Ashok Leyland - Employee Journal - December 15, 2018

ASHOK LEYLAND | EMPLOYEE JOURNAL | DECEMBER 15, 2018
Table of Contents
Quality Month Kicked Off With a Bang Inauguration of the Reliability Expo 2018
Ashok Leyland Corporate Office Building Aim for the world-class launch of MBP
Ras Al Khaimah Plant, UAE The morale of the employees is at an all-time high
Hosur Plant 1, Tamil Nadu A conversation with Mr. R Sivanesan
Pantnagar Plant, Uttarakhand Think Value to Clients at all times
Bhandara Plant, Maharashtra Why So Serious? Line up for some Fun
Alwar Plant, Rajasthan Come On, Let's Go Green!
KLT Automotive, Thiruvallur Top cop addresses Ennore Team
Black Belt Program Children excelled in ‘Wealth to Waste’ project
Quality Pledge and Quality Wall: A Note to Self Reliability in every walk of life
Live with Customers 2018 Visualize your day, to walk with conviction
Highway Camp A pat on the back. Well Deserved!

Run now, Work later
Quality Month Online Quiz
Supplier SAMRAT
Skit/Nukkad competition
Nambikkaiyae Thumbikkai
Planting tree saplings
Blood Donation Camp

Table of Contents
IMPROVE 2018
A breakthrough to make the world less polluted
PD team @ VVC wins Gold after lifting wheels of top selling models
Reducing bottlenecks results in increase in capacity
Innovative design change on the Reaming machine and Aligning tool
Golden Peacock Award : A matter of pride and honour
Book Review
Holiday gifting at the workplace

Quality Month at Ashok Leyland has always
been a celebration of all the incredible work
happening across the organization spread over
the countries, and an opportunity for teams to
Quality Month learn from one another. Also, it is a time to ac-

knowledge and honour employees across the
Institution who work continuously to improve
Kicked Off With A the quality of the product while ensuring the
safety of customers.
Bang We, at Ashok Leyland, had come together to

kick-start the Quality month with some best
selling ideas from 1st November 2018. The
Quality Month celebration was organized on
the theme ‘Road to Reliability.’
HOME ZOOM IN ZOOM OUT FULL SCREEN DECEMBER 2018
Quality Month celebration across Ashok Leyland

Ashok Leyland Corporate Office Building Ras Al Khaimah Plant, UAE
Around 500 of our The Quality Month cele-
employees partici- bration at Ashok Ley-
pated in the Quality land’s UAE plant was
month celebration at kicked off by Mr. Ananda
Ashok Leyland Cor- Thirtha T J (Head – IAO)
porate Office Build- in presence of IO Senior
ing, with the event Management team and
live-streamed across all employees of Ashok
all units of Ashok Leyland’s UAE plant.
Leyland. Our Manag-
ing Director and CEO Mr. Vinod K Dasari took part in the celebration and After the inauguration, the senior management addressed the gathering by
invited employees to be a part of this journey towards achieving excellence stressing on the significance of quality of material, the reliability of the
and delivering internationally acclaimed quality. system and process improvements. The event ended with prize distribu-
tion to the winners of Quality Month competitions.
Mr. Gopal Mahadevan, President, Finance & Chief Financial Officer, Mr.
Harihar P, Senior Vice President - Manufacturing and Project Planning and Mr. Senthil Prabhu, Quality Head – Ashok Leyland Ras Al Khaimah Plant
Mr. R Sivanesan, Senior Vice President - Quality, Sourcing and Supply Chain and Mr. Rajender Kumar Gandhi, Sourcing Head – Ashok Leyland Ras Al
had also joined. Khaimah Plant had organized and coordinated the entire drive.
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Hosur Plant 1, Tamil Nadu Pantnagar Plant, Uttarakhand
Mr. Ramakant Sharma,
Head Quality - Ashok
Leyland Pantnagar plant
set the context of the
Quality month by sharing
an understanding of
“Road To Reliability” and
briefed about the various
activities planned during
the Quality Month.
Inauguration of the Quality Month was formally done by Mr. Rakesh Mital,
Quality month celebrations were kicked off at Ashok Leyland, Vice President (ALP, ALA & ALB) by hoisting the “Quality” flag. He also
Hosur Plant-1 in the presence of Mr. R Kalyan, Head - HR and Mr. shared his thoughts on Quality and inspired the team to keep moving on
T S Manjunath, Head - Manufacturing, hoisted the “Quality” flag “Road to Reliability” by highlighting everyone’s role in delivering quality.
and addressed the gathering. He also shared the challenges ahead especially in terms of BS VI, MBP and
further role of Pantnagar plant towards achieving Ashok Leyland’s vision.


Bhandara Plant, Maharashtra Alwar Plant, Rajasthan
Quality Month Quality Month was
c e l e b r a ti o n kicked off at Alwar
inaugural func- Plant with the lighting
tion kicked off of the lamp and “Qual-
in Ashok Ley- ity” flag hoisting by
land’s Bhandara Plant Head Mr. V C
plant in the Dwivedi in presence
presence of Mr. of all functional heads.
Lakhote, Plant The Alwar team had
Head - Bhanda- taken the Quality
ra. He hoisted the “Quality” flag, addressed the gathering and read out the Pledge to reiterate total commitment towards quality.
Quality Pledge.
Mr. Santosh Kumar, Head Quality - Alwar, explained the Quality Month
Mr. S B Joshi – Head, Manufacturing Services briefed the gathering on vari- theme “Road To Reliability” and briefed the team about the various activi-
ous activities/competitions planned during the Quality Month. The cere- ties planned during the Quality Month. All functional heads shared their
mony was concluded by signing on the whiteboard for commitment to qual- thoughts to make Quality as the way of life, to delight our customers and
ity, customer delight and realization of the company’s vision. all associated members including society to realize the Ashok Leyland
Mantra - “Aapki Jeet. Hamari Jeet.”


