Manish Engineering Works
TPM REVIEW

17.07.2013
01
 Organic Growth

VEPL – PP3
5%
YOKE - Pulsar

YOKE – Enfield

YOKE – ø 48

VEPL – WP5
10%
BSC - 384

BSC - 834

VEPL – WP...
 NPD / In-Organic Growth

VEPL – WP7
20 %

Gear - 735

VEPL – PP3
50 %

YOKE - Suzuki

Gear - 742
MANISH ENGINEERING WORKS
Company started in the year 1998-99 with press part manufacturing set up

Existing Set Up
Precise...
Product Information Max 2 Slides
Category wise

02
Esteemed Customers

02
TPM PROGRESS EXECUTION
Parameter

Activities

Activities

A] TPM declaration with TPM policy.

29.11.11

B] Education to a...
TPM Progress Status
Methodology Followed for TPM Implementation
PQCDSM – Plant Targets

02
• 1S 2S Zone Mapping & Leaders
• 1S Top 3 Examples & Results
• 2S Top 3 Examples & Results
• Yoke Cell level Targets as explained by DTJ
• 2012 Tgt vs Act , 2013 Tgt Vs Act
• Yoke Cell Layout before & After ( Block
Diagram or sketeches ) with movie of after
stating lead time reduction
• Yoke Manufacturing Flow Stage & Photo
• P – Trend of P 1 , P2 , P3 , P4
• P – Approach OEE , Output / Man , Output /
Man
• Kaizens P 1 , P2 , P3 , P4
• Q – Trend of Q1 , Q2
• Q – Approach
• Q – Kaizens of Q1 , Q2
• Same way for C , D , S , M
• Summary of Results PQCDSM 2013 Tgt vs
MOM Act
• IPO of Yoke Cell for Sustenance of IHR Stage
wise IPO sheets with hyperlink
• Linkage of IPO to JH , PM , TBM Sheets ( small
window of IPO & big window of JH , PM or
TBM sheets
• Horizontal Deployment in other cells
• Plant level Results vs TPM Tgt PQCDSM
• Future Plan
• The Journey Continoues….
PQCDSM - Targets

02
OEE trend :
Low Light of
2012-13
● 4% gap in OEE
in 2013-13%

ACTION PLAN

Q2 (Jul-Sep)
●How to achieve
90 % OEE in Q2

On...
Cell-1 – BSC 384
Cell-2 – Yoke pulsar
Cell-3 - Other

OEE trend : Cell Wise
100%

Cell Wise OEE

LOSS Contributors :

86%
...
OEE: GAP Analysis (2012-13)
Detailed Action plan for Each Issue
Attached here

What went wrong : Learning from 2012-13
Iss...
OEE: Action Plan Q2 (Jun & Jul-Sep)
Target :

● Current OEE :80%  85%
Details

Who

When

1 Training and new appointments...
Output /Man & Hrs

07
OUTPUT/MAN

Low Light of 2012-13
●No consistency & sustenance in
OUTPUT/MAN

ACTION PLAN Q2 (Jul-Sep...
Output /Man & Hrs : GAP Analysis (2012-13)
What went wrong : Learning from 2012-13
Issue / Problem/Cause

Proposed Solutio...
Output /Man & Hrs : Action Plan Q2
● Output/Man : 3.22 k3.4 k ● Output/Hr : 464 500 nos./hr
Details

Who

1 Training and...
Customer Complaint PPM
Observation
● C.C.PPM
improvement
( 97%)
● C.C.Ph
improvement
(80 %)
● C.C.Occr.
Improvement
(83%)
...
C.C. PPM : Phenomenon/QTY : JUN
● R: Repetitive

Phenomenon

Categor
y
(R/N)

Jan

N: New

Feb

Mar

Apr

May

June

Gear-...
C.C. PPM : Action Plan
● C.C.PPM : 147 k0
Details (Top 5)
Problem: Gear 5 th pinion Depth u/s
1
Root Cause: Forging defec...
In house Rej PPM
Observation
● In House Rej
PPM : 75%
improvement in
yr 2012-13
● How to ach. Q2
trgt 0 (zero)

Action pla...
In house Rej: Phenomenon / Qty: JUN
● R: Repetitive
Phenomenon

N: New

Category
(R/N)

Jan

Feb

Mar

Apr

May

June

1

...
In house Rej : Action Plan: Q2
● IHR .PPM : 1125 k0

Details (Top 5)
Problem: ID o/s ( Lay shaft / YOKE )
1

Detailed Act...
Cost

19
Cost

Assessment year 2012-13

TPM

2012

Declaration
Parameter

UOM

BM

Assessment year 2013-14

TRGET
Mar’13

2013

201...
DSM
Assessment year 2012-13

TPM
Declaration

2012

Assessment year 2013-14

2013

2013

UOM

BM

TRGET
Mar’13

OCT NOV DE...
Loss Analysis
● TOTAL LOSS IN HRS :

