Town hall factory may 12

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  • 1. TOWN HALL MEET– 2nd May 2012 1
  • 2. 1.Plant & Production Performance2.News from the Product Desk Washing Machines /Commercial Washers / Kitchen Appliances3. News from Operations R n D/SCM/QC/Benchmarking/Training4. Cell Improvements – Corlim Cell5. Questions & Answers 2
  • 3. Volume Details – Vanaja Rane 3
  • 4. WM– Apr12 V/s Apr 11 Comparison Production v/s Despatch 18,000 16,000 14,000 12,000 10,000 8,000 6,000 4,000 2,000 0 2012 2011 PRODUCTION 15,828 11139 DISPATCH 16031 10791 4
  • 5. CD Apr 12 V/s Apr 11 Comparison Production v/s Despatch 350 300 250 200 150 100 50 0 2012 2011 PRODUCTION 32 330 DISPATCH 259 152 5
  • 6. Plant Performance - Kartik 6
  • 7. Business Performance Factory – Mar12 Particulars 2011-12 (Mar) 2010 –11 (Mar) Budget Actual Actual Net Sales 22.53 Cr 19.50 Cr 13.93 Cr RM 69.32 % 79.23 % 77.84 % % to Net Sales PBDIT 15.87 % 2.92 % 10.04 % % to Net Sales 7
  • 8. YTD Business Performance Factory -Mar YTD 2011-12 Mar 2010 –11 Particulars Budget Actual Actual 313.79Cr 294.32 Cr 234.50 Cr Net Sales RM 70.22 % 74.72 % 72.22 % % to Net Sales PBDIT 16.62 % 11.83 % 11.96 % % to Net Sales 8
  • 9. News from Product Desk~Washing Machines by Venkatesh & Mandar 9
  • 10. WASHING MACHINESales Performance FTM Apr 12 PRODUCT BUDGET ACTUAL %ACH %GOLY (VOL) (VOL) FRONT 14,280 15,995 112% 39% LOADERS TOP 4,284 1,628 38% -52% LOADERS 10
  • 11. AQUA SPA WASH – A UNIQUE FEATURE IN NEW TOP LOADERWASHING MACHINES1. 3D Water fall 2. Tornado Wash 3. Centre punch 4. Scrub board Wash 5. Air Bubble Wash 6. Dirt Sway away 7. High Speed revolution 11
  • 12. Commercial Washers by Kartikayein 12
  • 13. Commercial Machines – Performance FTM/YTD Quantity Value All India Budget Achieved Backlog LY GOLY% Budget Achieved Backlog LY GOLY% IDW 69 54 -15 34 59% 138 126 -12 80 58% ILE 33 27 -6 17 59% 66 82 0 33 150% Total 102 81 -21 51 59% 204 208 0 113 85% Esteemed Client Addition Repeat Orders Infosys, Gurgoan SAP labs Chung Wah Goa Shipyard Ltd. Dr. Reddy’s Lupin Ltd. The Bake House Inn Bangalore Club Royal Goan Beach Club Qualcomm Apollo Hospitals ABB HSBC Nala Hotels 13
  • 14. • All India trainers training – Trainers trained on the commercial machines. – Franchisee are provided training to take up the part of commercial machines service.• Laundry Chemicals- Testing started, to be launched in mid of June – AIO Detergent- Premium, medium and economic. – OXY and Chlorine Bleaches – Emulsifiers – Neutralizers – Softeners – Spotting Chemicals• Cross Selling is being done with great focus. – Modular kitchens at Royal Goan Beach Resorts. – Microwave oven billed to one of the IDW customer. Now going for Dishwashers 14
  • 15. Kitchen Appliances by Rajan Chandna 15
  • 16. Kitchen Appliances – April 2012Volume Built in Total Chimney Built in Hob Built In oven Built In DW MWO 221 58 33 3 10 325 Value - Lacs TY LY GOLY 48.69 42.17 15.46 %
  • 17. Why We require a Chimney BAD VENTILATION ...• Bad ventilation is when there is no proper channel to exhaust all the contaminated air generated during the cooking process and due to the burning of the fossil fuel .i.e. LPG and CNG, in the KITCHEN. Effects of bad ventilation:• Besides spoiling the aesthetic look of the kitchen it also causes various health problems like asthma, head aches, nausea, allergy, cancer, birth defect etc.
