The best thing living in Silvassa is to get some soul satisfying moments driving just 25 odd miles to Daman beach. Sitting at the sea-side rocks, I watch and enjoy the playful waves. Rushing and gushing forward as they slow down their pace, moving back as to gain their energy to hit back with more force. Crashing and racing with each other … that … who will splash at me. I know that the perseverance of waves will eventually win and they will reach me certainly. Waiting for that ultimate wave, I got lost in thoughts-Isn’t it similar to our life?
Everyone is in race with one another… our suppliers, our competitors, our customers, etc. Expectations are always high. I recall, earlier our customers were happy with 1 break/MT while drawing copper at speeds of 20 m/s. Now 0.3 breaks/MT and drawing speeds less than 28 m/s is unacceptable to them. Courtesy a gigantic advancement in wire drawing industry and dumping of superior imported rods. To match that rod quality and sustain in market, we knew we had to improve our Piparia rod quality – To reduce high Surface Oxide values (SOD) in rod which has hindered its performance.
The waves bobbled many times before reaching the shore….
Last year a separate team already worked on reducing the SOD value but couldn’t succeed. So, we called OEM. According to them, Piparia plant design was the constraint. They said upgrade the plant which meant a long shutdown and capital expenditure of Rs.90 crores! However Senior Management formed a new cross-functional team to beat the unimaginable challenge -‘To improve the rod quality by reducing the SOD value in rods’. They showed faith in the capability of the team and said ‘’You run the plant! You understand it better! You’ll deliver, don’t worry!
I realized the waves just touched my feet, breaking my thoughts…I guess… they were advising me to forget the past and take up this challenge. With an extensive data analysis and statistical tools like dispersal analysis, stratification, MSA, Correlation and Regression, DOE, Test of Hypothesis, reference to technical papers, etc. , our team implemented some innovative Kaizens (without any shutdown or CAPEX) in the rod plant.
Like persistent waves, without any prejudice, oscillating between faiths and expectations of the management, our team took the challenge head-on! Finally our actions resulted into breakthrough in SOD values.
Yes, target was achieved and we were sailing on euphoric waves of success.
Now, the ocean is calm and serene like it has undergone some retrospection. But deep-down, I know waves are restoring its energy to propel back for a new challenge… a new target…
Lessons Learned
- One who keeps on trying and doesn’t get discouraged will succeed at the end like determined waves
- Don’t be afraid of failures. Be ready to make a splash when facing new challenges