KLT Automotive, Thiruvallur Black Belt Program
As a part of Quality month A new initiative was
activities, SQ-FBVS had launched this year by
taken up initiatives to choosing 12 Execu-
hand hold the newly tives across the
established Fully Built organization after
suppliers by introducing rigourous elimina-
them to Ashok Leyland’s tions to take part in
culture of following No- the ‘Black Belt Pro-
vember as “Quality Month”. gram’ on Lean Six
Sigma spread over 12 months where they will work on various projects to
Quality Month inaugurations were done at KLT Automotive, Thiruvallur and enhance their problem-solving expertise and will be certified as ‘Black
Polyhose LLP, Gummidipoondi by Mr. Rajendran (Head – Supplier Quality ) Belts’ from Ashok Leyland at the end.
and Mr. Sekar M (DGM – Supplier Quality – FBVS) on 12th November 2018
respectively. A book on ‘Black Belt Program’ was released in the presence of our Manag-
ing Director and CEO Mr. Vinod K Dasari. He shared the copies of the
Mr. Rajendran urged the employees to take up small continuous improve- book with Mr. P Harihar, Senior Vice President - Manufacturing & Project
ments in their respective areas and promote a culture of “First Time Right” Planning, Mr. R Sivanesan, Senior Vice President - Quality, Sourcing &
among the operators. Mr. Sekar explained the Ashok Leyland theme for Supply Chain and Mr. Hemanth from Six Sigma.
“Road to Reliability” and activities planned for Quality Month.


Quality Pledge and Quality Wall: A Note to Self
Always exuberant The note by Mr. Gopal Mahadevan, President, Finance and Chief Financial
when it comes to Officer stated, ‘Continuously improve the outcomes and the journey.’
excellence, our em-
ployees committed Enjoying every bit of this event, the employees were happy to have an
to their goal of quali- event spreading the energy of motivation and oneness.
ty through a pledge.
A ‘Quality Pledge’
board was displayed
across all units of
the organization for
employees to sign on it as a token of their commitment to quality and ser-
vices. Another highlight of the day was the ‘Quality Wall’ set up in the arena
of the event. The employees were encouraged to put down their thoughts
on how they would like to develop and refine the quality of life and work for
themselves as notes on the wall.
The note by our Managing Director and CEO Mr. Vinod K Dasari read,
‘Achieve world-class level in Social, Environmental and Economic Goals. All
the best.’ Definitely motivating.


Live with Customers 2018 Highway Camp
Knowing how a customer Ashok Leyland’s Alwar plant orga-
drives our vehicles is key nized a highway camp on 22nd No-
to understanding their vember 2018 at Bhiwadi-Jaipur
requirements. To know Road with an aim to reach out to
better and gain insights, customers, as a part of the ‘Live with
three years back, Live with customers’ program. The camp was
Customers was initiated. formally inaugurated by Alwar Plant
Executives from various Head Mr. V C Dwivedi and Mr.
departments who share Venkat Kiran Kumar in the presence
their keenness is allocated a drive spread over 24 hours and drives around of the senior officials of Ashok Ley-
with the driver/owner of the truck right from loading to unloading materials land and Rajesh Motor Team.
in city, inter city or even over state lines. Food, Music and Feedback is
shared, discussed and a special bond is created over this drive. Vehicle inspection and minor repair work were done free of cost. More
than 65 customers participated and registered their feedback. The cus-
“We also conducted the ethnographic survey which is an online form with tomers were satisfied and the team at Ashok Leyland are looking at con-
readymade analytics of the customer feedback,” said Mr. Sriram B (ALCOB) ducting more such camps.
who organized the Quality Month program along with Mr. Amirtha Ganesh
(VVC).
Close to 150 drives have been planned spread over November and Decem-
ber pan India.


Quality Month Online Quiz Supplier SAMRAT
The Quality month In order to
online quiz was con- accelerate the
ducted on 12th No- improvement
vember 2018 where activities and
all employees of to recognize
Ashok Leyland, their suppliers who
customers and deal- make quantum
ers took part. The leaps, the "Sup-
quiz had around 30 plier Samrat"
Get your answers ready questions covering Competition was organised for the third successive year. This competition
various aspects of quality and reliability and some questions pertaining to was based on the improvements done by supplier partners in the catego-
Ashok Leyland. ries of Quality, Productivity & Cost.
Over 500 applications were received, and from that, seven winners were “We drive several improvement initiatives for our supplier partners. The
selected. This event was conducted online, and coordinators of different Supplier Samrat competition was conducted for South, West, North
locations awarded the winners in their respective locations. Regions for both Proprietary & Non-Proprietary suppliers. There were 213
suppliers who registered of which 96 were shortlisted for the presentation.
The winner from ALCOB was felicitated by our Senior Vice President - 18 suppliers were selected for the next level competition ie. "National
Quality, Sourcing & Supply Chain Mr. R Sivanesan. Supplier Samrat" scheduled for March 2019,” said Mr. T R Renukanthan,
Asst General Manager, CQ-Supplier Quality.


Quality Premier League - 2.0 Skit / Nukkad competition
Work Hard, Play Harder

Natkhat Nukkad (Street play) was organized as a part of Quality Month Cel-
It was a battle of epic proportions with CQ and Finance fighting it out in the
ebration at Bhandara on 24th November 2018. The skit was performed on
open with CQ bagging the QPL trophy in the finals. The QPL based on the
the theme “Road to Reliability” and “Quality.” Many teams from the Bhan-
IPL formula had 12 teams spread over three weeks playing gamely at the
dara unit took part in the skit and conveyed their message on “Road to
Loyola Cricket Ground, Chennai. Promoting a sense of oneness and sports-
Reliability” through this competition. All the employees had gathered and
manship, all the teams played with zeal and enthusiasm.
cheered the participants. A jury was set up to evaluate the teams and con-
ferred prizes to those teams that performed well.
The match was inaugurated by Mr. R Sivanesan, Senior Vice President -
Quality, Sourcing & Supply Chain.