  • 18. Size: 60/90 cmGL-10PL Type: Wall Mounting Suction: 1050 M³/h Finish: Glass /SS Motor: 250 watt- Centre Mounted Rotor: Metal -2 Rotor Outlet: 150/120 Filter: AL. Cassette-Outer layer SS -2/3 Control: Electronic – Touch Speed: 3 Light: 2 LED - 2 watt each Maximum Power – 254 Watt *Smart Feature – Auto – by activating the function Chimney will switch on by it’s own if certain amount of smoke is accumulated is under the chimney Timer – Chimney can be programme for 60 Minute Remote Sencer– optional - will be available from March SIZE SAP Code Offer MRP 60 8903287002267 14990 20990 90 8903287002311 16990 22990 *Feature deactivate in case of power failure
  • 19. Size: 60/90 cmC-1- PL- 60/90cm Type: Centre Island Suction: 960 M³/h Finish: SS Motor: 250 Watt Rotor: Plastic -I Nos Outlet: 120/150 Filter: AL. Cassette- 3 Control: Electric Push Button Speed: 3 Light: 2*20 halogen Maximum Power – 290 Watt Clean Air – Every hour Chimney will switch for 10 Minute at low speed to remove the stale air Filter block Indicator – will remind customer it’s time to clean the filter by way of blinking the light. Delay Timer – ideally chimney must be kept on for 10-15 minute even after the cooking to remove the cooking contaminate which are generated due to burning of fossil fuel ( LPG & CNG) beside smoke, smell which generated during the cooking process Booster speed – chimney is programmed with inbuilt prefixed time for high speed for initially air flow than automatically come to preset speed. SIZE SAP Code offer MRP 60 8903287002243 14990 22990 90 8903287002250 16990 25990 *Feature deactivate in case of power failure
  • 20. 532S- MLR- CG Size 590 X 520 Finish - check Glass Grid –Sheet Enameled Burner -3 Nos- Flat Burner One - LR – 3.8 Kw One TR- 2.50 KW One Auxiliary 1.00 KW Cutting Demission L*W*D MM 555 X 485X60 Code TP MRP 8903287004131 8800 14990
  • 21. RnD Dept by Oscar 21
  • 22. Wind chill PDM Link 22
  • 23. 23
  • 24. Product View 24
  • 25. Supply Chain Management byManerkar 25
  • 26. Supply chain management procurement cellTODAY & TOMORROW OBJECTIVE PRESENT PRACTICE FUTURE PRACTICE PLANNING *MANUAL SCHEDULE THRU * THRU PORTAL BY END E –MAIL AND TELEPHONE. JUN COMMUNICATION *SCHEDULES * THRU PORTAL BY END *SOB JUN *IFB DAY WISE PLAN RESPONSIBILITY OF * DELIVERY EX WORKS FOR •DELIVERY F.O.R VERNA VENDORS OUTSIDE GOA SUPPLIERS FOR ALL BY END JUN BUFFER MANAGEMENT *AT IFB AND ALL CARGO •AT SUPPLIER PLACE ALSO END MAY CAPACITY THEORITICAL ESTIMATIONS THEORITICAL ESTIMATION EVALUATION & AND FOLLOWED ACTUAL BUILDING DECLARATION BY SUPPLIER VERIFICATION AT SUPPLIER DURING PPAP -ON CONTINUOUS BASIS 26
  • 27. OBJECTIVE PRESENT PRACTICE FUTURE PRACTICEDELIVERY AND •AFTER 24 TO 72 HRS OF *SUPPLIERSQUALITY RESPONSE INCIDENCE REPRESENTATIVE AT IFB FOR TAKING ACTIONS ON THE SPOT. -BY END JUNQUALITY *COMPONENT APPROVAL •COMPONENT APPROVAL FOLLOWED BY PPAP FOR FOLLOWED BY PPAP FOR CONSISTENCY CONSISTENCY AND TILL MAKING THEM D.O.L. -BY END SEPPACKAGING *PACKAGING STANDARD AS PER •PACKAGING FOR D.O.L. IN SUPPLIER’S CHOICE. THE FORM SUITABLE FOR ASSEMBLY. -BY END SEPPAYMENT FOR *OVERDUES OF 1-2 MONTHS *PAYMENT AS PER CREDITSMOOTH SUPPLIES PERIOD FROM Q2 27
  • 28. Benchmarking by Mitesh Gajjar 28
  • 29. 1.Certification Requirement for Export to Europe – Model - Elite Sx and Senator Sx Test Remark Status LVD Low voltage directive -Included Completed 2006/95/EC in CB (Safety Certification) directive EMC Electromagnetic Compatibility Will be completed in-house 2004/108/EC Testing With the help of TUV ErP 1015/2010& Energy related product Testing To be tested in VDE Energy report (1061/2010) ROHS Restriction of hazardous In-progress 2002/95/EC substances REACH Registration, Evaluation, To be tested in INTERTEK 1906/2006 Authorization and Restriction of Chemical substances Package Heavy metal detection in Will be tested in TUV, 2005/20/EC or packaging materials Material already sent. 94/62/EC Noise Report NOISE level measurement of Noise testing is completed in- machine house and certificate has to be 29 received from TUV
