The Jayashree Group : Playing a Pivotal Role in Automation, Control & Safety
When we think of automation and control solutions for speed, position& power, the first name that conjures up in mind is that of the Pune-based Jayashree Group. Be it Soft Starters for smooth starting of Motors and do the energy saving or Electronic Load monitors for true power measurement and control, speed switches for non-contact speed monitoring or Level monitors, Proximity Switches or encoders, or conveyor safety switches, Jayashree has everything in its vast range to offer – all under one umbrella. A technology driven and customer-centric group to the core, Jayashree has a reputation for quality, reliability and integrity since its inception in 1972 when its first patented product ‘Electrodynamic Speed Switch’ triggered the revolution in import substitution in independent India. Armed with futuristic products and customized solutions, Jayashree is making its presence felt in every sector of our economy. “The greatest recognition for our knowledge base and reward for our relentless R&D efforts is when we are consulted on technology aspects even by the Defence,” says Mr. D. Dabke, Managing Director, Jayashree in an interview with Mr. P.K. Balasubramanian. Excerpts:
Q. Jayashree has since metamorphosed into a technology driven enterprise. Could you share your beginnings with our readers?
Jayashree was started in 1972 by Mr. Ram Bapat, our present Chairman. He is basically an Elect rical engineer, having had long tenures with the MNCs like Siemens and SKF. His first assignment was with Kirloskar Electric, as a Motor Design Engineer. Armed with his vast knowledge and experience, he decided to venture into business. This is how Jayashree came into being.
The first product the company introduced was the patented Electromagnetic type speed switch which was an import substitute. The product was well received by the market. That was the beginning. I myself joined the business in 1980. The rest is history.
Q. Which are the group companies today and what are their product lines?
The Jayashree Group comprises three companies. The flagship company is Jayashree Electrodevices P. Ltd. which makes conveyor safety products for bulk material conveyors. The range includes Pull Cord switches, Belt Sway Switches, Heavy duty limit switches, Rotary cam limit switches and belt watch systems. The company also makes DC brush type & AC/DC brushless servo motors.
Jayashree Electron P. Ltd. which makes electronics products started manufacturing Electronic products in year 1987 . The range includes drives and control products for induction motors – like Reactor Soft Starters for LT/HT motors, Digital soft starters for LT/ Ht motors, electronic brakes and load monitors. Under control and safety products for automation, we make electronic speed switches, tachometers & anemometers, level monitors, transducers and special purpose timers. We are the biggest Indian company making proximity switches of different types like inductive, capacitive, optical, magnetic and ultrasonic.
The third entity in the group, Jayashree Encoders P. Ltd., as the name suggests, makes Rotary Shaft Encoders. These are manufactured with technical know how and key components from Encoder Products Co., USA. Size-wise, Jayashree Electron contributes 60% of our group turnover which is currently Rs.50 crores. Jayashree Electrodevices contributes 30%, while Encoders contribute the balance 10%.
Q. What is your niche in automation?
Our proximity switches are the basic control products for automation. These are used in all automation systems whose control functions depend on the input signals from these sensors. Virtually every industry requires these. Some of the applications are position sensing, counting, speed monitoring in machine tools, Robotics, Bulk materials handling, pharmaceuticals, dairy, foundries, steel plants, plastics industries, etc. Special models such as color mark sensors, high temperature, intrinsically safe for flameproof applications, large sensing areas, linear output etc. are also available.
Q. What is special about your Reactor Soft Starters?
Our HFSR series Reactor Soft Starters for LT/HT motors are designed as per IS: 5553-Part 3 with air core(coreless) to achieve Harmonics-free starting of motors. These are ideal for starting cage motors and can be connected to line side/neutral side of motor terminals. Our Digital Soft Starters are energy savers. Manufactured with knowhow from Fairford Electronics Ltd, UK, these microprocessor-based soft starters are developed for smooth and jerkless starting of AC induction motors. These are connected to pumps, compressors, centrifugals, windmills, etc. for their smooth and efficient running.
The potential for energy saving by arresting electrical energy losses is phenomenal. In different machine shops hundreds of machines with old motors are running idle for long periods. Similarly, in battle ships, hundreds of motors are working. While going in for modernization, these facilities most ideally use soft starters for achieving energy conservation and savings for the exchequer.