Nambikkaiyae Thumbikkai Planting tree saplings
Taking this initiative forward, the As a water positive company with the
Quality Month was extended to aim of becoming carbon neutral, Ashok
schools too. New Town Government Leyland has in the past five years plant-
School students from Manali partici- ed around 5 lakh trees across India. In
pated and setup stalls. The speeches line with the company's vision to plant
and program were presented in Tamil 50,000 tree saplings within the Fiscal
("Nambikkaiye Thumbikkai") in an year 2019, our Managing Director and
interactive manner filled with fun CEO Mr. Vinod K Dasari inaugurated the plantation program by planting a
and games by Mr. P Kumaraiah (AGM sapling in the Ennore plant on 28th November 2018.
– NPQ) and Mr. K S Prakash (AGM –
CQMQ) on 27th November 2018. Blood Donation Camp
The program started with the inauguration by Mr. G Sathiyaseelan (VP – A blood donation camp was organized
Styling, PD) and with felicitations by Mr. D Suresh (AGM – CSR) and Mr. A in all units of Ashok Leyland. In Ennore
Sankar (DGM – NPQ). The program emphasized the need for reliability and plant, the camp was inaugurated by the
trust in every walk of life and the students were both inspired and educated. Rotary club co-ordinators in the pres-
ence of Mr. Sasi Kumar, Head - HR &
PD, VVC. Around 178 employees
donated blood in the span of 2 days.

Inauguration of the Reliability Expo 2018
Celebrate The Way of Life
The objective of the Reliability Expo with the theme –
Road to Reliability is to enable employees to seek,
learn and gain knowledge not only from their own de-
partments but from every single department irrespec-
tive of location, size or capability.
Our Managing Director and CEO Mr. Vinod K Dasari

inaugurated the Reliability Expo 2018 hosted in
Ennore plant on 28th November 2018.
Over 70 stalls were set up in the Expo from various

departments across India and even UAE. Around 2500
people visited the stalls, understood what was being
offered in terms of experience, knowledge and infor-
mation.

Reliability is the precondition for trust

Aim for the world-class launch of MBP
Mr. Vinod K Dasari Happy Birthday
addressed the gathering Mr. Vinod K Dasari
at the Reliability Expo
2018 and stated, “It is
fantastic to see the Third
Reliability Expo. As we
all know, it happens The morale of the employees is at an all-time high
once in two years and is
At the Expo, Mr. S Ramachandran, Vice Pres-
much sought after by
ident - Centre of Reliability Excellence and
everyone. I appreciate
organizer of the Reliability Expo said, “It is a
the presenter’s childlike enthusiasm while making presentations. Let me
beautiful feeling to see and experience the
remind you that all these ideas are implemented at the earliest.”
high energy of all our employees who have
Mr. S Ramachandran,
worked tirelessly to make this a success. The
“I have one simple target for you. The most important two launches that are Vice President - Centre of Reliability
Excellence team has worked continuously for nearly a
coming up are MBP and BS VI. I want all of you to find 100 areas which are
100 days to make this happen – Not only in Chennai but, all over.”
likely to fail as a Failure Mode Effects Analysis, and to make sure that those
don’t occur,” he added.
“The learnings that we will gain from here with every department having so
much to showcase, discuss and learn amongst each other is truly valuable
His speech was very encouraging and charged the employees with enthusi-
and will make Ashok Leyland achieve its goals.”
asm and a passion to deliver.


A conversation with Mr. R Sivanesan What is the objective of Reliability Expo 2018?
If the ground-level employee is able to connect his work with the organiza-
tion’s goal, it creates a lot of energy and synergy across all levels. It moti-
Mr. R Sivanesan,
vates them, and they also understand how their small action will help in
Senior Vice President - improving the quality of a vehicle.
Quality, Sourcing &
Supply Chain How much time did you take to plan the expo?
It took us around two months both in terms of thought process and to plan
the Expo.
How did the idea of Reliability Expo 2018 come about?
The purpose of this expo is to see how much we have progressed, the new How many people were involved in this whole process?
obstacles and what needs to be done. In a typical year, everything under- The entire Quality team with employees from various other departments
goes change, be it the environment or customer preference. Identifying played a major role in planning and executing the plans. Close to 200 em-
our priority for the next year comes first. By organising such expos, employees across Ashok Leyland played a crucial role to make this a grand
ployees across the organization will be kept aware of the activities carried success.
out by every department.


Is Reliability a long-term goal? Reliability Expo 2018 - A sneak peek
Reliability is a continuous journey of improvement and is never-ending.

You can never say that you have achieved the target, since change is the
only constant. So, if you do not continuously push your reliability effort
upwards, it will go down automatically. While trying to improve, you’re
also sustaining. So, sustainability is the main goal and improvement comes
as the second goal.
Can you tell us about your journey in Ashok Leyland?

I joined in 2011 and it has been very interesting. We had faced many chal-
lenges when I joined as we were focused on product quality. Customers
were happy when we fixed a problem and not charge for the same. Today,
it is not so. We are questioned for any failure, however rare it may be as
their awareness levels have increased. We are today more proactive than
reactive along with focusing on design, development, manufacturing and
the field quality along with sales and service.

Reliability creates credibility

Think Value to Clients at all times Why So Serious? Line up for some Fun
Since tyre costs come To give the spectators
just after fuel cost for a a break from the tech-
truck owner, the ‘Front nical stuff, employees
Axle and Tyres’ had the from the Ennore plant
‘Tyre Wear Diagnosis had set up two stalls
Manual’ for aiding the for fun activities.
dealers on tyre wear
and tear. The game had four
stumps arranged in
The team ‘Neptune Phoenix’ summed on the importance of products and two rows each with
its quality that has to be taken care of in order to ensure the satisfaction of notes like ‘Sing a song,’ ‘Rs. 500 fine,' ‘Play for VCC against ALCOB,’ ‘One day
customers. The ‘Defence’ team showcased their unique line of products leave cut,’ etc written on it. If the ball hits the stump in the first row, the
and vehicles that displayed their innovative ideas. player is bound to execute the task as per the note in the stump whereas he
does not have to do anything if the ball hits the second row.
Mr. Mukunthan from Ennore plant said, “The Expo gave us a chance to
understand what other improvements are going on across the organization When our Managing Director visited the stall, the employees handed him a
and made it easy for us to understand the entire process in a better way”. ball and asked him to aim for any one of the stumps arranged in two rows.
Hitting the stump in the second row, he escaped from the task and walked
away scot free.


