Manufactured
Capital
Optimising Operations for Growth
we are paving the way for a future-ready organisation that leads by example in quality, efficiency, and sustainability.
At Mahindra Accelo, we understand that the foundation of our success lies in our state-of-the-art infrastructure and cutting-edge technologies. Our strategic initiatives, backed by innovation and a commitment to safety, empower us to maintain our competitive edge while delivering exceptional value to our stakeholders. Through dedicated efforts in optimising our operations, we are paving the way for a future-ready organisation that leads by example in quality, efficiency, and sustainability.
Capitals Impacted
- Financial Capital
- Human Capital
- Intellectual Capital
Stakeholders Impacted
SDGs Impacted
Key Highlights
25
No. of Case Studies in the Kaizen Competition
13+
QC Stories (QC Story Competition across the Accelo Group)
4,129
Kaizens Completed across all Locations in FY 2024-25
90%
Participation Obtained for Kaizen Implementation
2
Innovation Projects Completed
13
Improvement Projects/QC Stories Completed
₹ 12.5 crore+
Cumulative Savings
The 6S Strategy
As a key part of our operational excellence framework, we have integrated the 6S strategy, combining safety with the 5S principles. This measure aims to create a disciplined approach that drives operational efficiency. Our Plants are organised into clearly defined zones, each with dedicated ownership and strict adherence to the 5S principles. Regular 5S audits and red tag campaigns, tracked by the management through the Balanced Score Card (BSC), ensure constant focus. We further enhance this culture by providing skill-building training to our employees. This commitment was further validated when we received the 5S Excellence Trophy from CII.
The Kaizen Journey
We focus on continuous improvement, using the Kaizen methodology as a critical tool for eliminating inefficiencies. Our Kaizen portal helps us replicate best practices across locations. It aligns initiatives with the PQCDSHM categories: productivity, quality, cost, delivery, safety, health, and morale. Non-manufacturing functions showed remarkable participation in this year’s Kaizen competition. This reflects a widespread commitment to operational excellence throughout our Company.
Visual Factory
To boost productivity, we introduced visual management systems across our manufacturing facilities. These visual controls help reinforce safety standards, Kaizen principles, and other operational frameworks. Also, they enhance employee engagement and provide better clarity.
Total Productive Maintenance (TPM)
Our Total Productive Maintenance (TPM) efforts continue to enhance equipment efficiency. We focus on achieving the ‘4 Zero's—Zero Accidents, Zero Breakdowns, Zero Waste, and Zero Defects. This approach has significantly improved our Overall Equipment Effectiveness (OEE), driving higher productivity and enhancing safety.
Innovation-Led Progress
Innovation is a core value at Mahindra Accelo. Through our MIND™ (Mahindra Innovation Method) programme, employees are empowered to contribute innovative solutions. From ideation to execution, we provide our teams with continuous training and resources to foster a culture of creativity.
Prioritising Safety and Well-Being
Our workforce’s safety is integral to everything we do. We enforce strict safety measures across all Plants through the Mahindra Safety Way (TMSW) model. We regularly conduct safety audits and track departmental safety scores. Additionally, we proactively engage with external experts to train our teams in critical safety areas like fire safety and first aid, further strengthening our commitment to our workforce’s safety. We also celebrate National Safety Week annually, reinforcing a culture of safety while achieving a remarkable record of zero reportable and non-reportable accidents.
Prioritising Safety and Well-Being ISO & IATF Certifications
All our Plants have ISO 9001:2015, ISO 14001:2015, and ISO 45001:2018 certifications. Some of our facilities also hold the IATF 16949:2016 certification. These certifications reflect our commitment to meeting international standards. They also highlight our ongoing efforts to maintain excellence in quality, environmental sustainability, and occupational health & safety.
Six Sigma
We have incorporated the Six Sigma principles into our operations to further ensure process efficiency and quality. Our Green Belt training programmes equip our employees to actively contribute to the improvement journey.
