You have to dream before your dreams come true. Your dreams are not what

you see in your sleep. They are the things that do not let you sleep.

… APJ Abdul Kalam11th President of India

3600 Customer ViewStar CastingThe Face of Indian Science & Technology Leadership

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The Face of Indian Science & Technology Leadership

APJ Abdul Kalam EDITORIAL

On July 27, 2015, as he got ready to start his address to an eager audience of bright young students at the Indian Institute of Management in Shillong, Meghalaya, Dr APJ Abdul Kalam, former President of the Indian Republic, suddenly died of an unexpected cardiac arrest. Dr Kalam had always reveled in continuous and stimulating interaction with bright young minds of the country, which he kept up right to his last breath on that fateful day in Shillong. As President of the world’s largest democratic Republic, Professor, ‘Missile Man’, Technocrat, Space Technologist, Musician, Philosopher, Writer, Abdul Kalam held myriad identities with consummate skill and ease, and always with a sense of informal playfulness and unbounded compassion for people of the country. He was a Bharat Ratna, but also a People’s President. His death was mourned across the nation with thousands, including Prime Minister Narendra Modi, attending the funeral ceremony in Rameshwaram where he was buried with full state honors.

Abul Pakir Jainulabdeen, ‘APJ’, Abdul Kalam, came from a humble background and was born and raised in Rameshwaram, Tamil Nadu. He overcame the crippling limitations of his personal circumstances to complete his studies in physics and aerospace engineering. He then spent the next four decades as a scientist and science administrator, mainly at the Defense Research and Development Organization, DRDO, and the Indian Space Research Organization, ISRO. He was intimately involved in India’s civilian space program and military missile development efforts. He thus came to be known as the Missile Man of India for his work on the development of ballistic missile and launch vehicle technology. He also played a pivotal organizational, technical, and political role in India’s Pokhran-II nuclear tests in 1998, the first since the original nuclear test by India in 1974.

Kalam was the Chief Executive of the Integrated Guided Missile Development Programme, IGMDP that developed some of India’s significant missile weaponry, including Agni, an intermediate range ballistic missile, and Prithvi, a tactical surface-to-surface missile. He rose to the top of India’s Defense Research establishment at a time when the country had to contend with a severe technology denial regime from the advanced countries of the world, including the USA, forcing the country to bootstrap itself on many key technological capabilities.

Abdul Kalam had tremendous faith in the capability of his countrymen to rise to the full extent of

their potential for development and advancement using science and technology. This was perhaps based on his own personal experience of overcoming crushing limitations of his personal background to rise to the very pinnacle of his profession, and indeed the country, to become the President of the Indian Republic. His achievements are a lesson in leadership: they were based on a simple, down-to-earth, ‘can-do’, drive for results that challenged the limits of the possible. He always showed a deep caring for the ecosystem around him and engaged it entrepreneurially to inspire people and drive change. He delighted in curiosity, patient research and minute observation; constantly and regularly networked with people and learnt from them; and based on these, acted to experiment and validate the next best step in his field. He had an uncanny knack to think laterally and ‘connect the dots’ to see the big picture and is widely remembered for his visionary approach to the country’s development.

In the ultimate analysis, Abdul Kalam’s legacy will be decided by the way he lived his life: with ‘malice to none and charity to all’; with fearlessness; unblemished purity and integrity of character; a certain austere simplicity that connected to the common man in India; and with a sense of steadfastness and conviction in his principles. His face of dogged technological prowess was also one of compassion, gentleness and modesty.

Best wishes,

Jitendra DivgiManaging Director

Innovation TIMES | 2 All Birds find shelter during a rain. But Eagle avoids rain by flying above the Clouds. - A. P. J. Abdul Kalam

EDITORIAL

3 | Innovation TIMES

Star Casting

A quick meeting with Mr. M. M. Umadi, Executive Director and explanation of our project and requirements saw the deal to manufacture HPDC components for DivgiWarner being sealed.

A joint DivgiWarner – Sipra Engineering team was instituted to oversee the development project right from the preparation of the dies to the final supply of the casting that would adhere to the

stringent DivgiWarner specifications. The team really did not have too much time to develop and supply the castings; just six months, start-to-finish.

The team, steered by Mr. Gangadhar Zanjad, Sr. Manager Engineering, DivgiWarner and Mr. M. M. Umadi, Executive Director, Sipra developed initial castings in March, 2012 within three months of the project kick-off. By April, 2013, the first lot of castings were ready for shipment. The 2nd set of dies were developed through a supplier in China well ahead of the project target time despite the difficulties of developing a die for a complex aggregate such as the transfer case. To optimize parameters and overcome earlier defects, Mr. G. S. Zanjad and Mr. M. M. Umadi jointly visited the die manufacturer and conducted rigorous die simulation studies and initial trial runs.

