2. QUALITY UFL (99%)
Q/A KPI DATA JUL-14 JUN-15
PPM Customer Rejection
( ASA & Tier II)
9764 5020 10969
PPM Internal Rejection
( Unik)
903 409 478
PPM Internal Rework
(Unik)
2554 19898 1719
Response to Customer
complaint in 8 working hours
100% 100% 100%
Plan v/s Actual Calibration / Verification of
Tools
100% 100% 100%
1 Kaizen 100% 100% 100%
Operational SOPs Gap Analysis
(QA Audit)
3 23
Problem tracking Charts to be raised in 16
hrs after receiving complain
100% 100% 100%
Monitor 10% inspection 3 times a day 100% 100% 100%
Expense Budget Monitoring (Cumulative) 100% 100% 100%
APR15 FEB15 MAR15

3. MRM MINUTES
KAIZEN STATUS
Target Per
Month
Till Total Received Total
Approved
Pending
1 10 10 10 0
7.2.1 Nil
Quality Malir Plant

4. UFL (Actual v/s Plan)

5. Customer Rejection – ASA & Tier ll
PPM
Best in World 0
Target 14-15 1500
UFL 14-15 2442
Target 13-14 1000
UFL 13-14 5048
Parts Reason Quantity

6. Internal Reject Rate
PPM
Best in World 400
Target 14-15 2000
UFL 14-15 1058
Target 13-14 2500
UFL 13-14 1452
Reason Action Taken Target Date Remarks

7. Internal Rework Rate
PPM
Best in World 100
Target 14-15 100
UFL 14-15 5238
Target 13-14 100
UFL 13-14 53
Reason Action Taken Target Date Remarks

8. Internal Scrap Rate
%age
Best in World 0
Target 14-15 1.75
UFL 14-15 1.15
Target 13-14 2.5
UFL 13-14 2.11
Reason Action Taken Target Date Remarks

9. Production time lost to machine/tool
changeovers
%age
Best in World
1.2
Target 14-15 3
UFL 14-15 4.27
Target 13-14 3
UFL 13-14 5.95
Reason Action Taken Target Date Remarks
Target Achieved
3 3.87

10. UNIK-1(51%)
SCORECARD UNIK I KPI JUL-14 TO JUNE-15
On Time Production daily 85% 25% 80% 71%
Man Minutes Utilization 90% 102% 97% 89%
Capacity Utilization 90% 86.2% 92% 92%
Rejection 3000 1180 551 360
Rework 200 5419 23932 3445
Production Efficiency 78% 83% 82% 77%
Labor Absenteeism 100% 100% 100% 100%
5s Audit variance 1% 0% 0% 0%
Kaizen Activities 100% 100% 100% 100%
Bom Accuracy 100% 100% 100% 100%
Variance QA Audit 99% 65% 97.62% 64.29%
Expense Budget
Cumulative
100% 100% 100% 100%
Cutomer Rejection 2500 1167 1239 1088
Maintenance
department kpi
95% 63% 71% 90%
5S Audit Management
Rating
80% 99% 78% 78%
Raw Material
Consumption Monitoring
1.5% -8% 53% 10%

11. UNDERLAY (AIRLAY)(83%)
SCORECARD UNDERLAY KPI JUL-14 TO JUNE-15
On Time Production daily 85% 99% 100% 91%
Man Minutes Utilization 90% 92% 80% 82%
Capacity Utilization 90% 100% 73% 86%
Rejection 1500 0 0 0
Rework 100 0 0 0
Production Efficiency 87% 103% 83% 89%
Labor Absenteeism 100% 100% 100% 100%
5s Audit variance 1% 0% 0% 0%
Kaizen Activities 100% 100% 100% 100%
Bom Accuracy 100% 100% 100% 100%
Variance QA Audit 99% 78% 94% 77%
Expense Budget
Cumulative
100% 100% 100% 100%
Cutomer Rejection 1000 134 27 114
Maintenance department
kpi
95% 63% 71% 90%
5S Audit Management
Rating
80% 99% 79% 79%
Raw Material Consumption
Monitoring
1.5% 3% 6% 3%