Streamlining Changeover Processes
By successfully implementing the Single Minute Exchange of Die (SMED) methodology, we have significantly reduced changeover times across our slitting lines. This approach has greatly improved our operational efficiency. By adopting the ECRS (Eliminate, Combine, Realign, and Simplify) principle, we achieved significant improvement in productivity and flexibility. This principle has also streamlined operations and enhanced efficiency.
The Mahindra Way (TMW)
The Mahindra Way (TMW) framework serves as the foundation of our operational excellence journey. This robust framework guides our commitment to systematic, continuous improvement. Our advancements in TMW assessments demonstrate our dedication to embedding best practices across all levels of operation, fostering a culture of excellence, and ensuring that we consistently raise the bar in our pursuit of business excellence.
Ensuring Compliance and Best Practices
We perform regular safety audits, including TMSW (by CSC assessors), IS14489 (by DISH-approved auditors), ISO 45001 (by TUV Nord), and internal safety audits. These rigorous assessments enable us to maintain compliance with safety standards and identify areas for improvement. Additionally, Plant heads and cross-functional teams conduct weekly safety Gemba rounds to proactively identify hazards and prevent potential incidents, reinforcing our commitment to a safe working environment.
A Long-Term Vision for the Planet
Sustainability is a fundamental principle that drives our approach to business. We adopt practices that prioritise the long-term welfare of the environment, society, and the economy. This year, all our Plants attained Zero Waste to Landfill (ZWL) certification following a thorough assessment by an independent body. This achievement reaffirms our commitment to sustainable practices across all levels of our operations.
Capital Expenditure Plans
We believe in making thoughtful, purposeful investments that align with our long-term goals of growth and leadership in the industry. By focussing on modernising our manufacturing infrastructure, advancing our technological capabilities, and embracing sustainability, we are ensuring that we create lasting value for our stakeholders—today and in the future.
Paving the Way for Industry 4.0
At Mahindra Accelo, we are constantly striving to stay ahead in the world of manufacturing. This year, we have made important upgrades across our Plants, bringing top-tier machinery and digital tools that help us work smarter. These changes are key as we move towards Industry 4.0, and they are already making a difference in how we enhance productivity, improve the quality of our products, and keep our workplace safe.
Key Progress Achieved
At Accelo Group, operational excellence is our constant goal. Our culture at Accelo always encourages ongoing development. We started several drives in various categories last year, which greatly benefited the business. We have carried out a few projects at our various locations using this continuous improvement learning strategy. We improve OEE by driving TPM everywhere, which results in the biggest volume ever contributed by all our plants. We also placed a strong emphasis on our teams’ competency development.
Significant advancements have been made in several important business domains during the previous year. By holding group-level Productivity Improvement Kaizen Competitions, Cost Booster Kaizen Competitions, and QC Story Competitions, we have established a strong basis for long-term growth and operational excellence through the effective application of volume-up strategies, quality and safety initiatives, cost-saving projects, and additional process improvements.
These advancements have not only contributed to financial gains but have also enhanced our competitive position in the market, bolstering our reputation as an innovative and reliable organisation. Moving forward, we remain committed to building on these successes, continuing to drive efficiency, and focussing on delivering value to our customers, stakeholders, and the broader market.
At Mahindra Accelo, we placed unparalleled importance on employee safety—a commitment deeply embedded in our comprehensive strategy that addresses every aspect of workplace security. By promoting personal hygiene practices alongside strict adherence to safety protocols and providing essential protective equipment, we take proactive strides towards safeguarding our workforce’s well-being. We adopt a proactive approach by conducting regular site audits and surveys to identify potential hazards and take swift corrective action. By adhering to ‘The Mahindra Safety Way’ (TMSW) model and our Quality, Environmental, Occupational Health, and Safety (QEHS) policy, we ensure the highest standards of safety and compliance are upheld. This approach combines hazard prevention, continuous education, and active participation, creating a culture where safety is deeply embedded in every level of the organisation.