● LOSS IMACT :
944.52

960.00

● Total Loss till date (Jan-Jun) : 5235 hrs .
(436Shif...
Loss Analysis: Detailed
(Loss in Hrs)
450.0
400.0
350.0

399.6 396.6 374.5
360.93
334.4
295.22

300.0

274.9 272.1 270.3

...
Action Plan : Losses June
●Set up & Adjustment : 295hrs 0
Causes / Problem
Problem: No raw material planning

Detailed Ac...
Action Plan : Losses June
● Due to operator : 241.0 hrs 

Causes / Problem

Detailed Action plan for Each Issue
Attached ...
JH Status
● JH as On Today
JH STATUS :

● JH: Scheduled Calendar
TTL M/C

JH Status

20

*JH ACTIVITY SCHEDULE *
20

Categ...
Moral-Employee Involvement
0.70

Tgrt 0.5 kaizen/Emp/Month

0.50
0.30
0.10

0.24
0.06

0.08

0.10

0.08

0.04

0.20

0.18
...
Plant layout improvement

BEFORE
BEFORE

Entry

CNC 1

VMC

VMC

CNC 10

CNC 2

CNC 9

CNC 3

CNC 8

CNC 4

Premachining

...
Plant layout improvement

AFTER

2nd

Lift - For
Floor for
Powder Coating

RM
Storage

BSC

VMC

CNC 7

Sawing

CNC 2

VMC...
Business Plan & SOB

28
BUSINESS GROWTH PLAN

8.55

Growth Plan :

Yr 2012-13

14

Yr 2013-14

● New m/c added : 3 ( Mar’13)
● Expected : 3 Machin...
SOB & Turn Over
SOB (12-13)

Year wise Performance
16

Turn Over Values In Cr
14

20
16

12

10
12

7

8

5

8

8.55

4

6...
 Summary of Business Growth Plan

63 %
Customer

VEPL - PP3

VEPL - WP5

OLC- WP-5 (Gears)

VEPL - WP7

VEPL - WP1

Birla...
New Initiatives – Employee Involvement
● Star performer award started for operators
Category :
1- Attendance incentives ,
...
New Initiatives
Best KAIZEN Award

GO GREEN
ACTIVITY

Best Productivity on Yoke Cell

Sr.No.

ACTIVITY

TARGET

1)

Pre-Tr...
Summary
Journey Continue….