Q. May we know more about your electronic speed switches?
Speed switches are non-contact type speed monitoring units for monitoring any over-speed/under-speed of any rotary or linear motion. For instance, conveyors can get damaged prematurely due to overload. This has to be sensed in time. Else there will be loss of production leading to financial losses. In the last 25 years we may have installed some 300,000 speed switches which are all giving peak performance in the industry.
Q. Which are your products normally customized?
Our Soft Starters are all customized products. They are tailor-made and integrated with other equipment. Hence selection of components, and mechanical dimensions and tolerances are all crucial.
Q. Among your various products, could you single out one product which is outstanding?
All our products are unique. But then technology-wise and in terms of contribution, our Reactor Soft Starters deserve special mention. They contribute 60% of Jayashree Electron’s turnover which is Rs.30 crores. We have more than 5000 installations in the country and outside. The next category in the order of importance is Electronic Speed Switches and then Proximity Switches. Our soft starters are exported to countries like Kazakhistan, Tunisia, Turkey, Saudi Arabia, Singapore, Malaysia, Thailand and so on. Our Proximity Switches have also being exported to USA, Canada, Sweden, Austria, Argentina, Bangladesh, Nepal, Philippines, and Sri Lanka. We are also developing a channel partner in Russia.
Q. How do you infuse quality in your products?
We are an ISO-9001-2008 company. So quality is very much embedded in our system. We are using the best of components sourced from world-class companies. Right from the raw material selection through the process of manufacture , assembly, and the final testing, we have a stringent QC regimen. We have pick-n-place machine and inspection machines for SMD assembly. All our test equipment are in-house to control the quality closely. On routine basis our products are tested at govt. test houses like CPRI,ERTL,ERDA, etc. Our people are also well trained. So we are self-reliant when it comes to quality assurance.
Q. Could you give some idea of your wherewithals?
Jayashree Electron has two plants admeasuring 35,000 sq. ft. Jayashree Electrodevices is housed in a new factory of 30,000 sq. ft. area. Jayashree Encoders have a plant area of 10000 sq. ft. All these facilities are in Bhosari/Pimpri , Pune. We have a total strength of 300 employees. This includes 75 engineers. We have our own R&D in-house which is engaged in product development and product innovations.
Coming to marketing, we have a nationwide sales and service network. Our representatives are in place in Mumbai, Delhi, Kolkata, Hyderabad, Bangalore, Ranchi, Raipur, and Nashik, staying close to our customers.
Q. Could you say something about your human resources and your operating philosophy?
Four decades is quite a long period in the annals of a company to prove its credentials. We are technocrats confident of our engineering acumen. Fifty percent of our employees are women. At Jayashree, they find a congenial work atmosphere and a safe and secure work place. We care more for the work culture, environment and relations than mere turnover. Frankly, all these years the adverse market conditions or ups and downs have not affected us.
The credit for this must go to our dedicated workforce as much as to the management. We disburse salary to our employees on 5th of every month. Not even once there has been a delay in all these forty years. We have also been banking with just one bank – State Bank of India . Never ever have we have overdrawn our account. All this speaks enough for our consistency, concern and commitment to people, institutions and business.
Q. What are your growth plans?
We have had a steady growth all these years. This trend will continue. We shall expand our product mix and add value to them on a continuing basis. We shall have a fair share of business from modernization programs of the railways and the defense. But any expansion/diversification will be in our domain and area of specialization.
Q. What are the challenges ahead for you?
We have to compete with the MNCs on quality and price even with our small operating levels, when the manhours are the same and all other inputs and overheads are the same. This is a big challenge. Getting good people in SMEs and retaining the existing ones is a challenge. Marketing is yet another challenge. In India, strategy varies from product to product. For a product like soft starter, it takes minimum six months’ lead time to get an order. We should be able to sustain till then.
Q. What’s the shape of things to come in automation and control?
As compared to Europe, in India automation in the manufacturing sector is at the level of 30%, and in engineering, chemical and pharma industries it is less than 50%. So there is so much of scope for automation in the country. In the coming years we shall see the share of automation increasing in all spheres including infrastructure – irrigation, road, airport … All these projects would go in for automation products like soft starters. Customization will also increase.
Q. What’s your moat remarkable contribution to Indian engineering?
We have developed two product s for measuring the speed of bullets, which normally travel at a speed of 800 m/sec., for the defence. We are glad that such establishments are consulting us on technology aspects. This gives a lot of inner satisfaction.
Q. Where will you be five years hence?
Five years hence we shall be a Rs.100 crore company. By then we shall be a 500 strong force as well.
