HI TECH ARAI LIMITED

Hi-Tech Arai Ltd is a Madurai based oil seals and automobile components manufacturing
company. Having joint venture with Arai Seisakusho co Ltd Japan and Mitsubishi Corporation,
Japan. The company previously called as Hi-Tech ancillaries‟ ltd after joint venture with Arai
Seisakusho co ltd, the company name has changed to Hi-tech Arai ltd. The company was
established to produce rubber components and oil seals for the world famous companies like
Maruti Suzuki, Bajaj, TVS, Honda, Yamaha, Toyota, etc.

Hi-Tech Ancillaries Limited originated as a private company founded by Mr. R.

Lakshminarayanan, a polymer technologist of repute. This unit is a product of his vision and was
set up in 1985 in anticipation of the revolution in the automobile industry, which had been
stagnating for decades. The company is unique in having an excellent R and D base which is
capable of absorbing the technology from Japan on a continuous basis to upgrade the entire
product range benefiting the various customers with high reliability combined with cost
effectiveness. R. Lakshminarayanan, Chairman of the company guides the technical, product
development and marketing activities. He is a renowned rubber technologist with more than 35
years’ experience in the rubber industry.

SIX SIGMA METHODOLOGY IN HI TECH ARAI LIMITED

Six Sigma projects follow two project methodologies inspired by Deming's Plan–Do–Study–Act

Cycle. These methodologies, composed of five phases each, bear the acronyms DMAIC and
DMADV.

 DMAIC is used for projects aimed at improving an existing business process

 DMADV is used for projects aimed at creating new product or process designs.
DMAIC Methodology phases:
DEFINE THE PROBLEM AND CUSTOMER’S AND EMPLOYEE REQUIREMENTS
Applying the define, measure, analyze, improve, and control (DMAIC) approach, the team began
by defining the problem using a suppliers, inputs, process, outputs, customers (SIPOC) analysis.
The VOC and their requirements, needs and wants was collected.
MEASURE THE PROBLEM
The main problem was
1) Needed employee benefits and some training classes.
2) Growth is slow and Customers are not responded on their urgencies.
3) Need flexible working time for employees.
4) Customers need products based on new technology and also fast deliver of products.
ANALYZING THE PROBLEM
All the problems are analyzed based on importance and what was the root cause for the problem.
All the problems are important and they need to be sorted out. Before sorting, company analyzed
the reason behind slow growth of its production. The main cause for the slow growth was due to
workers lack of skill due to improper training and also dissatisfaction of workers due to lack of
motivation.
IMPROVEMENT
Employees are taken into consideration and their problems were analyzed by providing proper
training and incentive schemes.
The workers and manufacturing process were updated according to the latest technology thereby
providing quick delivery of products.
CONTROL
After improving the defects a Proper Team must be employed for monitoring the process and
maintaining it accordingly. The defects must not be repeated and controlled in future.

Outcome of Six Sigma Methodology

1. Striving for continual improvement of our quality performance by meeting the changing
requirements of our customers and our environmental performance by prevention of pollution
and minimization of wastes.

2. Manufacture high quality products at competitive prices by adhering to the system, processes
and procedures and continually improving the same.

3. Promote energy savings and conservation of resources.

4. Comply with all applicable legislative, regulatory and other requirements including those that
apply to environmental aspects governing our activities.
5. Achieve the above by creating awareness among our employees through proper training and
providing conducive work environment.

QUALITY ASSURANCE DEPARTMENT

In Quality Assurance (QA)department, with help of six sigma methodology ,various activities
are carried out, which are required to assure the quality of the products.
QA consists of various functions like mould validation, layout, inspection. Input inspections, trial
production run, MSA study, PPAP document preparation. Issuing SOP, performance testing,
customer complaint/warranty analysis etc.
“Quality is to display your passion through your work”
Quality department do some important activities like,
1. Raw material inspection.

2. In curing inspection of inputs

3. Process specification issuing

4. Inspection standard

5. Layout inspection

6. Process audit

7. Product audit

8. Performance testing

9. Gauges calibration -Any organization compare with master and find the error or not is a
calculation.

10. Customer complaints handling

11. Warranty return analysis

12. Corrective action and preventive action

Mould validation:
By means of inspecting the products from new moulds, mould validation is done. In three
aspects like dimension, visual and profile, products are inspected.
Layout Inspection:
Moulds in production are validated at regular frequency to ensure the quality of the products and
the condition of the moulds. Products are inspected in the same way as in new mould validation
process.
Input Inspection:
Incoming inputs are inspected to confirm its quality and to ensure the final products
performance. Inputs like reinforcing metal and spring are inspected for each lot in random
sampling method. Critical characteristics of inputs are inspected and the lots are approved.
Trial Production Run:
Each processes of the products are carried as the SOP and if any deviations occurs in the
products quality necessary corrections done in the process condition as trial till the required
output comes.
MSA Study:
In any product, measurement plays are important role. Measurement may either for variable or
attribute characteristics or for both. Usage of appropriate inspection tool and adequate skilled
inspectors are confirmed in MSA study. Repeatability and Reproduciability(R&R) is are of the
major tool in MSA study.
PPAP Preparation:
Production Part Approval Process(PPAP) is a set of documents prepared and compiled to share
the available suppliers facilities and control systems to produce the products and also to
Applying the define, measure, analyze, improve, and control (DMAIC) approach, the team began
by defining project stakeholders using a suppliers, inputs, process, outputs, customers (SIPOC)
analysis

Performance Testing:
Conducting endurance testing to calculate or to ensure the performance of products. Products are
tested under specific condition based on its applications.