MANUFACTURED CAPITAL
Our state-of-the-art and advanced manufacturing facilities have end-to-end capabilities – right from designing and manufacturing to testing and packing of pumps. These facilities are equipped with best-in-class systems and processes that enable us to operate safely and sustainably. We utilise all our resources prudently in line with global best practices. With constant focus on innovation, we strive to deliver high quality products and create concepts that are scalable and replicable across plants.
Strategies Impacted
S2 S3 S4
S5 S6 S7
SDGs Impacted
Material Issues Impacted
- Product stewardship and innovation
- Emissions
- Health and safety
- Energy management
- Materials
- Talent attraction and retention
- Compliance
- Supply chain management
- Customer safety and product quality
- Risk management
- Cyber security and digitisation
KEY HIGHLIGHTS
10 %
Manufacturing Facilities
320,000+
Total Capacity -Pumps & Valves
227
New Product variants launched
09
Plants Certified for ISO 9001 & ISO 14001
05
In-house foundries at Kirloskarvadi
05
CII GreenCo Certified Plants
1,400+
HYPN Systems delivered
HPML
High Pressure Molding Line Technology for Cast Iron Foundry at Dewas
WHAT WE PROVIDE
- End-to-end offerings from conceptualisation and product manufacturing to implementation
- Growing presence in multiple sectors across regions (fast-growing ASEAN region)
- Strategic manufacturing locations spread across 4 continents in 5 countries
- Diversified presence across multiple segments (B2B, B2C and B2G) and multiple business models (Made to Stock, Made to Order, Engineered to Order, EPC and Services)
- Increasing the mix of value-added products, end-to-end solutions and new product launches
- Selectively supplying to large system integrators and service providers for government schemes
OUR VALUE PROPOSITION
- Offering customers a complete basket of solutions across multiple industries and geographies
- Strong presence in sunrise sectors like chemicals, petrochemicals, wastewater management and renewable energy
- Ensures cost efficiency, reduced turnaround time and adherence to local standards and sourcing norms
- Unimpacted by cyclicality due to diversified proposition
- Leveraging technological advances like 3D-printing, AI, AR and VR
- Products with superior performance, low life cycle cost and thereby low cost of ownership
System Certifications
Total quality management enabled manufacturing facilities certified for Integrated Management System comprising (HO and all 5 KBL Plants):
- ISO 9001:2015 (QMS)
- ISO 14001:2015 (EMS)
- ISO 45001:2018 (OH&S)
- ISO 50001:2018 (EnMS)
Product Certifications
- IS 9079 for Monobloc pump sets
- IS 14220 for Openwell submersible pump sets
- IS 12225 for Centrifugal jet pumps
- IS 6595 for Horizontal centrifugal pumps
- BEE Star rating
- UL/FM Certification for valves
CII GreenCo Certifications
Our four manufacturing plants are now GreenCo certified -
- Dewas - Received GreenCo Gold certification
- KPML (Stamping Unit) - Received GreenCo Gold certification
- Kirloskarvadi - Received GreenCo Silver certification
- Sanand and Kaniyur - Received GreenCo Bronze certification
MANUFACTURING MILESTONES
Dewas Plant
- 1)High Pressure Molding Line (HPML) commissioned in Aug-2023 at our Cast Iron foundry in Dewas. This has resulted in quality & productivity improvement along with reduction in carbon emission
- 2) In-house hydro test facility installed for hydrostatic pressure testing of pressure parts
- 3) Installed digital bursting tester to check strength of corrugated sheets/boxes used for packaging of pumps
- 4) Installed induction heater for hot pressing of KVM motor body to improve quality and capability
- 5) Recorded highest production in single phase assembly line in FY 2023-24 with growth of 37%
- 6) Commenced practising 8 pillars of TPM
Kaniyur Plant
- 1)Installed Servo Press for stator pressing in aluminium motor body
- 2)Installed automatic pump performance testing machine. No manual intervention is required with fully computerised testing
- 3)Commenced practising 8 pillars of TPM
Sanand Plant
- 1)Introduced 107 new product variants during the year; of these, 85% are star-rated ‘energy efficient’ models
- 2)Implemented 4 KARAKURI projects under TPM drive to improve productivity and reduce operator fatigue
Valve Plant
largest turbine inlet valve: manufactured the largest 3,800 mm valve with dual ground mounted arrangement
Key Achievements of Kirloskarvadi Plant
- 1)Achieved highest pump manufacturing in Small and Medium Pump Division a financial year with growth of 7%
- 2)Highest number of pumps manufactured in a month (March-24) recording 12% growth over the previous best
- 3)Achieved highest despatch in a month (March-24) with growth of 35%
- 4)Highest number of pumps tested with growth of 15%
- 5)Highest sale of small vertical turbine pumps - with growth of 44%
- 6)Highest Large Pump Division despatch with growth of 16%
- 7)Highest despatch of End Suction Pumps with growth of 15%
- 8)Improved OTIF performance with growth of 20%
Foundry
- 1)Replicast Foundry - Produced highest tonnage in a financial year with growth of 23%
- 2)Alloy Cast Steel Foundry - Produced highest tonnage in a financial year with growth of 24%
Key Initiatives at Kirloskarvadi
- 1)Initiated standardisation of VT Pump components for 16 pump models. Conducted optimisation of packing box sizes for better utilisation of containers
- 2)Commissioned 1,250 kW new induction furnace of 1,500 kg in cast iron foundry to achieve 80 tonnes of melting capacity per day
- 3)Initiated refurbishment and upgradation of K-line sand plant to achieve 300 numbers of moulds per day
- 4)Completed revamping of Split Case Pump division layout achieving increase in assembly productivity by 15%
- 5)Commenced modernisation of small vertical turbine Pump Assembly
- 6)Initiated modernisation of DBxe Assembly to increase pump production by 50%
- 7)Established a dedicated R&D pump testing facility
- 8)Established a state-of-the-art Safety Training Centre at KOV. The centre displays a gallery with all types of Personal Protective Equipment (PPE) used at KBL, with detailed information presented in the local language. Orientation at this Centre starts with a message on Audio Safety.
