BENTEX AUTO Pvt. Ltd.

By Malay Kumar

Mandi

Bentex Engineering Private Ltd.• Business type – Manufacturer & Supplier• Plants- Maharashtra(Mumbai, Nagpur) and Uttarakhand (Rudrapur)• Products- 12 fabricated sub assemblies, 13 machined components, 4 Press

components• Clients – Ashok Leyland, Mahindra & Mahindra, Sonalika & Swaraj• Suppliers- Ashok Leyland, Bhushan Steels• Production Pattern -25 day advance delivery schedule• Area- 60,000 Sqft.• Workforce- 150-200 (Variable according to demand)• Shifts – 2 (12 hours each), Lunch time- Half hour, Tea break- 15min, Breakfast- 30min• Product Focussed- Engine Mount Bracket• Plant Manager – Mr. P. Das

Pictorial View Of Process

Shearing Press (Bending and Punching) Welding (Spot and Line)

Powder Coating Grinding Chipping

Key Insights• 75% of revenue coming from 20% key products• 25% from the remaining 80%• 25 day early receive of demand by customers• Customers only responsible for supplying raw materials• Pull system• No kiazen, Kanban followed• Lot of scope for improvement• 25 products of M&M, 300 products of Ashok Leyland

On Other Medium • ROIC• Value Stream Mapping• Future Value Stream Mapping

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Demand Variation In BENTEX AUTO Pvt. Ltd.

Production Planning In BENTEX AUTO Pvt. Ltd.

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Action Plan• Safety:• Glass box in wielding area• Shoes, gloves, helmets, vests/aprons

• Decentralisation of die Store Points• Travel path of workers will be reduced• More efficient use of space

• Visual management:• Board displays• Colour code (dress) – manpower management

• Backtracking too high• Reduce backward moving of products• Saves time and energy.