TQM Strategy for ContinualImprovements – the SRF Way   3rd Continual Improvement   and Innovation Symposium           DQG,...
Backbone of our TQM Journey     We are what we repeatedly do….EXCELLENCE, therefore, is not an act but a              HABI...
Contents of this Presentation About SRF The Deming Challenge      Early Phase: 1991-1999      Momentum Phase: 2000-200...
About SRF        4
SRF – at a glance   A multi-business manufacturing entity   India, Thailand, UAE and South Africa   12 (nine in India)   8...
Products SRF Manufactures                                        CB                                                       ...
Diverse applicationsTTB       CB                PFB                EPB               Touching your lives every day        ...
Present in four countries                                     Bhiwadi      Pantnagar                                      ...
Global Foot Prints for SRF Products     Meeting requirements of customers in more than 75 countries                       ...
SRF – Proud Winner of Deming Application Prize                                             10
The Deming Challenge                   11
How TQM was chosen as SRF Management Way              How TQM was chosen                          Negative forces       Po...
TQM Introduction: Early Phase: 1991-99JUSE Program – attended by TOP Management Decision to adopt TQM  Creation of TQM Cel...
TQM Introduction: Momentum Phase: 2000-04                           14 Elements of QualityQuality First Approach     Moder...
TQM – The SRF Way , for Continual Improvements                                             15
Continual Improvement Framework                                                         Cherokee WisdomDesign of TQM Frame...
He who has a hundred miles to walk should reckon           ninety as half the journey.                                   T...
Transformation Model         SenseiMaster   (Truth sayer)         Guru                               Leap of              ...
Message from the thenVice-chairman   Message from the then Vice-Chairman1992   It is vital that SRF builds up its strength...
Constant Training and Communication    5S Training         Kaizen Training Program                                        ...
Progress of 5S                                                                   Arrangement for all items                ...
14 Dimensions of Quality                                                                                      (Q3)        ...
Quality First                                                        Demonstrating Quality First:                         ...
Revolutionary Equipment DesignTwisting Machine     Cabling Machine                   SADC Machine                         ...
Problem Solving ProcessImpact of Improvement                                               Gold                           ...
Autonomous Maintenance                     • Ownership of Machines People                     • Daily Cleaning, Lubricatio...
People Red Book                                                     People Red BookDiagnosis   and Surveys                ...
Cherokee WisdomAccording to Cherokee tribal lore, there is an ancient formula for success :• Clear intention : You must kn...
TQM Triangle                         (Customer Focus)                              Quality                             Lea...
SRF TQM FRAMEWORK                          Our Own Unique TQM Framework                       • Integrates Principles, Met...
Diagnosis - Five Stage Capability Model                                                 Vision    Hardware                ...
Diagnosis - Five Stage Capability Model             How Effective              are systems                                ...
Planning Process                                                                          Vision                          ...
Improvement Hierarchy         World Class R&D Facilities                                           Business Process       ...
Constant Training and CommunicationSome of the key Topics:•   TQM Basics•   About Company , Products , Process, Customers ...
Improvement Hierarchy         Kaizen Week     QCC Day        AM Day        DM Week       5S Week Plan     13-17th June   1...
Glimpses of External Competitions                            •   80 external accolades during                             ...