Come On, Let's Go Green! Top Cop addresses Ennore Team
One team went a long Dr. C Sylendra Babu, IPS was at the
way in preventing the Ennore plant on 26th November
wastage of resources 2018 to deliver a guest lecture on
and the depletion of the our Quality month theme “Road to
environment by design- Reliability.” Mr. M Sellamuthu, Head
ing multilayer dense for- - HR, Ennore welcomed him, and
ests and setting up the session was inaugurated by Mr. V Subramanian, GM - CQ MQ.
‘Oxygen Corner’ in many
parts of both Westland Dr. C Sylendra Babu IPS is an inspiration for thousands of youth who aspire
and the Eastland of the Ennore plant. They had also set up water recycling to join the civil services today. His zeal in directly engaging in rescue opera-
units in the plant thus reducing the depletion of freshwater. tions has won him several awards. He currently serves as the Additional
Director General of Police of the Railways (GRP), Tamil Nadu.
Mr. Manoj Kumaar of ‘Go Green’ stall said, “We collect spring and rainwater
from the subway of the Ennore plant which is then filtered and stored in the The visionary thoughts and inputs shared by him were inspiring, and he
storage unit for future use. The plant has the potential to recycle around stated, “Reliability starts from every individual. As a reliable person, we
20,000 liters per day.” should be true to what we say.”
“Also, the grinding waste of coolants are recycled and are proven to be Nearly 400 employees attended the guest lecture session by Dr. C Sylendra
adopted as an alternative to almost 20% of sand in the production of bricks. Babu. After the session, he interacted with the employees and planted a
This idea received the breakthrough award in Sri Lanka this year,” he added. tree sapling. He appreciated the green drive of Ashok Leyland and our com-
mitment to nature.


“We identify the slow learners in these schools and appoint one resource
Children excelled in ‘Wealth to Waste’ project person per school who help the slow learner. We also conduct health
As a part of its CSR camps and have held major medical checkups. So far, 30,000 students have
initiative, Ashok Ley- benefited from the Road to School program,” said Mr. R Venkatasubramani-
land joined hands with am, Senior Manager - CSR.
Government schools of
various districts to help He also added, “We conduct sports called ‘EduSports’ and we teach educa-
the children who strug- tion through music called ‘Rhapsody’ in Chennai. To teach the children
gle to get proper guid- about the core values like honesty, discipline, and respect, we have taken
ance in both their lives many initiatives which are presented in the stalls as a part of the Expo. It is
and studies. to get the children to learn that honesty is a part of Reliability.”
The Ashok Leyland “Road to School” initiative began in the year 2015 by Over 20% improvement in learning levels of students from class II to class
working with the Government Primary and Middle Schools of Tamil Nadu. VII, as measured by Base Line and End Line tests and remarkable improve-
As of today, they are assisting 36 schools in Chennai, 172 schools in Hosur, ment in reading skills as measured by standard reading tests are the key
45 schools in Namakkal, and 80 schools in Sankagiri. outcomes of the ‘Road to School’ project.
The students took part in the Reliability Expo and exhibited their artworks Our Managing Director and CEO Mr. Vinod K Dasari congratulated them on
generated from waste materials. They left the viewers in complete awe by developing such innovative concepts at minimal cost. “Very nice to see such
their art built on the theme ‘Wealth from Waste.’ They also had other dis- early signs of leadership. Keep it up!” he lauded the students on ‘Children’s
plays like ‘Children’s Parliament’ and ‘Honesty Shop’ where they exhibited Parliament’.
their leadership qualities and the core values they acquired from the “Road
to School” project.


Reliability in every walk of life
A guest lecture on of completing the Tamil book, ‘Puyalai Thaandinal Thendral’ which targets
‘Reliability in every the vision for the development of Tamil Nadu State that Dr. Kalam and
walk of life’ by Mr. Ponraj has been co-authoring while the former President was alive.
Ponraj Vellaichamy
was arranged for Mr. Ponraj Vellaichamy addressed the audience and shared the experiences
the employees of he gained while working with Dr. A P J Abdul Kalam and the difficulties he
the Ashok Leyland faced while serving in various government organizations. He also shared
on the day of the the vision of Dr. A P J Abdul Kalam in establishing the solar satellites and
Reliability Expo. Mr. Electric Vehicles and requested the senior management to share the com-
“You have been riding in the roads, and P Harihar, Senior pany’s knowledge on automobiles with the educational institutions in
designing their syllabus thus helping in increasing the quality of education.
”
ISRO has been riding in the space. Vice President -
Mr. Ponraj Vellaichamy Manufacturing &
Project Planning He shared his ideas on how the interlinking of rivers is important in the
delivered the welcome speech and introduced the guest to the gathering. transportation sector and how companies like Ashok Leyland are contribut-
ing to the welfare of the Nation by their CSR activities. He also answered
Mr. Ponraj Vellaichamy is an ADA Scientist, Former DRDO Scientist and the queries raised by the employees and stated that it was a great honour
Technical Advisor to Dr. A P J Abdul Kalam. He has co-authored the book for taking part in the company's Quality month celebration.
‘Manifesto for Change’ along with Dr. Kalam in the year 2014. Mr. Ponraj
has also taken the responsibility


Visualize your day, to walk with conviction
Mr. CK Rangana- He told the employees
than, Chairman and about the 'Sachet Revolu-
Managing Director tion' pioneered by his
of CavinKare, who father and how he started
created strong his business with Rs.
FMCG brands that 15,000/-. He widely cov-
have successfully ered the topic of how EQ is
withstood MNC important when one wants
power was the guest to succeed in career or
“If you can imagine it and visualize it, lecture speaker of business and how to manage oneself and invest in our inner self. He empha-
you can creat it.” the Reliability Expo sized the importance of daily solitude and how it will make a huge differ-
Mr. CK Ranganathan 2018. ence in leading a successful life and explained his daily morning routine and
his professional life experiences. He also covered topics such as time man-
Mr. CK Ranganathan started his speech with the message, "We should seek
agement, visualization, and reading habits.
quality not only in products but in whatever we do." He averred that having
a right attitude redefines one’s career and shared his life experiences on
He said, “Quality and innovation is the key to the success of my company.
how vivid imagination and dreaming helped him succeed in both his per-
And right attitude will take you to great heights.” He ended his speech with
sonal and professional life.
the note, “Learn from your mistakes.”

