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Engineering Excellence - IEEEP
 

Engineering Excellence - IEEEP

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    Engineering Excellence - IEEEP Engineering Excellence - IEEEP Presentation Transcript

    • symposium 2009 8 APRIL,2009 24th Multi-Topic International Symposium Pearl-continental Hotel, Karachi. Engineering Excellence Syed Khurshid Pervez 1 SKP 04/09 SKP 04/09
    • OBJECTIVES 1.To provide a hands-on knowledge and experience of introducing both qualitative and quantitative ingredients of excellence of managing an engineering organisation 2.To be able to make use of our own cultural values to achieve high productivity and efficiency 2 SKP 04/09 SKP 04/09
    • CONTENTS 1.Strategic Framework 2.Self assessment Evaluation Model 3.Business Process Re-Engineering 4.Lean Management 5.Employee participation / Empowerment 6.ISO Certification 7.Monitoring of non-financial Indicators 7.1 Dashboard Concept 7.2 Quality Indicators 3 SKP 04/09 SKP 04/09
    • STRATEGIC FRAMEWORK STRATEGIC FOCUS The Strategic Management Program 4 SKP 04/09 SKP 04/09
    • STRATEGIC FOCUS A powerful, participative management process that provides vision and direction 5 SKP 04/09 SKP 04/09
    • STRATEGIC FOCUS Mission & Values Goals Objectives Measures Action Plans 6 SKP 04/09 SKP 04/09
    • STRATEGIC FOCUS MISSION We deliver innovative customer driven products, services and system solutions in the field of power engineering for domestic and international markets. We aspire to become a key regional player in the targeted business segments with world class manufacturing, continuous improvements and optimized skills and resources to exceed customer needs. We measure our success by achieving sustained growth and profitability, employee and customer satisfaction and positive impact on society. 7 SKP 04/09 SKP 04/09
    • STRATEGIC FOCUS VALUES Integrity and Trust : we act with integrity and mutual trust in everything we do. Responsibility and Ownership : we are responsible for, and take ownership of, all our actions. Team Work : we achieve our common goal through equal participation at all levels by working together, benefiting from the synergies released by differing opinions. Obligation to Society : we recognise our obligation to the society in which we live and operate. 8 SKP 04/09 SKP 04/09
    • STRATEGIC FOCUS GOALS  People  Product leadership  Customer Focus  Skill and Resource Utilization  Good Citizenship  Growth and Profitability 9 SKP 04/09 SKP 04/09
    • STRATEGIC FOCUS Mission & Values Strategic Business Plan 6 Goals Objectives Personal MBOs Measures Action Plans Budget EQA Self Assessment 10 SKP 04/09 SKP 04/09
    • STRATEGIC FOCUS STRATEGIC FRAMEWORK OBJECTIVES GOALS MEASURES ACTION PLANS People Product M Leadership I Customer S Focus S I Skill & Resource Utilization O N Good N Citizenship Growth & Profitability VALUES 11 SKP 04/09 SKP 04/09
    • SELF ASSESSMENT EUROPEAN QUALITY AWARD 13 SKP 04/09 SKP 04/09
    • SELF ASSESSMENT Primary Purposes Self assessment of all major areas to be considered in designing, evaluating and improving quality systems. 14 SKP 04/09 SKP 04/09
    • SELF ASSESSMENT Evaluation Model People People Management Satisfaction 9% 9% Business Leadership Policy & Processes Customer Results Strategy Satisfaction 10% 8% 20% 14% 15% Impact on Resources Society 9% 6% Enablers Approach Results 15 SKP 04/09 SKP 04/09
