An Indian role model

In addition, the Chakan factory has a feature unique to India, called gurukul. This hands-on training program – related to the word guru, or teacher – prepares workers before they are put on the job. “The gurukul training facility has been a big help with efficiency,” Sharma says. The plant is also unusual for its energy-saving features, which meet targets for LEED certification (Leadership in Energy and Environmental Design). “The building’s design allows hot air to exit at the top, keeping the temperature inside about six degrees lower than the ambient temperature,” she says. “As a result, the plant does not need air-conditioning.” Overall, the factory receives high marks from its employees. “People find it pleasing to work there,” says Sharma. “The plant facility provides safe work conditions, and much attention has been paid to ergonomics. During the workday, people don’t feel tired.” To date, the factory’s safety record is impressive: more than 18 months without a single accident. Above all, lean-style transparency of production has made a huge difference, Sharma says. “The new plant allows visibility of both problems and waste. In the past, problems might have fallen between the cracks, or employees might have said, ‘That is not something I need to take care of.’ But now everyone sees where the problems are, and this improves both teamwork and production efficiency.”