The beautiful Holy Town of Rishikesh.
At Haridwar I understood only state buses were plying between Haridwar and Rishikesh.
Without wasting further time I boarded an ill maintained rickety ,weather worn out bus for Rishikesh. The bus was full but could found a seat, crumpled ,worn out in the corners , to sit and relax .
I ventured to ask the conductor who was checking the ticket “ hello sirji in how much time we will reach Rishikesh ?. I need to get down near Glass Factory. Will you let me know please?.”
“ we will reach Rishikesh in thirty minutes. I will help you to get down at Glass Factory. It is en-route to the town. No problem” the conductor answered with a smile.
Haridwar is city of God ,the gateway to Lord Shiva and Lord Vishnu.
The Holy Ganges river flows through the city .
It is said Sage Bharthari came to Haridwar in early Eightees and meditated on the banks of the Ganges .
Soon after his death his pupils including his brother constructed a big Ghat which later came to be known as Har Ki Pauri.
The pilgrims in thousands throng this Ghat every day to offer prayers and meditate on the ghats surrounding the Har Ki Pauri giving a serene spiritual panoramic view ,a real treat to the eyes.
The bus zoomed on the dingy narrow zig – zag alleys ,lanes. The jolts jerks did not allow me to relax any way.
After nearly fifteen minutes the bus halted and the conductor hollered “ glass Factory stop. Get down please.”
I gathered my things and got down thanking the conductor very much.
A t the gate of the Glass Factory I asked for Mr Thadani.
The security guard , a puny sized man went inside and returned in short time ,picking up my belongings and ushered me into the office of Mr Thadani.
“kindly wait here ,Sahib will come soon”. The security man said shutting the door upon me.
I was frazzled and slumped into a chair.
After a while a short statured pleasant looking man opened the door and said “ Mr Kaul morning I am Sood ,Administrative officer. You seem to be tired.” extending his hand for a hand shake.
we shook hands warmingly and I thanked him for knowing about my arrival.
“ A great relief Sood Sahib to see you moreover your pleasant smile. Yes I am tired.”
I said smiling .
Mr Sood laughed heartily.
“ Mr Thadani spoke to me about you on telephone. He will be coming in half an hour. He lives in Dehradun and has to drive down the hilly road. “ He concluded politely.
A boy with a tray of two cups of tea and a plate of cookies walked in and kept the same on the nearby table leaving without uttering a word.
“ help yourself to tea kaul sahib, please.” Mr sood said while picking the other cup for himself.
“ Thanks I needed something to warm up. Tea is fine “ I said sipping the tea from the cup having a nimble on the crunchy cookies.
Suddenly the door opened ajar and an elderly tall bespectacled man entered saying “Hello Mr Kaul , Thadani here ,how was the journey .pleased to see you finally.”
Pointing to Mr Sood Thadani continued “ I will discuss with Mr kaul and take him for a Factory visit . You talk to IDPL Guest house for his accommodation on our company quota.”
“ yes sir I will do that” replied Mr sood and walked out slamming the door after him.
After exchanging pleasantries Thadani spoke of the difficulties in running the operation profitably.
He was candid enough to admit that things were bad.
And need to put systems in place and set the things in order with my assistance.
“ I will take you for a factory round and you can have graphic picture of problems and I would like you to present me with plan proposal to improve the working systems so that we pack good saleable production.” He said anxiously.
“ Will do my best . “ I replied briefly.
“ Yes one more thing you can call me Thadani ,no formalities as such.” He walked out of office and we went for a round of the production hall., machine end followed by cold end operations.
The cold end operations were awful. The continuous production on the conveyers was uncontrollable and falling off to the floor in large heaps.
“This is biggest problem and we are unable to cope up with the size of the production . “ he bemoaned.
“ I want you to address to this problem first. “ He said anxiously..
“ Yes I understand . we will set it right. “ Ireplied confidently.
