fluctuations by Customer

Requirement as it reaches to subsequent tiers for achieving a smoother production flow.

4. Standardized Work- The principle of standardized work is based on assigning the right

work to every individual to small number of man power to minimize the unfair of work,

to increase the motivation of individual, increasing productivity & finding opportunity for

new skills.

The all module which are 3S Map, V-Map, Hei-Junka & standardized work are learned by

various participants of community at Visionary Learning Centre (NMIET) as per schedule.

Figure 1 Session at Visionary Learning Centre by Prof. Saideep Ratnam

The schedule is as follows: VLCI Learning Sessions Calendar-2017-18 – Pune (Batch-2)

The same module is then applied onsite & performed. The review sessions are conducted by

the following expert under guidance of Mr. C. S. Patel onsite or at Visionary Learning centre

(NMIET):

1. Prof. Saideep Ratnam.

2. Prof. Furuhashi san.

3. Mr. Sharad Anerao.

Figure 2 Sessions by Mr. Sharad Anerao at Nutan

Figure 3 Onsite Performance by Nutan Faculty

Constraints:-

The NMIET is affiliated to Savitribai Phule Pune University. The academic curriculum from F.E.

to B.E. is as per university syllabus which does not permit additional employability skill courses.

The add on courses such as VLCi or VLMi becomes complimentary course for mechanical

students. So to improve the employability skill of mechanical students, it is necessary to have

modern manufacturing approach awareness among students to minimize the gap between student

& industry, industry & engineering college, engineering college & student. The VLCi or VLMi

course outcome requires semester wise planning and implementation which takes more duration.

For example, refer following tentative planning of VLCi journey.

Figure 4 Community Meeting at industry

Prerequisite AUDIT COURSE for TPS Flow Concepts:-

• Generic Session – 0 can be administered to all 180 students of Mechanical Engineering

• Generic Session – 1 will be only for filtered 60 students of Mechanical Engineering

• Generic Session – 2 will be only for filtered 40 students of Mechanical Engineering

• Elective at 6th Sem. Introduction to Toyota Production System will be a prerequisite for the

Elective of 7th sem. namely TPS Flow Concepts.

The seventh sem. Elective courses will be for 3 credits and will have CIE 50 marks and SEE 50

marks.

However, the evaluation pattern will be as under:

1. CIE (50 marks): IA Test -10 marks, Industry Assignment (Case study presentation) - 30

marks,

Class performance- 10 marks.

2. SEE (50 Marks): Exam will be for 100 marks in 3 hours.

Question paper will have two parts.

Part A will be of 20 marks comprising of 3 questions of 10 marks each.

Part B will be of 80 marks comprising of case study. (The students will be given the

company as a case for study one day in advance so that they can visit and collect

required data for the exam)

5. Evidence of Success

The basic observation skill module was conducted for pilot batch of students, academic year

2016-2017, second semester by Prof. Nitin Jadhav under guidance of Mr. C. S. Patel (Mentor),

Dr. Rajendra Kanphade (Principal) & Anand Managers. The students of first year engineering

were selected for basic observation skill module. The numbers of participants were 105. The

session was conducted for group of 30 students. They learned by active participation the

importance of cleanliness, safety rules, 4W1H format of observation. The selected place for

observation was within college campus such as different floors, workshop, canteen, and hostel.

Pilot Batch Trial in DEC 2016:

The skit was performed by group of students of NMIET to create excitement about to know the

industry culture.

Figure 5 Skit on Industrial Safety

Figure 6 Pilot batch Orientation session by Mr. T. S. Rana(Anand Manager) for Nutan

Polytechnic by December 2016

Figure 7 Pilot batch session by Nutan Faculty December 2016

Student Performance of Observation task:

The student’s performed the task of observation. The theme of observation was on Safety &

Cleanliness.

Figure 8 Observation on Safety at Nutan Campus

Figure 9 Observation on safety in Nutan Workshop

Figure 10 Observation on Cleanliness

Figure 11 Class room session for FE 2016-17 Div P

Figure 12 Class room session for FE 2016-17 Div Q

Figure 13 Class room session for FE 2016-17 DIV R

6. Problems Encountered and Resources Required

The faculty training to implement the various modules such as observation skill, 3S map, V map,

Hei-junka is necessary & the onsite performance along with industry interaction is highly

recommended. The learn – apply & learn technique is useful to get conversant with different

modules.

The motivation for students is required to contribute in these additional courses because it has no

credit marks in academic. The enthusiasm conception among the students is essential to learn the

modern manufacturing approach, industrial culture, safety norms & its importance.

The resources required are as follows:

Trained Faculties

Industries Delicates

Physical

infrastructure/onsite