12. LINE-3 (80%)
SCORECARD UNDERLAY KPI JUL-14 TO JUNE-15
On Time Production daily 85% 74% 84% 96%
Man Minutes Utilization 90% 93% 75% 80%
Capacity Utilization 90% 87% 69% 80%
Rejection 500 0 0 0
Rework 100 1400 45379 1327
Production Efficiency 83% 113% 85% 97%
Labor Absenteeism 100% 100% 100% 100%
5s Audit variance 1% 0% 0% 0%
Kaizen Activities 100% 100% 100% 100%
Bom Accuracy 100% 100% 100% 100%
Variance QA Audit 99% 71% 98% 70%
Expense Budget
Cumulative
100% 100% 100% 100%
Cutomer Rejection 500 3 26 4072
Maintenance
department kpi
95% 63% 71% 90%
5S Audit Management
Rating
80% 100% 78% 77%
Raw Material
Consumption Monitoring
1.5% 100% 0% 0%

13. STANTER (61%)
SCORECARD STANTER KPI JUL-14 TO JUNE-15
On Time Production daily 85% 85% 70% 56%
Man Minutes Utilization 90% 93% 88% 89%
Capacity Utilization 90% 55% 69% 65%
Rejection 2500 855 1176 1433
Rework 200 0 0 0
Production Efficiency 87% 91% 92% 107%
Labor Absenteeism 100% 100% 100% 100%
5s Audit variance 1% 0% 0% 0%
Kaizen Activities 100% 100% 100% 100%
Bom Accuracy 100% 100% 50% 50%
Variance QA Audit 99% 100% 75% 76%
Expense Budget
Cumulative
100% 100% 100% 100%
Cutomer Rejection 2500 3495 9311 0%
Maintenance
department kpi
95% 71% 90% 63%
5S Audit Management
Rating
80% 78% 78% 98%
Raw Material
Consumption Monitoring
1.5% 51% 134% 131%

14. KAIZEN STATUS
Target Per
Month
Till Total
Received
Total
Approved
Pending
4 40 40 40 2 (due date)
MRM MINUTES
7.1.1 Nil
Manufacturing Malir Plant

20. UFL MAINTENANCE KPI 2014 ~
15
FY 2014- 2015
DESCRIPTION
(KPI's)
Target % FEB MARCH APRIL REMARSKs
5S
80% or
Greater
80.0% 80.0% 76.0%
Variance of 5s
Audit
1% or Less 0% 0% 0%
Schedule
Preventive MAINT
vs. Actual
100% or
Greater
67.0% 133.0% 100.0%
Ratio of
Preventive
Maintenance v/s
Breakdown
50% or less 144.0% 77.0% 248.0%
Machine
Breakdowns 4%
4 % or less 3.5% 3.6% 9.5%
Kaizen Activities
100% or
greater
100.0% 100.0% 100.0%
Inventory
Accuracy
1.5% -12.0% 1% 1.0%
Timely Issuance
of Work Orders
100% 100% 100% 100%
Ratio of
Emergency
Purchases
1% 0.1% 0.0% 0.3%
Exp. Budget
Monitoring
(Cummulative)
100% 87.0% 89.0% 89.0%

21. Reason Action
Taken
Target Date Remarks
Production time lost to machine/ tool
breakdowns
%age
Best in World
0.49
Target 14-15 4
UFL 14-15 4.79
Target 13-14 4
UFL 13-14 5.76

22. DESCRIPTION
REASON ACTION TAKEN TARGET
DATE
REMARKS
Line IV
Card Wire Damage Change Wire 23.4.2015
to
26.4.2015
In House
Line IV
Feeding Motor Problem Change Motor Bearing 11.4.2015 In House
Line III
Entry roll Shaft Problem Repair Shaft 13.4.2015 In House
Stanter
Heater Problem Clean Heater & Adjust Air
Pressure
27.4.2015 In House

24. Total Kaizen Given till
March 2015
Total Kaizen Approved Pending Kaizen
4 40 0
MRM Minutes March, 2015
7.3.1

25. Thank You