    • SELF ASSESSMENT Actual Potential Criterion (%) (%) 1. Leadership 29 71 2. Policy and Strategy 34 66 3. People Management 23 77 4. Resources 29 71 5. Processes 34 66 6. Customer Satisfaction 26 74 7. People Satisfaction 13 87 8. Impact on Image 20 80 9. Business Results 29 71 16 SKP 04/09 SKP 04/09
    • SELF ASSESSMENT Policy & Strategy Leadership 8 9 People Management 10 Business Results 2.16 1.8 2.9 2.34 15 9 Resources 6.6 6.72 6 0.72 Image on Society 14 Processes 10.2 1.08 9 People Satisfaction Customer Satisfaction 20 17 SKP 04/09 SKP 04/09
    • SELF ASSESSMENT Improvement Potential TQM-Status and Potential for Improvement Result 29 1 34 2 23 3 29 4 34 5 26 6 13 7 20 8 29 9 0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100% 18 SKP 04/09 SKP 04/09
    • SELF ASSESSMENT 1. Governance 2. Financial Performance 3. Customer Satisfaction 4. Commitment to Employees 5. Risk Management and Prevention 6. Respect for the Environment 7. Innovation 8. Community Involvement 9. Dialogue and Consensus-Building 10.Continuous Improvement 19 SKP 04/09 SKP 04/09
    • PROCESS RE-ENGINEERING THE BUSINESS PROCESSES Order Fulfillment I : Enquiry to Order & Design finalisation Order Fulfillment II: Order & Design finalisation upto delivery & warranty end Sales Design Commercial Production Planning Materials Management 20 SKP 04/09 SKP 04/09
    • PROCESS RE-ENGINEERING THE GREENFIELD CONCEPT Centers of Excellence Process Focus Teams Commercial KK KKK Strategic (K) KKK KK VV VVV Sales (V) Tactical VVVVVV TTT TTTT Technical Operational (T) TTTTTTTTTT VT T KVP K Production V TK PPP PPP K KVT (P) PP PPP P P TT PPPPPPP 23 SKP 04/09 SKP 04/09
    • LEAN MANAGEMENT 24 SKP 04/09 SKP 04/09
    • Objectives achieved • Productivity increased by three times – 3 completely tested panels per shift. • Quality of workmanship improved drastically – Zero defect. • No stocking of material at shop floor. • Elimination of non-value adding activities. • Multi-skilled work force. • Reduced Stocks. • Improved customer deliveries. 25 SKP 04/09 SKP 04/09
    • EMPLOYEE PARTICIPATION/EMPOWERMENT • WORKPLACE CONCEPT • INFO. STATIONS • INTERACTIVE BOARDS • CREATIVE SUGGESTIONS • KAIZEN CONVENTIONS • OPEN HOUSE 26 SKP 04/09 SKP 04/09
    • EMPLOYEE PARTICIPATION / EMPOWERMENT WORKPLACE CONCEPT  Ownership  Structured  Process Unit  Cost Responsibility 27 SKP 04/09 SKP 04/09
    • EMPLOYEE PARTICIPATION / EMPOWERMENT DEPTT. INFO. STATIONS “A Voluntary Exhibition” exhibit the deptt.’s : • quality targets • kaizen team themes • skill developments • job rotation • pareto charts • absenteeism 28 SKP 04/09 SKP 04/09
    • Information on Info Centers • Departmental KPIs like: • Productivity figures. • Cost of Poor Quality. • Material Scrap figures. • Quality targets of the department. • Layout. • Cleanliness Plan. • Job rotation plan. • Pareto Analysis of defects. 29 SKP 04/09 SKP 04/09
    • 30 SKP 04/09 SKP 04/09
    • EMPLOYEE PARTICIPATION / EMPOWERMENT • skill developments • job rotation Schedule of Job Rotation 1997 S. TRADE POWER MARKING PUNCHING MANNUAL DIGITAL DRILLING CARD PRESS TABLE NOVO BENDING BENDING MACHINE NO. NAME OF WORKER NO. PRESS 1/5 - 30/8 1/9 - 31/12 MUMTAZ ALAM 20092 1 G. L. 1/9 - 31/12 1/5 - 30/8 AFZAL BAIG BENDING M/C 20005 2 1/9 - 31/12 1/5 - 30/8 SHOUKAT ALI BENDING M/C 20147 3 1/9 - 31/12 SOHAIL AHMED PUNCHING M/C 20002 4 1/5 - 30/8 1/9 - 31/12 BILAL 5 SHEARING M/C 1/6 - 30/8 1/9 - 31/12 6 HYDER UL MURTAZA MARKING 1/9 - 31/12 1/6 - 30/8 JAVED IQBAL 7 MARKING 1/5 - 30/8 1/9 - 31/12 NOORUDDIN 8 PUNCHING M/C 1/9 - 31/12 AHSAN SHEARING M/C 20027 9 1/9 - 31/12 1/5 - 30/8 M. HUSSAIN 10 DRILLING M/C LEGEND: UNDER TRAINING TRAINING COMPLETE _____________________________ ( DEPARTMENT INCHARGE - P3 ) 31 SKP 04/09 SKP 04/09