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TQM Strategy for Continual Improvements – the SRF Way” by S. Illango (Associate Vice President-TQM, SRF)

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Keynote presentation by S. Illango (Associate Vice President-TQM, SRF) titled “TQM Strategy for Continual Improvements – the SRF Way” at the 3rd Continual Improvement & Innovation Symposium organized by Dubai Quality Group's Continual Improvement Subgroup to celebrate World Quality Day 2011

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TQM Strategy for Continual Improvements – the SRF Way” by S. Illango (Associate Vice President-TQM, SRF)

  1. 1. TQM Strategy for ContinualImprovements – the SRF Way 3rd Continual Improvement and Innovation Symposium DQG, Dubai S. Ilango Associate Vice President - TQM 17th Nov 2011
  2. 2. Backbone of our TQM Journey We are what we repeatedly do….EXCELLENCE, therefore, is not an act but a HABIT - Aristotle 2
  3. 3. Contents of this Presentation About SRF The Deming Challenge Early Phase: 1991-1999 Momentum Phase: 2000-2004 TQM - for Continual Improvements TQM Models TQM Practices Results 3
  4. 4. About SRF 4
  5. 5. SRF – at a glance A multi-business manufacturing entity India, Thailand, UAE and South Africa 12 (nine in India) 800 million USD 5500 globally 75 countries 5
  6. 6. Products SRF Manufactures CB Refrigerant Gases CMS Yarn Griege Fabric TTB EPB Dipped Fabric EP - Chips PFB Packaging FilmBelting Fabric Coated Fabric Fishnet Twine 6
  7. 7. Diverse applicationsTTB CB PFB EPB Touching your lives every day 7
  8. 8. Present in four countries Bhiwadi Pantnagar Kashipur Gwalior Dubai Dahej Thailand Indore Thailand TrichyBusinessTTB ManaliCB Port Elizabeth GummidipoondiPFBEPB 8
  9. 9. Global Foot Prints for SRF Products Meeting requirements of customers in more than 75 countries 9
  10. 10. SRF – Proud Winner of Deming Application Prize 10
  11. 11. The Deming Challenge 11
  12. 12. How TQM was chosen as SRF Management Way How TQM was chosen Negative forces Positive forces Economic reforms from 1991 Adverse union relationship • Import of tyrecord fabric • Possible closure • QC Circles born 1981 and ended 1987 Opportunity to become World class Exposure to Denso Low desire for change of Management way TQM programme for Top Management at JUSE • Any way we are making good profit TQM Way Chosen 12
  13. 13. TQM Introduction: Early Phase: 1991-99JUSE Program – attended by TOP Management Decision to adopt TQM Creation of TQM Cell Communication from Chairman Design of TQM Frame Work TQM Education 5S Training and Introduction 13
  14. 14. TQM Introduction: Momentum Phase: 2000-04 14 Elements of QualityQuality First Approach Modernization - Technology Breakthrough Equipment Design 5S, Kaizens People Development and QCC and PSP Involvement Maintenance Practices People Red Book Daily Management Strengthening System Policy Management Management Diagnosis 14
  15. 15. TQM – The SRF Way , for Continual Improvements 15
  16. 16. Continual Improvement Framework Cherokee WisdomDesign of TQM Frame Work Management Diagnosis Annual Planning Improvement Hierarchy Constant Training and Communication People Participation Initiatives – Internal People Participation Initiatives - External ARC- Acknowledgement , Recognition and Celebrations 16
  17. 17. He who has a hundred miles to walk should reckon ninety as half the journey. Thank You
  18. 18. Transformation Model SenseiMaster (Truth sayer) Guru Leap of Faith Cultural change ActionAwareness Attitude Theory-in-use — adapted from Don Wheeler 18
  19. 19. Message from the thenVice-chairman Message from the then Vice-Chairman1992 It is vital that SRF builds up its strengths and becomes a world class company, able to compete with the world’s best. TQM is a means to that end. The road to Total Quality will be a long one, spanning many years. In fact, over the next nine months, we are simply going to prepare ourselves to introduce TQM. Arun Bharat Ram (Chairman and Managing Director) 19 19
  20. 20. Constant Training and Communication 5S Training Kaizen Training Program Basic TQM Training Program Control Points Training ProgramAM Training Program PSP Training Program Training Action 20
  21. 21. Progress of 5S Arrangement for all items Gangway Markings APC Training 5S Introduction – Mass Cleaning View of Stores Filing System Factory – Internal View5S – Coordinator’s training Factory External View 5S – Introduction of Trophies 5S Recognitions 21