  • 30. 2.NABL ACCREDITATIONNABL accreditation for Test Lab NABL Manuals andPhase-1 proceduresPhase-2 Level 2 user DocumentationPhase-3 System deployment 2012 Apr May Jun Jul Aug Sep Oct Nov DecPhase-4 GAP Analysis Phase 1 Phase 2 Phase 3Phase-5 Internal Audits Phase 4 Phase 5Phase-6 Deployment actions based on the requirements identified Phase6 by NABL assessors.STATUS : NABL implementation will be done with help of ALPHA & OMEGA Consultancy 30and expected to be completed by NOV-2012.
  • 31. 3. TESTING AND VALIDATIONTo Test and validate Senator SX 8Kg 1400rpm Model.1. Al bracket cracked and shaft loosened.• Action: Drum shaft is Improved and is Under Test2.WireHarness Cut at Motor Connector. SENATOR SX 8Kg 1400rpm• Action: Taping length is increased3.Display flickering• Action: Problem reported to Topband4. Pressostat /Bubble pump tube cut• Action: Spring collar orientation is changed and foam ring will be provided.5. Controller capacitance switch Resistorfailure• Action: This is due to manual soldering process will be resolved in production batch. 31
  • 32. SAP & IT by Mr Sanjeev Saxena 32
  • 33. Material Receipt Process Optimization at Security Gate for Stores 33
  • 34. Previous Process at IFB Verna Material Unload and Vendor park the Gate entry - 103 made vehicle at Gate at Store Bottleneck 2 – 3 Bring the Documents Material placed at hrs waiting time of to store for validation counting scale of schedules lines vendor and processing time of After confirmation of While weighing, document schedule line, vendor system print the tag for make the gate entry in fixing on box/carton the register Manual Record Get the stamp at keeping at Security Security Counted Qty – with tag forwarded to store for GRN Vehicle move to allotted way 34
  • 35. Revised Process at IFB Verna Material Unload & Result Vendor park the placed at counting vehicle at Gate scale Reduction in Document process at waiting time of While weighing, vendor and Gate by Security in system print the tag for Bartech System fixing on box/carton processing time of document Security stamped paper with System Gate Entry Number Counted Qty No Manual document forwarded record keeping at to store for GRN Vehicle move to security allotted way 35
  • 36. Training by Krishan 36
  • 37. Online Test General Total ScoreSl. No. Participants Name Product Feature Awareness out of 40 1 Sudhakar Raut 17 85% 16 80% 33 2 Mitesh Gajjar 16 80% 14 70% 30 3 Ramkrishna Bale 16 80% 12 60% 28 4 Petcy Monteiro 17 85% 10 50% 27 5 Senthil Murugesan 11 55% 14 70% 25Out of 174 employee, 45 employees only appeared for on line test and out of them29 employees appeared for online test on Product Features. And 38 employeesappeared for online test on General Awareness and only 20 employees haswritten both online test.Test dates – 18th & 19th of every month 37
  • 38. Service Centre – Rohit Gaad 38
  • 39. Goa Service Center• Objective of the Goa service center is to drive closure of pending calls greater then 48 hours by co-ordinating with the Franchisee and Branches and to improve customer satisfaction.• Currently operating the Goa Service center from Digisol premises in Verna Industrial Estate.• Total 15 agents were recruited and trained on product /process and CRM.• Currently we are running two outbound processes from the service center i. e Welcome Calls to new customers who have bought our products post installation and driving pending calls greater then 48 hours from CRM.