A pat on the back. Well Deserved!

Senior Management shared their views at the Reliability Expo.
In 2016, we had a fantastic expo on Reliabil- I can see a great sense of pride in the people Attending the Reliability Expo is a nice expe-
ity. This year, we are seeing an 80% increase when they showcase their projects and the rience because we keep on discussing many
in the number of people involved in the problem-solving methods that they have of these issues in our day-to-day activities.
Expo. I strongly say, Reliability should deployed. It is this sense of pride which But seeing all of them together in one place
become a part of our everyday life. keeps Ashok Leyland's flag fly high and I am and also seeing the aggregates, I feel the
sure we won’t have a problem in challenging enthusiasm of the team. The passion and
our competition and staying ahead. energy from every individual who is show-
Dr. Seshu Bhagavathula,
Chief Technology Officer: Mr. N V Balachandar, casing their improvement are fantastic. It
President-HR, Communication and CSR gives a lot of confidence to the senior man-
agement members that we are making the
right progress and taking the right direction.
It is surprising to see so many participants

The progress that is being made in terms of
and so many different booths and stalls. I
improving the quality is impressive. I am Mr. Anuj Kathuria,
wasn't expecting so much. The event is
sure that our levels of quality, reliability, and President, Global Trucks
good but I think we need to focus on the
durability will improve multifold with these
speedy resolution of the actual problem in
real life and focus on customer problems kinds of effort. It's an amazing event.
and solve it as soon as possible.
Mr. Sanjay Saraswat,
Dr. N Saravanan,
Senior Vice President & Head - Global Bus
Senior Vice President, Product Development

Run now, Work later

Pumped up and raring to do more marathons,” who apart from swimming,
gymming and playing basketball does the occasional bit of running. Pan-
cham who is a GET 2017, says, “I believe in keeping a healthy mind and a
healthy body always.”
Nearly, 70 percent of the runners opted for the 5K run but, the more seri-
ous runners opted for the 10K marathon. One such person was Mr. Nedun-
chezhian N, Project Planning - Ennore who has already done a 130 Kms hill
run at Kodaikanal in Tamil Nadu and a 110 Km run at Chikmagalur in Karna-
taka.
The 5K and the 10K Marathon were organized by the Product Develop- He was thankful to Ashok Leyland and Mr. Ramesh, DGM - Project Plan-
ment team at VVC unit of Ashok Leyland. The 5K and the 10K marathon ning, and Mr. Shankarananth, DGM - Project Planning for supporting him
saw nearly 500 participants enrolling from across VVC, ALCOB and Ennore every time he gets the urge to wear his running shoes.
Plants with an equal mix of men and women.
Ms. Swetha M.R.S, from Ennore Project Planning department, took part in
The first runner who touched the finish line was Ms. Madhuri Khanduri, this after she participated in the 3K Marathon for Girls sponsored by Ashok
from the Chassis Structure Design Department, VVC. She ran the 5K chal- Leyland two months back. Kicked about the running 5K this time, she and
lenge. She said, “I had always wanted to be in a marathon, but just never did a group of girls jumped into the fray and ran all along. “We want Ashok Ley-
till today. It was just easy and am totally motivated.” land to have more of these marathons in the upcoming years,” says Swetha
and her team.
Running the 10K in about an hour or so, Mr. Pancham Bhatt, Deputy Man-
ager - IVT Department said, “What a rush it is. Motivated absolutely.

A first-time participant, Mr. Sathya Prasad, Vice President - Product Devel-

opment, VVC, says, “The marathon had no winners category at all. It was a
conscious decision as we wanted everyone to participate irrespective of
how fit he or she is. Running a marathon is an equal level playing field, and
everyone helps others by motivating, pushing and ensuring everyone
reaches the finish line irrespective of the time it takes. It’s a healthy way of
bringing us all together.”
Not to be outdone, Mr. Ranganathan and his colleague, Mr. Harshraj Mehta
from Marketing Communications team, ALCOB ran the 5K challenge for
the first time and was happy that all along the route, they were encouraged
by the employees who stood on the sidelines applauding, cheering and mo-
tivating everyone to run and enjoy the moment.
“This is the third time we are organizing this marathon here and it’s just get-
ting better and better every time,” said Mr. Seshu Bhagavathula, Chief Tech-
nical Officer, who already is a serious runner with three half marathons and
one full marathon under his belt. Keeping in mind the requests for more
marathons, he is toying with the idea of introducing two marathons in a
year instead of once in a year.

A breakthrough to make the world What is the breakthrough all about? How did this spark
get ignited in your minds?
less polluted
This whole process started off way back in June 2017 and by March 2018,
A few glimpses of this achievement in an interview with Mr. Gajendran:
we made the breakthrough. The spark that made us get this award was a
The next time you very simple questioning of how to ensure we have zero discharge of indus-
see a wall, house, trial waste?
m u l ti - s t o r e y e d
building or even a We explored recycling of wood, cartons and other natural resource prod-
concrete road, just ucts but were not convinced with the results. The scarcity of natural
smile and be resources was eating us up and we felt the pain. That triggered us to make
assured that this breakthrough.
Ashok Leyland has
contributed not a Why is it so critical for industrial waste to be treated
small part, but a properly?
HUGE part in maintaining a healthy environment not only at its plants in
India but perhaps all over the world. Industrial waste is generated in tonnes as part of the discarded grinding
wheels and metal ribbons. These auctioned Industrial wastes are normally
It was no mean achievement that the Quality Control team at the Ennore auctioned and transported to far off locations. There is a huge cost
plant bagged the Breakthrough award for this year at the IMPROVE 2018. involved apart from logistics and inventory. This process has been going on
Led by Mr. D Parthiban, AGM, Quality Control and his team of able engi- for decades.
neers, it was made possible.