“Really” He beamed.
“ Yes why not ? “ I said cooly.
I went to the Lehr end and picked up a few bottles . The quality of bottles was bad ,very bad. Production were not rectifying defects. Because of inadequate packing and inspection at the cold end. Right decision by the production Engineer. Since cold end operations were in jeopardy he could hardly afford to spoil costly mould sets.
I realised the enormity of problem and the urgent need to arrest it as soon as possible.
I drew up my plan in Mr Thadani’s office and discussed at length the steps to be taken in with him . He was desperate to do anything everything to see good production on the floor to be despatched to restore confidence of primary customer IDPL(Indian drugs and pharmaceuticals limited).
We were supposed to give 7.5 ml 10 ml and 15 ml glass vials about 200,000 nos every day.
I pleaded with Mr Thadani to give me 20 days to train inspectors and take other quality measures to pack 2 lakh good quality bottles per day ,which was roughly 80% of the total production.
I spoke to M.D Mr Agarwal on phone highlighting the problems at hand, there by assuring him the problems are being addressed to and could be set right within stipulated time of about 20days..
I further told him that Mr Thadani had given all necessary inputs for meeting the challenge.
I formed a team of two supervisors and three senior inspectors to conduct training of time and speed control of the production on cold end on the running conveyers technically called glass Lehrs.
We put initially eight inspectors on each Lehr in each shift to handle the inspection for sorting of glass defects .
After 6days I reduced two inspectors on each Lehr for the inspection job.
The training session was carried round the clock in all three shifts.
I requested the Maintenance Engineer Mr Rao to make Inspection boxes with glass and lighting facilities to tone up the speed and time of inspecting the 100 percent bottles.
He was kind enough to fix the inspection boxes on the Lehrs speedily.
After around 8 days of intense training , the inspectors handled full production of three Lehrs of three shifts .
After achieving the break through I requested Production engineer , Mr RK Gupta JI, a very efficient affable young man to change the moulds blanks etc on the machines so that we could pack good production for onward despatches to the customers.
He was too good to cooperate and made the required changes rapidly.
All worn out damaged equipments were weeded out .
I put one inspector in each shift on machine end(hot end) to find defects and get them rectified before feeding into the cold end Lehrs so that defectives are controlled at hot end itself.
With effective coordination of all concerned we could pack 200,000 good quality production exactly after 16 days .
Soon after I formed a statistical quality team under one qualified good supervisor Mr Mathur.. The team was trained to divide day’s production in adequate lots for statistical final inspection.
The lots were drawn as per international plans M, N, P etc.
Thus we ensured AOQL (accepted out quality levels) as major defects 0.5 and minor 1.5 .
Mr Thadani was perhaps happiest man to see the company heading for a good fortune after nearly a year of its starting date.
“ Thank you Kaul . what I could not do ,you did it .” Thadani said calmly to me.
“ sir it is my duty and due to your cooperation and of all concerned ,we are successful” I replied humbly.
Needless to say I was requested by Mr Thadani to stay permanently in RISHIKESH.
RISHIKESH is a beautiful town with the Holy Ganges flowing in the midst of it.
Rishikesh is gateway for pilgrimage to the four holy places in India known as “Char Dham”, The pilgrims throng to this place for its bewitching picturesque mountainscape , tumbling streams, waterfalls. thus presenting a panoramic view.
The beauty of the town enthralled me and I made up my mind to accept Mr Thadani’s offer.
Interestingly I worked in the glass factory of Rishikesh for ten long years before moving to one more great company in Delhi.
By then The company expanded its production capacity by installing three more MCs and were manufacturing quality products ranging from the sizes of 7.5 ml vials to 750 ml liquor bottles.
Life is a challenge at every step ,the timely decisions right expertise ,sincerity and determination leads any one to the door of success and satisfaction of accomplishments.
P.S on great demand of my readers and blog followers I wrote the part 2 of MY STORY.