  • 40. Goa Service CenterThe two processes have been initiated for customer’s fromGoa, West and North.Welcome Calling Snapshot• Total Customers Dialed – 4064• Total Customers Spoken -2672• Customers Satisfied with Product -2120• Customers Di-satisfied with Product -48• Customer Satisfied with Service and Installation -2003• Customers Dis-satisfied with Service and Installation -130• First Time IFB Buyer -1602
  • 41. Goa Service CenterVoice of Customer• Tap adaptor should be provided with the machine.• Recipe Book should be provided with all MWO.• Only experienced Technicians should be sent for demo.• Dealer should inform customer about trolley at the point of sale.
  • 42. Pentair Cup – Siddesh 42
  • 43. Pentair Cup was organized by Pentair for all the IDC organizations in Verna .IFB cleared 3 rounds and we reached the quarter finals for the secondconsecutive year .We also gifted the player of the tournament award with a20PM1S MWO Sanjay /Yeshwant /Sudan/Desai /Siddhesh /Kapil/Samir 43 Shishir /Vinay / Rohan / Sanket /Sunil – Team IFB
  • 44. New Employee Introduction Worked in Sumi Motherson for 13 yrs & Samsung Mobiles for 3.5 yrs Speciality in Plastic injection Moulding DOB : 4th Feb DOJ : 16th Apr 2012 Home town : Noida Mr Manish Thakur Language : Hindi /English 44
  • 45. Corlim Plant Cell by Dattaram 45
  • 46. Productivity increase of dryer • Before shifting of dryer assly line to corlim plant, production out put per day was 40no’s of dryer • Which was increased at corlim plant by 20no’s, • Output production per day now 60no’s
  • 47. Improvement for the month• During painting of Front panels Insulation tape was provided on four studs , which was replaced by 6mm pipe resulting in better productivity. Before
  • 48. Improvement for the month After
  • 49. Improvement for the month • Paint shop hangers were modified for better painting of single piece cabinet. Before modification
  • 50. Improvement for the monthAfter modificationOne person was reduced during loading
  • 51. Improvement for the month• Conveyer length was increases to accommodate five no’s of dryer after electrical testing Before After
  • 52. Goa Branch by Nilotpal & Joyce 52
  • 53. SALES PERFORMANCE APRIL- VOLUME Sr. No. PRODUCT BUDGET ACHIEVED LY GOLY 1 FL 272 275 187 47% 2 TL 128 60 60 16% 3 MWO 441 375 404 -7% 4 DDW 19 28 14 100% 5 CD 17 29 21 38% 6 IDW 3 4 1 300% 7 ILE 4 1 1 - 8 B. in O. 2 2 2 - 9 Hob 19 6 10 -40% 10 Hood 18 3 9 -66% 11 MK - 2 1 12 TOTAL 923 785 710 11%
  • 54. SALES PERFORMANCE PRODUCT APRIL- VALUE (in Rs. Lakhs) BUDGET ACHIEVED LY GOLY FL 63 56 37 51% TL 17 7 7 - MWO 36 28 25 12% DDW 5 7 3 133% CD 3 4 3 33% IDW 4 6 2 200% ILE 6 1 1 - B. in O. 0.5 0.5 0.7 -28% Hob 2 0.7 1.3 -46% Hood 1.3 0.4 0.87 -54% MK - 5 2.34 113% TOTAL 138 116 83 40%
  • 55. COOKERY SHOW – IFB Art Kitchen
  • 56. INITIATIVES1. Driving cookery classes to ensure positive word of mouth. We are conducting this on a weekly basis at the kitchen showroom.2. New chef has been recruited – idea is to promote the IFB mascot concept. Internet platforms like YouTube, Facebook, etc. to be used for streaming our cookery shows online.3. “Target the kids” – we have seen the best way to lure people into an IFB store is to target their kids. Special tutorials on certain recipes, its presentation, etc. are being held especially for the kids of parents who are our target audience.4. Free Service camp & canopy activity conducted @ Model’s Millennium, Kamat Complex & Factory.5. DW home demo – branch has invested in a DW. Plan for conducting at least 10 home demos every month will be driven from May onwards.6. Tie up with plumbers and electricians to close installation calls speedily .
  • 57. Your Questions Please….. 57