  22. 22. 14 Dimensions of Quality (Q3) (Q0) (Q1) (Q2) Sign off forUpstream QA Product Product Preparation for mass production mass planning development production (Q6) (Q7)Down stream (Q5) Physical Roll rating (Q8) Packing (Q4) QA (before Intermediate properties and logistics supply) Vendor items product (Q11) (Q12) (Q9) (Q10) Application Commercial (Q13) Down steam Service service Tyre Tyre Relationship(after supply) processability Performance 22
  23. 23. Quality First Demonstrating Quality First: Investing in Technology & FacilitatesBefore Economic Reforms, Production came first Technology Before Now Yarn Conventional Spin draw Education Weaving Shuttle Shuttle less on Quality First Dipping Multiple , Slow Single, High Speed Power Elec Board Captive Power Plant Shed Uncontrolled AC Conditioning Flooring and Old Epoxy Flooring Roofing “We believe in the principles of Quality First and Market In…” 23
  24. 24. Revolutionary Equipment DesignTwisting Machine Cabling Machine SADC Machine Convert 2-stage WACKY IDEA twisters uniquely to single stage Results Cost: 25% of 285 parts • Half the lead time, waste rate, power new twister converted cost, space, maintenance cost. • Double the productivity 24
  25. 25. Problem Solving ProcessImpact of Improvement Gold Silver Blue (Officers & Supervisors) Blue (Workmen) Problem: Local Business Process Business Unit 25
  26. 26. Autonomous Maintenance • Ownership of Machines People • Daily Cleaning, Lubrication, Abnormality Tagging and Minor Corrections • Knowledge on machine parts, operation, process and inspection Machine Machine cleaning and cleaning and Inspection Inspection 26
  27. 27. People Red Book People Red BookDiagnosis and Surveys Preventive Action Months Corrective Action Correction Communication People Red Book System Work Related Treatment Related Admin Related Personal Problems People Related Issues 27
  28. 28. Cherokee WisdomAccording to Cherokee tribal lore, there is an ancient formula for success :• Clear intention : You must know what your purpose is and persist in its pursuit.• Skillful means : You must have good methods and be skilled in their use.• Affirmation : Your task must have integrity, it must not clash with fundamental values, it needs support from the tribe and from your own heart. Clear intention Successful work Skillful means Affirmation - From Peter Scholtes 28
  29. 29. TQM Triangle (Customer Focus) Quality Leadership 1. Mobilise everyone to create value for customers 2. Sense reality by being at the workplaceSystematic Improvement All one team (Process Focus) (People Focus) 29
  30. 30. SRF TQM FRAMEWORK Our Own Unique TQM Framework • Integrates Principles, Methods, Systems and Tools • Integrates Productive Maintenance and Toyota Production System • The Way We Do Think and Do Things • The Way We Manage • The “Results” that we want to achieve“People satisfy customers efficiently.” 30
  31. 31. Diagnosis - Five Stage Capability Model Vision Hardware Strategy Structure Software Human ware Business Results Customers Shareholders Employees Society 31
  32. 32. Diagnosis - Five Stage Capability Model How Effective are systems Benchmarks are for set for the rest of the world MIT? Breakthrough improvement and upstream 4 management are Maintenance institutionalised and continuous improvement 3 are institutionalised Basic conditions 2 are establishedBasic conditions 1 A Happier Worldrequired arenot present 0 32
  33. 33. Planning Process Vision Inputs from Strategic PlansInputs from Developments Diagnosis External Annual Planning Routine Plans + Breakthrough Plans Financials Communication of Plans at Various Levels Hierarchy of Reviews Achievement Measurement 33
  34. 34. Improvement Hierarchy World Class R&D Facilities Business Process Re-Engineering, Transformation, Breakthrough System Level Technology Improvements PSP Silver, Gold, Process Level NPD Improvements QCC, PSP Blue, Sub-Process Level TPM Improvements Activity Level 5S,AM, Kaizens Improvements 34
  35. 35. Constant Training and CommunicationSome of the key Topics:• TQM Basics• About Company , Products , Process, Customers , Suppliers• 5S, Kaizens, QCC, AM• PSP, Lean, TPM, DOE• Knowledge and Skill Improvements• Leadership, Team working 35
  36. 36. Improvement Hierarchy Kaizen Week QCC Day AM Day DM Week 5S Week Plan 13-17th June 18-22nd July 17-21st Oct 14-18th Nov 23-27th JanActual 13-17th June 18-22nd July 17-21st Oct 36
  37. 37. Glimpses of External Competitions • 80 external accolades during 2010-11 • Already 46 external accolades in H1 of 2011-12 37

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