It was the year 2016 and TITAN Jewellery was going through a tough time as gold bullion of 99.99% purity, commonly referred to as 9999 gold, was scarcely available in the Indian market.
The newly procured German equipment was working overtime to meet the ever-growing demand for 9999 gold which serves as the raw material for making gold jewellery in different karatages.
Mr Sanjay Ranawade (Vice President-Jewellery ISCM) had called for a hurried meeting with Mr Rajendran G (General Manager-Studded Jewellery) and Mr Leo Michael Y D (Group Manager) to discuss the developments in the Bullion market and the impact it would have on jewellery production.
Mr Sanjay explained that alternate sources for 9999 bullion came at a premium of Rs 65,000/kg, with a minimum order quantity of 100 kg, and a promised lead time of four weeks. This would greatly affect the cost competitiveness and delivery of Tanishq jewellery.
However, what was not spoken, but nevertheless understood, was that TITAN, being a torchbearer of TATA’s ethical values, could not stoop down to the dubious practices adopted by its industry competitors. This meant that TITAN was to take drastic measures to step up its production of 9999 gold.
Mr Kanthanathan P (Manager-Refining) hastily entered the meeting room and apologized for his lateness. He conveyed grave news. He had been informed in the morning that the purity results indicated that iron was in the 9999 gold produced in the Electrolytic Refining process. That too in the new German equipment.
Iron is deadly in a jewellery alloy. It causes quality defects in castings and machine-made chains such as blistering and porosities. This meant that both the productivity and the quality of the existing process were in question.
While Mr Sanjay brooded seriously over the matter, questioning himself if he should consider outside options for sourcing bullion, Mr Rajendran G, Mr Leo, and Mr Kanthanathan were in deep discussion, determined not to let down their company in its time of need.
Mr Leo raised a basic fundamental question/challenge. “If our Aqua Regia process can deliver 999 purity gold, then why can’t 9999 purity gold”? He announced that, with the In-house expertise of his Refining team he would develop a world-beating process that would deliver on both the productivity and quality fronts.
For three months, the Refining team was completely focused on this challenge. They brought to bear all the quality tools in their arsenal to realize every opportunity for quality improvement. Input quality of chemicals was improved, key process parameters were standardized and innovative ideas were tried and refined repeatedly.
Mr Sanjay & Mr Rajendran, whose trust and support in the team gave rise to the whole initiative were kept abreast of the entire proceedings on 20th August 2016, they were greeted with the news that this team of highly motivated Titanians had achieved the World’s first Aqua-Regia Process that gives a guaranteed output of 9999 gold.
Mr Bhaskar Bhat, MD of TITAN, during his visit to the Jewellery Division, visited the Refining plant as well. The Refining team showcased their efforts in developing the World Class Refining Process. The MD congratulated the whole team for their innovative approach that created a new benchmark. Titan’s Flag flew to greater heights. He remarked that a deep yearning to achieve the impossible, coupled with determination and trust in one’s own abilities, will guarantee success. This is going to be our first step towards our future approach.
This team which demonstrated all the above went on to successfully bag the “Dream Team” award for excellence in team work for the year 2016 and Rs 1.8 lakh in prize money.
Lessons Learned