The new innovative dies helped DivgiWarner reduce its machining cycle time on the castings by almost 15%. Deburring and leakages were also significantly controlled.

To Sipra, its extension of support to DivgiWarner on this project showed a new direction, the opportunity to expand its capacities and its business. It quickly procured a 1250T machine to add capacity to its existing 800T machine. The move also enabled them enhance tool life by up to 15%.

The focus and dedication shown by Sipra in executing the project simply deserved to be recognized. DivgiWarner expressed its gratitude to Sipra by awarding it the “Special Recognition Award – 2012” at DivgiWarner’s Annual Supplier Conference, 2012.

Sipra continues to maintain 100% On-Time-Delivery record with DivgiWarner till date.

In late 2011, when DivgiWarner began exploring an alternate source of supply for its requirement of Case, Cover and Adaptor High Pressure Aluminium Die Castings (HPDC) for its transfer cases, it did not have to look too far or think too much about the supplier who could give the best balance between price, quality and delivery. Sipra Engineers Pvt Ltd, Nashik’s presence in the manufacture and supply of High Pressure Aluminium Die Castings for over four decades ended its search.

M. M. UmadiExecutive Director

DivgiWarner recognizes local HPDC Castings Supplier

Contributor: M.J. Patil SCM & Logistics

FEATURE STORY

Cover Case Transfer

Case Transfer

Adaptor Front

Mr. Vandan Shah, MD, Sipra Industries, receiving the “Best Supplier Award – 2012” from Mr. Pundalik Kudwa, Director, Divgi Metalwares Pvt. Ltd.

Great dreams of great dreamers are always transcended. - A. P. J. Abdul Kalam

Contributor: Vijay NevrekarAdvance Business Development

EVENTS3600 Customer View

Mahindra Officials visit the DivgiWarner facility at Bhosari

Innovation TIMES | 4 Excellence is a continuous process and not an accident. - A. P. J. Abdul Kalam

Mr. Shashank Raodeo, Senior General Manager, Demand Chain Management (below right) and Mr. Pushkar Bhobe, Deputy General Manager, Supply Chain Management (below left) Mahindra Vehicle Manufacturers Ltd. with Mr. Jitendra Divgi, Managing Director, DivgiWarner Pvt. Ltd. (below centre) at the DivgiWarner facility at Bhosari, Pune.

5 | Innovation TIMES

Contributor: Vijay NevrekarAdvance Business Development

3600 Customer View

DivgiWarner trains TATA Motors Service Team at Thailand

EVENTS

The bird is powered by its own life and by its motivation. - A. P. J. Abdul Kalam

Mr. Gajanan Chitale, Sr. Engineer, Customer Support (below left) and Mr. Mahesh Patil, Manager, Production, (below right) DivgiWarner, at the new TATA Motors production facility at Thailand for the training of Service Engineers on the Dual Cabin TATA Xenon (4x4).

What is your current role in DivgiWarner?I am working as Head - Purchase and Global Supply Management and lead the direct and indirect purchasing activities at DivgiWarner. The activities include Supplier Development, Supplier Technical Assistance and Supplier Quality Monitoring. I am also responsible for Global Supply Management activities and the sourcing of various commodities such as Casting, Forging, Sheet Metal, Electrical and Electronics Parts, bought-outs and sub-contracted components.

What has been your experience with DivgiWarner?In the nine years of association with DivgiWarner, I got opportunities to learn key things in the areas of Manufacturing, Quality Systems, Planning, Material Procurement, Supplier Management, QA and Export-Import Management.

Starting my career with DivgiWarner in the Quality Assurance Department as a Graduate Engineering Trainee, I moved to Quality Systems and Project Management. It was during this implementation that I learnt how to effectively apply world class Quality Systems Tools and Lean Tools like Quality Systems Basics, Operator Licensing, Layered Process Audits, Lean Manufacturing, VSM, Line Balancing and SMED.

A stint in the Production Planning Department helped me develop skills in planning and coordination with overseas suppliers for DivgiWarner’s Synchronizer business. Then, as Manager, Purchase and Global Supply Management, I oversaw all purchasing, supplier development & supplier technical assistance aspects of DivgiWarner’s business. In 2014, I was given the responsibility of heading the Purchase & GSM Department.

Through my involvement in a Cross Functional Team (CFT) for cost reduction for existing supplier parts as well as new development parts by implementing best purchasing practices, LEAN initiatives and localization of imported parts, we were able to achieve cost reduction targets with high quality

standards, improving profitability of DivgiWarner.