About Ashok Leyland’s commitment towards being a Not an easy task it was, as they had to see multiple times a bit of success
and failures too. The ratios had to be got right with various proportions of
carbon footprint company.
sludge and cement and how much of bonding it created, curing, composi-
The earlier process resulted in more carbon footprint for the company fur- tion and other factors.
ther contributing to the world’s pollution. As you know, we are a “Water
Positive” company and we are aiming to be a carbon neutral company. So, The result was indeed encouraging and the breakthrough idea – Replace
this process that we have made as a breakthrough is extremely crucial. natural sand which is a precious resource with industrial waste. A matter to
note is that till date, no one across India or worldover, have created this
What is this breakthrough all about? unique mix up.
The team mulled over various possibilities, and after analyzing the sludge Apart from our internal team who worked on this project over a period of
that is being formed from the industrial waste, they found that its constitu- time, credit should be given to Engineering Institutes such as Chennai
ents are similar to that of natural sand that is in huge demand across India. based Rajalakshmi and Velammal who came forward to help in this effort
The idea is mind-boggling. Imagine, every industry across the world uses along with the Government organizations especially TNPCB.
sludge to create sand which can be used in the construction industry. The
rivers and oceans will be saved, lesser pollution and better air quality Is it true that the Pollution Department showcased your
would be just the starting point. case study at New Delhi?
Yes. We were pleasantly surprised by the enthusiasm shown by TNPCB
The team, excited with these prospects they found, wanted to not only
and particularly Mr. Charles, Joint Chief Environmental Engineer. The team
double check but quadruple check with Government authorized laborato-
pushed forward and was rewarded when Mr. Charles inaugurated the
ries, engineering colleges with state of the art laboratories, and even IIT
“Curb Wall Project at the Ennore plant” which was made up of industrial
Madras to find out if this sludge will bond with cement.
waste. Mr. Charles went to the extent of presenting this to the Central

Pollution Control Board, New Delhi on behalf of the Tamil Nadu Govern-
ment. Obtaining a letter of Certification from the Pollution Board, a patent
for this technology has been applied for.
After winning this, what next?

We are not resting on our laurels, and we are now working on how to gen-
erate power internally with a new team as we notice there is energy all
around us! How do we capitalize on this? Another thought process is the
huge Industrial paint sludge that is being created inside our factories and
how to convert that. For the next year, they are working on “Water positive
Not surprisingly, the management at VVC encouraged free thinking and
improvements”.
motivated the team to work. It was common to see them all working post
PD team @ VVC wins Gold after lifting office hours, weekends and also sometimes on family time. The families
did encourage them which was a big boost for them.
wheels of top selling models How does this victory feel?
The product development team is seen by everyone smiling and ecstatic
It was worth the efforts we put in together. It is a win not only for this team
and it is not due to a new product that has been approved nor for the
in particular, but for the Product Development department itself as it is for
development team bagging an overseas all paid trip but for something far
the first ever time, in the history of Ashok Leyland, the team has won a
more valuable. After sleepless nights and burning of midnight electric
Gold Award. It took all of 20 solid years to get this despite coming close
bulbs at home and in their offices.
many times. This year, four teams from the Product Development entered
the Nationals.
Mr. V Dilip and team from Product Development are excited as they
bagged the Gold for lifting the wheels of the best selling models.

Tell us about your team. ensures the wheels are dropped down and it supports the load weight.
This, unfortunately, was not happening, and the field service reports thus
As the leader of this group, I was ably backed by Mr. Karunakaran, Lift Axle indicated the same.
Team, Mr. Aanandaroopan from Vehicle Integration Team, Mr. Gauri Shan-
kar Chamoli from Field Quality Team (Ennore), Mr. Saravana Kumar from How many years of data was analysed?
Field Service team – ALCOB and Mr. Ramesh from Plant Quality Team –
Hosur (Plant II). We worked equally hard completing our regular duties and Mr. Saravana Kumar and Mr. Gauri Shankar from the field service team
then set aside some time post work for improving something vital for the gathered past four years data pan India and while discussing with us, we
Ashok Leyland’s best-selling model – 3118 and 3718. decided to IMPROVE the sensing system and rectified the problem by
making it more compact and user-friendly
What is this technology all about?
Post data, what were the next steps?
The project was titled - Innovative Lift Axle Sensing System. As the name
suggests, it’s all about sensing and lifting the wheels when there is NO We formed the team, we had constant brainstorming, identifying the root
Load and bringing down the wheels when there is a load of materials in the cause(s), sorting out issues with 360-degree feedback collected over a
truck. period of time. As it was a complex assembly, we had to figure out a way of
how to improve without changing everything.
This technology though not new, had its share of failures and complaints
from the customers who shared with the field service team across India. As It took nearly 4 months just to design and make changes in other systems
the numbers were growing alarmingly large, we realized this needs to be without altering too many parts as it would affect the whole assembly line.
corrected at the earliest. In the 2nd phase, we had to validate this, and physical parts were devel-
oped and this was fixed in the top-selling models and tested.
Simply put, the tyres in a truck will lift when there is no load thus, resulting
in less wear and tear of tyres, less fuel consumption and overall savings for Post validation with development of parts etc. took over 5 months. Finally,
the customer. When there is a load in the truck, the sensors work and by end of 2016, approval for manufacture of parts commenced with the
high ceiling model “3718”.

What did success look like?

Normally, feedback is gathered from the field service team from 3 months Realizing the 15 minutes time slot provided is to be managed efficiently,
to 18 months and failures analyzed in minute details. With the new tech- we practiced 5 times and made improvements in the presentation. This
nology implemented by us, we first waited for feedback from our custom- helped us a lot.
ers in the first three months, then 6 months and we knew that the chances
are extremely minimal. Even after 18 months, there were no reports of fail- What is the next project all about?
ures and we had won.
We are working on an innovative truck model (yet to launch) wherein, it’s
Costs play a major role here. What is the kind of cost going to be a game changer for the company and the industry.
reduction your team managed to make?

Reducing bottlenecks results in increase
After the implementation, we applied for a patent in 2017. We then, anal-
ysed the costs saved for Ashok Leyland and it was a whopping Rs. 1 crore in capacity
per annum under the accrual savings with reduction in parts, sub-assembly
parts, manpower reduction, and warranty. Now, all the four plants pan
India are manufacturing the models with IMPROVED sensing technology.
What was the key takeaway?