Flagging off ceremony of special pumps for nuclear segmet by high level delegates from BARC and ATVP
DIGITAL MANUFACTURING / AUTOMATION
- Installed ANDON Board, a signalling system that notifies teams about the status of a manufacturing line
- Implemented returnable and nonreturnable challans through SAP, a leading data processing system
- Installed CCTV at High Pressure Moulding Line
- Use of Zebra printer to provide technical specification of export order on the MRP sticker
- Auto linkage of name tag recognition software (Agile) through SAP for task management and delivery of quality products
- Installed Industry desktop for achievement of higher precision at turbo testing of all production lines
- Installed 3 laser marking machines to improve product aesthetics and productivity
- Eliminated manual intervention and record keeping in registers by introducing bar code-based motor serial number recording and data storage in computer
- Installed new robotic welding machine for achieving superior weld overlay quality in house
Digital Tracking with Live Reports
- Availability of live status of each sales order for complete manufacturing cycle, from order receipt to logistics
- Digitisation triggers each process owner to complete task on time
- Live dashboard for pending orders
- Tracking of pending purchase requisitions and purchase orders at supplier’s end
- Improved plant efficiency and on-time delivery
AWARDS & ACCOLADES
- Dewas plant won the prestigious Total Productive Maintenance (TPM) award by Japan Institute of Plant Maintenance (JIPM)
- Dewas and Sanand plants awarded ‘Silver medal’ following National Awards for Manufacturing Competitiveness (NAMC) 2023 assessment, conducted by International Research Institute for Manufacturing (IRIM)
Other Recognitions won by Sanand plant
- Won the ‘Par Excellence Award’ for 5S Kaizen Case Study Presentation in the 9th National Conclave on 5S organised by Quality Circle forum of India (QCFI), Ahmedabad Chapter
- Awarded ‘Winner - Excellence in Engineering & Design’ in large category by Manufacturing Today Conference & Awards 2023
- Awarded ‘Winner - Excellence In Innovation’ in large category by Manufacturing Today Conference & Awards 2023
- Awarded ‘Winner - Excellence In Operation’ in large category by Manufacturing Today Conference & Awards 2023
- Awarded ‘Winner - Excellence In Sustainability’ in large category by Manufacturing Today Conference & Awards 2023
- Awarded ‘Runner up - Excellence In Human Resources’ in large category by Manufacturing Today Conference & Awards
Kirloskarvadi plant received the prestigious ‘Narayan Meghaji Lokhande Award for Industrial Safety and Health’. In a state level competition, KOV plant ranked 3rd in ‘Hazardous Industry Large-scale’ category in Maharashtra.
SUBSIDIARY COMPANIES
Kirloskar Corrocoat Private Limited (KCPL)
KEY HIGHLIGHTS
- Achieved OEE as per the annual target
- Achieved highest sale in FY 2023-24 exceeding 5-year-old previous best
- Corroglass AR4 - Special corrosion coating product manufactured for special application like caustic soda
Kirloskar Ebara Pumps Limited (KEPL)
KEY HIGHLIGHTS
Developed BB5 model pumps with higher efficiency for use in 4 stations of NRL pipeline job
Key Product, Systems and Other Certifications
- Successfully completed plant audit for manufacturing and testing facility of pumps by North Oil Comapny, Qatar
- CE-ATEX Certification for turbine models KTB, KTD and KTB high back pressure
- Lead Auditor Certification in QMS – 5 nos.
- NACE Level-II Certification – 1 no.
Major Milestones Achieved in Manufacturing / Production
- Installed and commissioned SCADA system for online monitoring and recording of turbine test performance results
- State-of-the-art machine monitoring system to record vibrations during pumps and turbines testing, installed and commissioned
- Installed and commissioned torque meter for performance testing, which is conducted for power measurement, as per customer’s requirement
- Advance technology tooling (Thread mill & End mill cutter) adopted in CNC machine shop to reduce machining cycle time, which has resulted in saving 399 machine hours and achieved energy savings of 69,825 kWh
Technology-related initiatives
- SCADA system in Turbine Testing Lab
Karad Projects And Motors Limited (KPML)
KEY HIGHLIGHTS
- Expansion of manufacturing facility for Healthcare application completed and inaugurated by Mr. Ravindra Samant, Managing Director at Motor Division on 27th June, 2023
- Installation of Submersible Turbine Pump (STP) manufacturing setup at Motor division
- Installation of higher capacity punching press for higher frame laminations in Stamping division
NEW PRODUCTS LAUNCHED
- Oil circulating pump for healthcare application
- Special motors for fire fighting application, up to 315 frame size
- Submersible turbine pump for fuel dispensing system
- Coalescer and priming tank assembly
- Vacuum pump
AWARDS & ACCOLADES
- Won Platinum award in CII’s National Kaizen competition for safety
The Kolhapur Steel Limited (TKSL)
KEY HIGHLIGHTS
- OTD achieved above 92%
- Increased order booking for superior grades product basket of MS:AS:SS -31:17:53 (FY 2022-23: 43:09:47)
- Increased ratio of proof/finish machined orders to 29:71 machined: unmachined casting (FY 2022-23: 8:92)
- Achieved highest production and despatch value in a financial year