    • EMPLOYEE PARTICIPATION / EMPOWERMENT • trends in performance • absenteeism Attendance Record of Tool and Die Dept Price of non- 8000 conformities R U 7000 1997 1996 P 6000 E 5000 Average Price E Average Price Rs. 1517.94 per S 4000 month Rs. 4701.00 per month 3000 2000 1000 0 NOV OCT JAN FEB APR JUN DEC SEP MAY JUL AUG MAR MONTHS 32 SKP 04/09 SKP 04/09
    • EMPLOYEE PARTICIPATION / EMPOWERMENT INTERACTIVE BOARDS Empower the employees to voice their problems. 33 SKP 04/09 SKP 04/09
    • EMPLOYEE PARTICIPATION / EMPOWERMENT CREATIVE SUGGESTIONS 34 SKP 04/09 SKP 04/09
    • EMPLOYEE PARTICIPATION / EMPOWERMENT • quality targets • kaizen team themes ALSTOM Pakistan (Private) Limited TIGERS JAGUARS EAGLES  TO REDUCE PRICE OF NON- CONFORMANCE BY 30% IN 1997 AS MV/LV SHAHEENS LEOPARDS COMPARED TO THAT OF 1996 ASSEMBLY  TO ENHANCE THE SKILLS OF THE WORKERS IN THE DEPARTMENT AT LEAST BY 30%. HAWKS FALCONS PANTHERS LIONS 35 SKP 04/09 SKP 04/09
    • EMPLOYEE PARTICIPATION / EMPOWERMENT KAIZEN CONVENTIONS   Participation of all Employees  Continuous Improvement 36 SKP 04/09 SKP 04/09
    • EMPLOYEE PARTICIPATION / EMPOWERMENT PRACTICING THE STATISTICAL QUALITY CONTROL MACHINE MAN Unskilled Workers Shortage of tools Lack of supervision Disturbed worker Improper tools EXCESSIVE WIRING Components TIME OF RK-PANEL not available Uncomfortable working height Design of interlocking in time Plug wiring plate Uncomfortable Most of the wiring Unnecessary Inst. working environment dependent on panel mounting plate structure assy. Non-conformance to FK-2000 philosophy Design of Inst. door mtg. + inst. box wiring MATERIAL METHOD 37 SKP 04/09 SKP 04/09
    • EMPLOYEE PARTICIPATION / EMPOWERMENT OPEN HOUSE Appreciation of Work & Social Interaction of Employees and their Families 38 SKP 04/09 SKP 04/09
    • WORLDWIDE RECOGNITION ISO 9001 – Quality Systems ISO 18001 – OHSAS ISO 14001 - Environment APK-HR 05/97 APK 09/02 04/09 3939 ALSTOM Pakistan (Private) Limited SKP
    • QUALITY MANAGEMENT SYSTEM (QMS) IS0 9001:2000 ►MAINTAIN A QUALITY MANAGEMENT SYSTEM ►MANAGEMENT RESPONSIBILITY. ►RESOURCE MANAGEMENT. ►PRODUCT REALIZATION. ►CONTINUAL IMPROVEMENT OF SYSTEM ►CUSTOMER SATISFACTION. ►PROCESS APPROACH. ►BASIC MODEL PDCA ► DO ► ► PLAN CHECK ACT ►CONTINUAL IMPROVEMENT IN PROCESSES & PRODUCTIVITY. ►MONITORING AND MEASUREMENT OF EFFECTIVENESS OF QMS ►CORRECTIVE & PREVENTIVE ACTIONS FOR OVER ALL IMPROVEMENT OF QMS. APK-HR 05/97 APK 09/02 04/09 4040 ALSTOM Pakistan (Private) Limited SKP
    • ENVIRONMENTAL MANAGEMENT SYSTEM (EMS) IS0 14001:2004 ►ORGANIZATION ARE ABLE TO ASSESS THEIR ENVIRONMENTAL PERFORMANCE. ►CONTINUAL IMPROVEMENT IN ENVIRONMENTAL PERFORMANCE OF ORGANIZATION & FULLFILL THE REQUIREMENT OF THE NATIONAL ENVIRONMENT QUALITY STANDARDS (NEQS) & ENVIRONMENTAL PROTECTION AGENCY (EPA). ►OPERATIONAL CONTROL OVER SIGNIFICANT ENVIRONMENTAL ASPECTS ASSOCIATED WITH THE ACTIVITIES OF ORGANIZATION. ►DEMONSTARTE THE ORGANIZATION SENSE OF RESPONSIBILITY TOWARDS ENVIRONMENT & ECO –SYSTEM & MINIMIZE ENVIRONMENTAL FOOTPRINT. ►IMPLEMENTATION OF EFFECTIVE ENVIRONMETAL MANAGEMENT SYSTEM. ►ENVIRONMETAL ISSUES:AIR, NOISE, CONTAMINATION TO LAND, GROUND WATER, CO2, EMISSIONS, (GHG) GREENHOUSE GASES, WASTE WATER FROM INDUSTRIES, ELECTRICITY. ►PREVENT LIABILITIES & ALSO PREVENT RISK, IMPROVE IN WORKING CONDITION. ►BASIC MODEL PDCA ► DO ► ► PLAN CHECK ACT ►MEASURE & REPORT WITH SIGNIFICANT ENVIRONMENTAL ASPECTS IN ORDER TO FACILITATE THE DIALOGUE WITH THE STAKEHOLDERS. ►CORRECTIVE & PREVENTIVE ACTIONS FOR OVER ALL IMPROVEMENT OF EMS. APK-HR 05/97 APK 09/02 04/09 4141 ALSTOM Pakistan (Private) Limited SKP