Last year, I had worked with another team and bagged a Bronze, and the
learnings and experiences I gained were implemented this year. One of
them was not to take pressure to the head and heart. Be focused on work
and with a clear mindset and another factor is time management.

Mr. P M Saravanan, Hosur II who won the MFG Gold at the Improve 2018 YOKE system in line, all related documents like SOP and control plan was
spearheaded this project with his able team to remove the bottlenecks, amended.
increase capacity, save lakhs of unit power per annum and this is just the
What are the benefits that you have made possible
start…
with this?
You have won the MFG Gold. Tell us how you feel.
The immediate benefit is that we have increased the capacity of our plant
It was a great feeling for our six member team while taking the Manufac- by 9000 vehicles without much investment. Secondly, we have power
turing Gold Award, in front of all Ashok Leyland stalwarts. saving of 20.8 lakh units per annum.
We have been also participating and winning many national/international What kind of budgets did you ask for?
awards, but I can tell you that Improve is just like a festival for Ashok Ley-
The budget required for this project was less than Rs. 10 Lakhs. The senior
land and winning the Manufacturing Gold is like icing on the cake.
management supported us with the budget, resources and the freedom to
do trials and experiments to achieve our goal. This is the reason we could
What problem did you solve?
enable our PTED line to have the lowest process time in India and probably
There was a requirement of 90 K vehicles but the only bottleneck in our in the world for Car/CV OEM’s.
plant was PTED line. We have identified the domain experts from the line
and took the challenge to increase the capacity by utilizing our expertise How was the journey?
and capabilities. We thoroughly studied the line, did elemental analysis
We had sleepless nights not only during the project execution but also
and arrived at benchmark solutions and implemented.
during Improve presentation preparing to give the best performance. Defi-
How many years of data was analysed? nitely, without family support and sacrifice, the achievement would have
not have been possible.
Any project will not sustain if it is not standardized. We introduced POKA

What kind of changes have been made at Ashok Leyland Innovative design change on the
by your project?
Reaming machine and Aligning tool
Now the bottleneck process has been eliminated by our project, which has
resulted in challenging other processes to perform better and benefitted in
the uplift of the overall performance of Hosur II.
Is this going to be replicated in all other plants of Ashok

Leyland?
Yes, already this improvement first phase has been implemented at Pant-
nagar.
How would this benefit the common man/suppliers/

vendors/Government? A breakthrough improvement was done by Mr. A Sellamuthu and team
This project has helped in reducing power consumption by around 20.8 from Ennore for resolving the production team pain point through innova-
lakh units per annum which will result in the reduction of 936 Metric ton tive design change on the Reaming machine and Aligning tool. The drilling
of CO2 emission. Also, this productivity improvement can be horizontally machine was made suitable for special application at Frame Assembly.
deployed to other ED plant which will improve productivity. This, in turn, not only gave the benefit of breakdown reduction and pro-
duction loss elimination but also ensured high life for drilling machines.
The above solution was communicated to the equipment manufacturer
and they rectified the problem immediately thus benefiting everyone relat-
ed to this field.

You have won the MSS Gold. How does it feel? How difficult was it to get this process streamlined?
It was a major milestone and recognition for our teamwork in solving the After successful trials of solution implemented, our team took enormous
technical issue at the frame line. We tasted the fruit of problem-solving effort to streamline the process as the usage pattern with respect variation
step by step with a sequential way of achieving success till the end. in bought out items like Reinforcement Flitches, Cross members, Frame
side member, Spring brackets and equipment parts such as Gears, Bearings
Having bagged the prestigious Gold, our team will not stop to resolve bot- and Aligners to get into control of required dimensions and to standardize
tleneck issues in terms of productivity improvement, quality, EEI related by old parts quarantine and operator willingness to produce.
projects.
What are the benefits that you have made possible
What problem did you solve? with this?
Our team consists of 6 members comprising of 3 from production and 3 ● Zero breakdown line concept with respect to Reaming machine failures
from plant engineering along with 1 facilitator. Our team observed bottle-
● Multi-model assembly process establishment
neck in Frame line on a day-to-day basis for which we took responsibility
● Line capacity enhancement
of solving with a thorough study of process/product in depth with step by
step analysis along with Black belt support which required intense study
from the basic with a balanced team from production and maintenance to
How would this benefit the common man/suppliers/
address it.
vendors/Government?
On time delivery to customers is ensured.
We observed failure on Reaming machines bearing and later with the prob-
lem-solving approach thus identified the issue with the designing process
along with the equipment failure.

Golden Peacock Award

Golden Peacock Award : We started publishing our Corporate Sustainability Report since 2017, in
accordance with the internationally accepted framework specified by the
A matter of pride and honour Global Reporting Initiative (GRI) Standards that are used to measure and
report economic, environmental, and social performance of our organiza-
Ashok Leyland has been
tion. Our report has specified the several initiatives we have taken in the
bestowed with the 'Golden
areas of material, energy, water, waste management, carbon footprint,
Peacock Award for Sustain-
community development, safety & health, employee engagement, etc.
ability' for the year 2018.
The trophy and the certifi-
Ashok Leyland has also been declared as the Winner of ‘Golden Peacock
cate was received by Mr. P
Award for Risk Management’ for the year 2018 in the category ‘Automo-
Harihar, Senior Vice Presi-
tive,’ by the Awards Jury constituted by the Institute of Directors.
dent - Manufacturing &
Project Planning and Dr.
The Golden Peacock Award Trophy and the Certificate was presented, at
Vikram Batra, Vice President - Corporate Strategy & Planning, at the Insti-
the ceremony held on 5th December 2018 in Singapore. The award was
tute of Directors (IoD), India's "18th Annual London Global Convention on
conferred by the High Commissioner of India to the Republic of Singapore
Corporate Governance & Sustainability” and “Global Business Meet” on
Mr. H E Jawed Ashraf, in the presence of a distinguished gathering of busi-
25th October in London.
ness leaders during IOD India's "3rd Annual Global Convention on Corpo-
rate Ethics and Risk Management.”
This award is a matter of great pride and honour to our Ashok Leyland
family and is a tribute to the robust sustainability practices and our commit-
Our Ashok Leyland family is remarkably happy for contributing our best in
ment to drive social inclusion and conserve the ecological integrity of the
the fields of Sustainability and Risk Management, and we pledge to uphold
locations we operate in.
the same in the up coming years.