What has been your contribution to DivgiWarner’s Product Leadership Initiatives?Some areas where I believe I have been able to contribute in DivgiWarner’s Product Leadership Initiatives are:

Research work in the area of Value Stream Mapping Publishing paper on Lean Manufacturing & VSM at SAE

COOMVEC,USA in 2010 Authoring SAE Papers on Quality System Basics for the

manufacturing industry in 2011 and Supplier Capability Maturity Model in 2012

Part of the team that achieved 1st rank in BWPS and QSB implementation amongst all seven BorgWarner Torque Transfer System TTS plants globally.

Continuous improvement in the supply chain to maintain 100% on time delivery with best quality products in affordable prices from domestic as well as overseas suppliers

Implementation & Sustenance of Quality System Basics (QSB)

What do you believe are some of your notable achievements at DivgiWarner?My career growth in DivgiWarner from Graduate Engineer Trainee to Head- Purchase & Global Supply Management is one of my most notable achievements. Another that I consider as notable is the “President’s Award that was awarded to me by Mr. Timothy Manganello, President BorgWarner (2003 – 2012) for implementation of BorgWarner Production System at DivgiWarner Bhosari & Sirsi facilities.

Some of the other successes that I consider notable include achieving organization supplier PPM targets and implementation of DivgiWarner best practices at supplier end, developing suppliers having world class manufacturing facilities and technologies and developing suppliers for high density powder metal parts.

Deepak A. VaniHead Purchase and Global Supply Management

Education: M.S.( Manufacturing Management-BITS, Pilani) B.E (Production Engineering- Shivaji University, Kolhapur) Total Experience: 09 Years With DivgiWarner: 09 years Career Goals: Bringing world class transmission technologies

to India at affordable prices Hobbies: Reading, Listening to Music, Playing Chess and

Cricket and Gardening Family Details: Spouse: Shamal, Son: Tanishq

Contributor: Gopal DalviHuman Resources

Tête-à-TêteFace of Product Leadership

A mindshare with stalwarts within our workforce

Innovation TIMES | 6 Science is a beautiful gift to humanity; we should not distort it. - A. P. J. Abdul Kalam

DivgiWarner designs a Double-Offset Transfer Case

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Double-Offset Transfer Case

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In our issue exactly a year ago, we had spoken about the OEM’s’ scramble to enter the sub-4 meter segment for the benefits it gets from a lower excise duty rate of 12 per cent and the resultant higher market penetration.

As per market researcher IHS*, the sales of subcompact sedans and subcompact SUVs made up a sixth of the 2.6 million cars sold in India last year i.e. around half-a-million. It further says that with such a market growth, sales is likely to double to nearly 1 million by 2020.

DivgiWarner realized that packaging the vehicle into an overall length under 4-metres would, in most cases, necessitate the OEMs to maintain a wheelbase of less than 2500 mm. The lesser packaging space would, in turn, restrict the options available to OEMs to offer “off-roadies” a technologically superior 4x4 solution on these new compact SUV’s.

“It’s no big deal” says Prasanna Deshpande nonchalantly, Head of Product Engineering. “Why should OEMs be at a loss of solutions to satisfy those “macho” enthusiasts who would like to off-road with these under 4-meter cars” “We’ll simply design and build a transfer case that fits into these cars”.

Ah!…the thinking caps of the DivgiWarner Design Team were donned and the “Spirit of Innovation” kindled yet again. And, out came the DivgiWarner Double-Offset Transfer Case design to satisfy the demand for a 4x4 option for SUVs with wheelbase less than 2500 mm.

With the market for these vehicles growing in leaps and bounds, the DivgiWarner “under-4 meter” Double-Offset Transfer Case is all set to provide the much-awaited option to all 4x4 enthusiasts.

Contributor: Prasanna DeshpandeProduct Engineering

Thailand VisitEVENTS

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Customer AngleTECHNOLOGY NEWS

7 | Innovation TIMES To succeed in your mission, you must have single-minded devotion to your goal. - A. P. J. Abdul Kalam

Longer Wheelbase – Single-Offset

> 6 deg.

< 6 deg.

< 6 deg.

Shorter Wheelbase – Single-Offset

Shorter Wheelbase – Double-Offset

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*[ Source: Business Today, June, 2015]

Contributor: Sudhin DeshpandeOperations

All matter in this newsletter is copyright & is for meant for private circulation only.For additional information visit www.divgi-warner.com

INSIDE BUZZClassy Sirsi

First Cultural Event staged at DivgiWarner, Sirsi

(Navollasa-2015)

Innovation TIMES | 8 No sanction can stand against ignited minds. - A. P. J. Abdul Kalam

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