12
Mon, Nov

MANUFACTURING & SUPPLY CHAIN

Perspectives
Typography

Mr Vikash Vohra

Director - Sales & Marketing

SAPA



Challenges faced by company while managing supply chain?

The Challenges are manifold, primarily it is difficult to get accurate forecasts from customers as the lead times are very aggressive due to a lot of uncertainty in the solar industry.

In a typical installation for a solar power plant, aluminium structures require a lot of components and subcomponents which can differ depending on the system being installed on the layout. For example, our Short Rail System comprises of four sub-components, whereas the Additional Tilt System comprises of 7 sub-components. Then add the fact that you require a combination of two or more systems to be applied to the same site. This may seem easy to manage if you are servicing only a handful of projects, however in Sapa, we pride ourselves on servicing multiple projects, large and small, each one with a strict deadline and requiring customized solutions.

Being part of the World’s Largest Aluminium Solutions Company, we have a robust production system to ensure quick turnaround for large volumes. We have inherently reduced the lead time by ensuring ready materials are always in stock for downstream processes of coating and fabrication, all are under a single roof. In addition to the above, we keep ample stocks of subcomponents and accessories, which are imported from Mounting Systems GmBH, Germany.

The standardization of the clamps & subcomponents is another engineering advantage we have for all our products and services all the modules available in the market.

Implementing TQM to maintain quality of the product?

As the Industry Leader, we recognize the importance of compliance and quality in delivering high-value products to customers. All of our manufacturing sites maintain certification standards set by our Hydro Quality System. Being the World’s Largest Aluminium Solutions Company, a lot of our customers are looking for the same quality of products as is received by their counterparts in other countries. Focusing on such specific needs from our customers, we follow the same global quality policies and adopt similar quality maintenance techniques while manufacturing as our other plants in Europe & North America. Total Quality Management (TQM) is an integral part of every process and best quality practices like 5S, Genesis and six sigma are thoroughly followed to achieve customer satisfaction.

How can companies ensure better quality management while manufacturing?

In manufacturing, quality is a process that ensures customers receive products free from defects and meet their needs. Quality must be built in the fundamental of any organization. While manufacturing the challenges are to have control of the processes, this could be achieved by constantly monitoring the process using statistical process control and measurement system analysis. Failure mode effective analysis and control plans help to keep process in the control proactively. Continuous training and motivating employees in the organization for improving the quality builds quality from grassroot. Every day, daily management L1 meeting monitoring quality helps to ensure that all process is in control. Implementation of ISO 9001 Quality System, conducting internal audits and regular management review meeting provides top management focus directly on quality. Total productive maintenance helps the machines and equipments to perform more reliable. Advanced quality planning and production part approval process helps to develop products without defects.

Quality is the standard of the organization.

 

Mr. Bhavesh Modi,

Director,

Sanelite

  • What are the challenges faced by the company in managing the supply chain?
    As most of the people in the industry are aware, this business is capital intensive. You need a huge working capital even if running a comparative smaller industry. Hence the turnaround time which is the time you invest for a product or a project and the time you realize the money must be as short as possible. While there is little issue with the PV modules supply chain, it becomes bigger with the EPC, as there are lot of dependencies on the external factors. There are government agencies involved, Discoms involved, and a whole lot of different suppliers from different sectors. Aggravating the pain are the incentives and subsidies offered by the government for which there is no timeline and no commitment. All in all, it’s all about the turn-around time, the shorter it is, the better you can manage your supply chain.
  •  How you are implementing TQM in order to improve the quality of your products?
    Quality is an integral part of life for all of us at Sanelite. Sanelite Group itself while spread in many verticals stands on the sole pillar of quality. India being a lucrative market, very few people understand the importance of the quality and the value it provides the customer. Very few people understand that the solar projects come with a lifelong promise. And when you commit to the lifetime promise, you cannot afford to deteriorate quality of products. At Sanelite Solar, we take utmost care to provide our customers with the best quality products. We deploy thorough QC procedures and stringent quality checks to maintain TQM. At every stage of the lifecycle, right from raw materials till packaging of the product, right from gathering requirements through commissioning, quality is the principal lived. An important thing to note here that the earlier a defect is identified, the least costly its solution is.
  • How can companies ensure a better quality management while manufacturing?
    Quality is a virtue by itself, and it needs to be lived. For instance, every personnel at our manufacturing facility – labour, engineer, technician, manager, everyone – follows a quality manual. Whatever work they do has a defined set of quality checks to be done, and they are evaluated regularly. The key is that every person being involved in the lifecycle of the product should know his contribution towards the product they are creating, and know the quality standards the product is set to achieve – be it checking raw materials, processing them, operating machines, product testing or packaging.

Mr. Manik Garg,

Director,

Saatvik Green Energy



What are the challenges faced by the company in managing the supply chain?

   Managing the supply chain of any company requires constant coordination between various departments within the organisation as well as all the people involved in a transaction. Since the promoters have an experience in the manufacturing sector of over 30 years, we directly implement their learnings with some customisation to the industry. Given that there are so many raw materials to be procured to assemble solar panels, it becomes very important to restrict the number of vendors, which not only helps maintain the timeline of raw material procurement, but also improves quality. When the product is ready, one of the major challenge that prevails across the industry is to serve the customers located in the other part of the country, due to high transpiration costs. We are overcoming this challenge by building a network of warehouses across states, to help assist regular demand.

How you are implementing TQM in order to improve the quality of your products?

     People. Process. Precision. We work on these three principals to ensure TQM in our organisation. People are the most important resource in any organisation, and we go an extra mile to make sure that our people are performing to their maximum abilities at all times. We conduct regular training and personal guidance sessions for all our staff, to ensure that they are satisfied both at work, and outside work. If processes are well defined and easy to understand, it leaves no room for error. Not only do we comply with ISO, but we have also implemented SAP H4 HANA which helps in automating a lot of manual processes, for superior records and quality implementation. If your people and processes are sorted, precision comes naturally, and we are a very quality conscious company, hence precision plays a very important role. To assist our people and processes, we have all necessary quality control/inspection equipment both in-line and in the laboratory, to ensure precision in our production for highest quality products.

How can companies ensure a better quality management while manufacturing?

    While the basis to have quality management is to install quality inspection tools and equipment in the manufacturing process. Starting from incoming quality control to finished product quality check, various machines can be installed. More important is to train to the people working on these machines, to help achieve the purpose of these machines. Adequate off the job and on the job training to all employees is a prerequisite for better quality. Most important is to set the internal standards as to what is acceptable or not. If the criteria of rejection is kept very basic, the production process will definitely churn out some defective products. Hence, it is a comprehensive process, and depends on the vision of the management. Our values of sustainability and integrity dictate that we follow a strict quality policy, for long term relations with our esteemed customers.

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