    • OCCUPATIONAL HEALTH & SAFTEY ASSESSMENT SERIES (OHSAS) 18001:1999 ►ABILITIY TO DEAL WITH ALL SORTS OF OCCUPATIONAL HAZARDS RELATED TO PLACE, PERSON, PROCESS & MACHINE OF ORGANIZATION. ►EFFECTIVE OH&S MANAGEMENT SYSTEM LOWER THE RATE OF ACCIDENTS AND ALSO AFTER ACCIDENTS COST. ►INLINE WITH INTERNATIONAL LABOUR ORGANIZATION LAWS (ILO) & LABOUR RULES OF COUNTRY. ►GENERIC SYSTEM CAN BE INTEGRATED EFFECTIVLEY WITH OTHER INTERNATIONAL MANAGEMENT SYSTEM FOR EXAMPLE (ISO). ►DEMONSTRATES ORGANIZATION’S REPONSIBILITY TOWARDS SOCIAL VALUES & ITS WORK FORCE. ►CONTINUAL IMPROVEMENT MINIMIZES THE RISKS & ACCIDENTS INCREASE EFFICIENCY OF ORGANIZATION. ►BASIC MODEL PDCA ► DO ► ► PLAN CHECK ACT ►CONTINUAL IMPROVEMENT IN PROCESSES & PRODUCTIVITY. ►MONITORING AND MEASUREMENT OF EFFECTIVENESS OF OH&S MANAGEMENT SYSTEM. ►HAZARD IDENTIFICATION & RISK ASSESSMENT WITH OPERATIONAL CONTROL CAN MINIMIZE ACCIDENTS. ►EMERGENCY PREPAREDNESS & RESPONSE PLAN HELP ORGANIZATION TO RESPOND TO ACTUAL EMERGENCY SITUATIONS & PREVENT OR MITIGATE ASSOCIATED ADVERSE OH&S CONSEQUENCES. ► IMPROVE THE HEALTH AND WORKING CONDITIONS FOR STAFF & WORKERS. APK-HR 05/97 APK 09/02 04/09 4242 ALSTOM Pakistan (Private) Limited SKP
    • MONITORING OF NON-FINANCIAL INDICATORS -DASHBOARD CONCEPT -QUALITY INDICATORS APK-HR 05/97 APK 09/02 04/09 4343 ALSTOM Pakistan (Private) Limited SKP
    • DASHBOARD CONCEPT SUSTAINABLE DEVELOPMENT & CONTINUOUS IMPROVEMENT INDICATORS - SAFETY •Frequency Rate, Severity Rate and Number of accidents - ENVIRONMENT • Water consumption • Energy consumption Electricity consumption • GreenHouse Gases SF6 Emissions • Paper • Waste APK-HR 05/97 APK 09/02 04/09 4444 ALSTOM Pakistan (Private) Limited SKP
    • QUALITY INDICATORS OBJECTIVE: To measure the progress in productivity & set targets to increase productivity. APK-HR 05/97 APK 09/02 04/09 4545 ALSTOM Pakistan (Private) Limited SKP
    • QUALITY INDICATORS INDICATOR GROUP INDICATOR EHS Number of lost time accidents CUSTOMER COMPLAINTS Number of received customer complaints during the period CUSTOMER COMPLAINTS % of acknowledgement done to customer within 24 hours CUSTOMER COMPLAINTS % of customer complaints closed on time during the period PRODUCT QUALITY Product quality related costs PRODUCT QUALITY First Pass Yield SUPPLIER QUALITY External Supplier Quality Rate % HUMAN RESOURCES Total Head Count (as end of the month) HUMAN RESOURCES Absenteeism APK-HR 05/97 APK 09/02 04/09 4646 ALSTOM Pakistan (Private) Limited SKP
    • QUALITY INDICATORS INDICATOR GROUP INDICATOR COMMERCIAL Margin on direct costs on orders booked % COMMERCIAL Gross Margins on orders booked % SALES (HIT RATES) Hit Rate on offers (numbers) in % SALES (HIT RATES) Hit Rate on offers (volume) in % PROJECT Margin on direct cost deviation PROJECT Gross Margin deviation SUPPLY CHAIN Customer on time in full delivery SUPPLY CHAIN Supplier on time in full delivery SUPPLY CHAIN Manufacturing Productivity SUPPLY CHAIN Total Gross Inventories SOURCING Secured Sourcing Savings on purchased volumes APK-HR 05/97 APK 09/02 04/09 4747 ALSTOM Pakistan (Private) Limited SKP
    • The Journey never ends APK-HR 05/97 APK 09/02 04/09 4848 ALSTOM Pakistan (Private) Limited SKP
    • THANK YOU FOR YOUR ATTENTION APK-HR 05/97 APK 09/02 04/09 4949 ALSTOM Pakistan (Private) Limited SKP