Book Review The book ‘The 5 AM Club’ will walk you through:
The 5 AM Club: Own Your Morning, Elevate Your Life - Robin Sharma • How great geniuses, business titans, and the world’s wisest people start
their mornings to produce astonishing achievements.
“The hour when legends are either waking up or going to sleep”
• A little-known formula you can use instantly to wake up early feeling
The 5 AM Club is a work by
inspired, focused, and flooded with a fiery drive to get the most out of
the renowned Canadian
each day.
writer Robin Sharma that will
transform your life forever. It • A step-by-step method to protect the quietest hours of daybreak so
is an entrancing story about you have time for exercise, self-renewal and personal growth.
two struggling strangers who
• A neuroscience-based practice proven to help make it easy to rise while
meet an eccentric tycoon
most people are sleeping, giving you precious time for yourself to think,
who becomes their secret
express your creativity and begin the day peacefully instead of being
mentor. In this book, he has
rushed.
described in detail about the
revolutionary morning rou- • “Insider-only” tactics to defend your gifts, talents, and dreams against
tine that has benefited his digital distraction and trivial diversions so you enjoy fortune, influence,
clients in maximizing their and a magnificent impact on the world.
productivity, activating their
Organizational leadership begins with self-leadership. Getting up early to
best health and protecting do your inner work, to sculpt your character, to sharpen your life’s philoso-
their serenity in this age of phy or to review your goals is not a waste of time. That Holy Hour infuses
overwhelming complexity. every remaining minute of your day with a perspective that elevates each
The early-rising habit has helped so many achieve epic results while area of your life. It’ll transform you and make you better as a leader, as a
upgrading their happiness, helpfulness, and feelings of aliveness. parent, and as a human being.
So join The 5 AM Club. Win The Battle of The Bed

workstation is the best place to get clues; people decorate it according to

Holiday gifting at the workplace their personality. You could also do with some asking around her friends or
“I just got my Chris-child a really apt gift”, gushed the friend. They’re playing finding out hobbies, goals, and interests over a casual chat.
Chris-ma and Chris-child at work and he told me that someone gifted him a
juice box. I was not sure whether to laugh or feel bad at the choice of gift. Don’t get personal : however close you are to a person, avoid giving per-
He, on the other hand, had picked out a pretty neckpiece to gift his sonal gifts like roses, lingerie, perfume, cosmetics or after shave. Wine and
Chris-child. Since he shares a good rapport with the colleague and has been tobacco are also avoided in the workplace. Look for books, a piece of art or
working with her over the last decade, it seemed alright that he chose a store vouchers. I personally do not like vouchers because they seem too
piece of jewellery. Exchanging gifts at work can be tricky. You don’t want to impersonal and gives off the signal that you didn’t find the time to choose a
be over the top, nor do you want to look like you’re scrounging. Giving gift.
something meaningful and keeping it professional is the best thumb rule to
follow. With Christmas around the corner, here’s some gifting etiquette you Steer clear of practical jokes : to avoid the risk of hurting the other person’s
could use for the workplace: sentiments, stick to clean humour. What you find funny may end up humili-
ating the other.
Spell out the budget : to offer clarity on what is expected, setting a budget
limit gives guidelines and makes the gift selection a lot easier. This also pre- Pool in : it always works better if the team gets together to give the boss a
vents you from appearing over-the-top or stingy. Stick to the budget-al- gift rather than each one gifting separately. This makes it less likely that any
ways. one, in particular, is trying to win a favour.
Keep it optional : while you must invite everyone at the workplace to take Say- thank you : if you’ve received a gift, it is always polite to say thank you,
part in gift-exchanging, no one is obliged to take part. People may have a better still, take a moment to handwrite a thank you note. There is no obli-
variety of reasons to stay out, right from very personal ones, to religious or gation to reciprocate a gift if someone surprises you with one. However, try
economic reasons. Don’t probe the reason or make fun of the person for to keep a small inventory of wrapped gifts in your office drawer, just in case.
not taking part. If you know that it could be an economic reason, try to sur-
Playing these little gift exchange games is a great way to ring in the festive
prise the person with a gift.
season. It’s a good time to foster friendships and keep the mood upbeat at
the workplace.
Scout around for clues : the best part about giving a gift is when you know
the receiver will appreciate it. Look for clues about the person's taste. The Merry Christmas!

www.ashokleyland.com
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ASHOK LEYLAND | EMPLOYEE JOURNAL | DECEMBER 15, 2018

Hosur Plant 1, Tamil Nadu A conversation with Mr. R Sivanesan

Pantnagar Plant, Uttarakhand Think Value to Clients at all times

Bhandara Plant, Maharashtra Why So Serious? Line up for some Fun

Alwar Plant, Rajasthan Come On, Let's Go Green!

KLT Automotive, Thiruvallur Top cop addresses Ennore Team

Black Belt Program Children excelled in ‘Wealth to Waste’ project

Highway Camp A pat on the back. Well Deserved!

Planting tree saplings

Blood Donation Camp

Reducing bottlenecks results in increase in capacity

Innovative design change on the Reaming machine and Aligning tool

Golden Peacock Award : A matter of pride and honour

Holiday gifting at the workplace

Quality Month learn from one another. Also, it is a time to ac-

Bang We, at Ashok Leyland, had come together to

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Work Hard, Play Harder

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Our Managing Director and CEO Mr. Vinod K Dasari

Over 70 stalls were set up in the Expo from various

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Reliability is the precondition for trust

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Reliability is the precondition for trust

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Reliability is the precondition for trust

Reliability is a continuous journey of improvement and is never-ending.

Can you tell us about your journey in Ashok Leyland?

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Reliability creates credibility

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