CASE STUDY: BUBBER INDUSTRIES

Introduction
Bubber Industries, established in 1980, has earned a good reputation in manufacturing intricate
components with precision. While catering to a growing OEM segment, Bubber Industries has
achieved excellence through state of the art technology, superior manufacturing capabilities
and dedicated personnel. This makes them the most preferred supplier in the domestic
markets. However, there are certain issues which are disturbing its owner Gulshan Bubber.

Background
Bubber industries is a known manufacturer in the auto components industry. Today, it is
supplying many established OME’s like Swaraj, PTL, etc. Earlier, they were also involved in the
task of metal forging to supply raw materials parts but later they discontinued because of
business compulsions and higher costs than metals forged in Ludhiana. Since then they are
focused on producing auto parts. Initial lathe machines used for years have now been replaced
by Computer Numerically Controlled (CNC) machines. This has helped them achieve high
production levels with increased quality. Four CNC machines are already in operation but lathe
machines are still required for certain tasks. Automatic cutting machine and a metal marking
machine has also been employed to increase efficiency and effectiveness of operations. Pictures
of the major defects that occurred in the past have been put in the production area to keep the
workers aware and take precautions not to repeat the same.

Bubber industries took the quality initiative few years back when some programs were
conducted by the trainers of Eicher. The results were visible in the form of organized inventory
in different colored boxes and the improved waste management practices. However, the
benefits of the same cannot be reaped for long because of inconsistent execution. The main
motivation factor behind the actions of workers as well as the owner was getting a certification.
A very short term focus was driving their actions and thus they could not continue once the
certification was awarded as the sole motivator ceased to exist. A significant point to note is
that the owners were not aware of the need of training, motivation as well as long term focus
to ensure consistent performance and benefits. But now they are. They are motivated to
improve the operations, layout, and overall structure so as to have a better future. Their focus
has shifted from short run to long run and their actions are thus attempted to ensure
sustainable competitive advantage.

Quality policy
Bubber industries has a vision to capture global market and its owners are working consistently
towards it. It is a 9001 certified company and has been implementing several quality processes.
Their quality policy states- “We at Bubber industries, Panchkula are committed to strive for
total customer satisfaction by providing highest quality of products and in time, every time
consistently. Our goal is to succeed customer satisfaction through innovations, quality, and
providing the customer the best value for his money by meeting statutory and regulatory
requirements.”

Customers
Bubber industries is a known supplier of auto components in the domestic market. It has
achieved a good reputation of providing quality products in time. Bubber industries major OEM
customers include Punjab Tractors Limited (Mohali), Swaraj Engines Limited (Mohali), Swaraj
Mazda Limited (Ropar), HMT Limited (Pinjore), Northern Railways, Loco Modernization Works
(Patiala), Sigma Vidracoustic (India) Pvt. Ltd., and Bawa Machine and tools manufacturing
Company (New Jersy, USA).

Current Scenario
Although, Bubber industries has achieved a good reputation in the domestic industry, it is
striving hard to improve certain areas which can help it achieve its vision of expanding in global
markets. Improvements are required to sustain an image of high quality manufacturer and
increase their profitability in the future. Certain plant layout and human resource problems
need immediate attention.
Problems and Recommendations
The major issue here is the problem of unsystematic layout. The machines are arranged in a
random fashion with little consideration given to efficient material flow. The major reason as
we see is poor planning. Machines purchased were installed randomly without thinking much
about the future requirements and purchases. Improving the product layout now is a
cumbersome task and could not be accomplished without halting the operations.

The inventory- raw material, work-in-progress as well as finished goods, is also suffering the
problem of unorganized storage. It kept lying on the floor where the actual operations are
being conducted. Gunny bags and metal rods can be seen everywhere on the shop floor. There
is a need to organize the inventory so as to minimize wastes and keep the operations area free
of hindering material. Also, separate storage for raw material, work-in-progress, finished goods,
as well as defects, is desired. They may go for different colored racks for each type which will
enhance the speed of finding the desired material and the tidiness as well.

Poor working conditions are another area asking for immediate attention. The unhygienic
environment could be a big demotivator for the workers. Bubber industries has been finding
tough to keep workers with them for long. Labor turnover is high and thus most of the
workforce is temporary. This can be managed to an extent by providing better working
conditions to the workforce that motivates them to continue. The workers confidence in the
company is very important and can do a lot for achieving the desired changes, which may have
invoked high resistance otherwise.

Management of waste is also lacking in Bubber industries. Waste materials and the scrap lying
around hinder the production process. The scrap needs to be cleared early and workers should
be provided with higher platform to avoid any injury due to entanglement with scrap strings.
Machines should be checked at regular intervals to ensure that the tool which cuts the strings
into smaller parts is in place and working properly. Also, the bucket that is receiving the scrap
during production should be placed at a proper height to ensure that all the scrap is dumped
into it and not scattered outside.

Certain operations like marking the finished goods with a symbol ‘B’ are automated but still
involve human intervention which could be dangerous. The worker has to closely work with the
product and the machine needle and any mistake could cause serious damage. Thus need for a
fully automated machine is felt. Also, the training of the workers on such machines becomes
extremely important.

The CNC machines are being managed solely by a single person. If he is not available due to
some reason, the operations are halted. Thus there is a need to train few more people to work
on these CNC machines.

Conclusion
Bubber industries is one of the preferred suppliers in the auto component industry. They have
achieved a reputation of providing high quality products. Still a need to improve has been felt
by its owner. Improvements like training employees, plant layout according to product flow,
inventory and waste management, better working conditions, etc. are suggested. Supervision in
the initial stages along with motivation can be really helpful. Above all, a consistent execution is
desired.