32
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Manish Engineering Works

  1. 1. Manish Engineering Works TPM REVIEW 17.07.2013 01
  2. 2.  Organic Growth VEPL – PP3 5% YOKE - Pulsar YOKE – Enfield YOKE – ø 48 VEPL – WP5 10% BSC - 384 BSC - 834 VEPL – WP1 5% M.Bkt.Assy. Drive Shaft Assy. Gears (All)
  3. 3.  NPD / In-Organic Growth VEPL – WP7 20 % Gear - 735 VEPL – PP3 50 % YOKE - Suzuki Gear - 742
  4. 4. MANISH ENGINEERING WORKS Company started in the year 1998-99 with press part manufacturing set up Existing Set Up Precise set up in one roof for manufacturing components like 1. Sheet Metal Press Components :- Press Capacity in the range of 10 – 60 MT 2. Turned Components :- 10 CNC + 2 VMC + Precise Premachining Set Up like Lathes ,Drilling , Milling, Traub Machines 3. Grinding & Sawing :- Cylindrical Grinding + Band Saw ( Dia 250 MM ) 4. Welding & Brazing Assembly : - TIG / ARC / CO2 Welding + Brazing + Riveting 5. Surface Treatment :- Dedicated Set up of Surface Treatment like Powder Coating for Yoke
  5. 5. Product Information Max 2 Slides Category wise 02
  6. 6. Esteemed Customers 02
  7. 7. TPM PROGRESS EXECUTION Parameter Activities Activities A] TPM declaration with TPM policy. 29.11.11 B] Education to all employees. 1S- 2S Training Completed. A] No unwanted material. Done. B] Prefix location, Prefix quantity. Done. A] Handling as per agreed norms in container/Trolley Plastic Bins B] Elimination of quantity shortages container should have visual countability. Plastic Bins with partition & Part wise Qty. A] Study of fitment, Aesthetic & Functional Parameters & implementation of perfect inspection system for all parts. All components fitment and functional parameters known to all section heads and resp.operators. B] Cause side Kaizens & Poka-Yokes implementation & sustenance. Training given to all & examples shown. In-house Defects A] Defect stratification by ABC way. - B] Implementation of countermeasures/Kaizens following PM analysis way. Activity in continuations Delivery Performance A] No line stoppages at customer end. No line stoppages B] Daily/Weekly/Monthly delivery adherence. Daily TPM Policy 1S~2S Material Handling Customer Complaints
  8. 8. TPM Progress Status
  9. 9. Methodology Followed for TPM Implementation
  10. 10. PQCDSM – Plant Targets 02
  11. 11. • 1S 2S Zone Mapping & Leaders
  12. 12. • 1S Top 3 Examples & Results
  13. 13. • 2S Top 3 Examples & Results
  14. 14. • Yoke Cell level Targets as explained by DTJ • 2012 Tgt vs Act , 2013 Tgt Vs Act
  15. 15. • Yoke Cell Layout before & After ( Block Diagram or sketeches ) with movie of after stating lead time reduction
  16. 16. • Yoke Manufacturing Flow Stage & Photo
  17. 17. • P – Trend of P 1 , P2 , P3 , P4
  18. 18. • P – Approach OEE , Output / Man , Output / Man
  19. 19. • Kaizens P 1 , P2 , P3 , P4
  20. 20. • Q – Trend of Q1 , Q2
  21. 21. • Q – Approach
  22. 22. • Q – Kaizens of Q1 , Q2
  23. 23. • Same way for C , D , S , M
  24. 24. • Summary of Results PQCDSM 2013 Tgt vs MOM Act
  25. 25. • IPO of Yoke Cell for Sustenance of IHR Stage wise IPO sheets with hyperlink
  26. 26. • Linkage of IPO to JH , PM , TBM Sheets ( small window of IPO & big window of JH , PM or TBM sheets
  27. 27. • Horizontal Deployment in other cells
  28. 28. • Plant level Results vs TPM Tgt PQCDSM
  29. 29. • Future Plan
  30. 30. • The Journey Continoues….
  31. 31. PQCDSM - Targets 02
  32. 32. OEE trend : Low Light of 2012-13 ● 4% gap in OEE in 2013-13% ACTION PLAN Q2 (Jul-Sep) ●How to achieve 90 % OEE in Q2 On Next Slide Assessment year 2012-13 2012 2013 TPM Declaration Assessment year 2013-14 2013 BM TRGET Mar’13 OCT NOV DEC JAN FEB MAR % impr % 67 % 85 % 74 72 71 78 79 77 Output / Man Nos 2996 3500 Output / Hr Nos 368 450 Parameter OEE UOM Mar'14 Q1'13 (Apr-Jun) Apr (act) May (Trgt) (act) Jun (Act.)) Jul (Proj) 16% 85 85 72 79% 80% 87% 3525 2526 2715 2879 3156 3442 15% 3800 3200 2975 3013 3224 3200 494 17% 500 450 419 403 416 441 426 432 434 464 450 03
  33. 33. Cell-1 – BSC 384 Cell-2 – Yoke pulsar Cell-3 - Other OEE trend : Cell Wise 100% Cell Wise OEE LOSS Contributors : 86% 82% 76% 75% 74% Cell 1 ● Line balancing not maintained 84% 81% 75% 80% 73% 83% 79% 78% 75% 78% 81% 83% A 78% ● Shot man power and new operators ●no Operator standardization. 73% P ● CTQ and CTP issues ● Need base training to new operators Q ● Operator not fixed comp. wise 50% JAN FEB MAR APR MAY JUN ● tooling/insert adjustment A:Availability P:Performance , Q:Quality OEE Calculation Availability A Cell 1 Cell 2 Cell 3 P Q OEE 81% 85% 79% 97% 96% 95% 99% 98% 96% 83% 81% 76% Planned Actual GAP Time Hrs Time Hrs 2140 1615 2764 1791 1346 2126 349 269 638 Performance Production Actual as per GAP Prod Std cycle time 93036 74678 18358 198281 160565 3716 163795 121862 41933 Quality Total Prod Rej Qty 74678 97 160565 142 121862 134 04
  34. 34. OEE: GAP Analysis (2012-13) Detailed Action plan for Each Issue Attached here What went wrong : Learning from 2012-13 Issue / Problem/Cause Proposed Solution Problem: setting time Who When Machine fixed component wise 2M/c required for fulfil the qty. 1 Mr. Gosavi/ Mr. Kishor Aug.1st Week Forging batch Qty. To be increased ( 735742) Pre machining of 384 to be done 100% Mr. Gosavi/ Kishor/ Aamte Jun.2nd Week / July.1st Week Root Cause: Frequently job changed Problem: Line balancing 2 Root Cause: Less material stage wise Problem : Operator performance not ok 3 Root cause : Review of training Training and review frequently , Component wise operator f to be fixed . Mr. Gosavi/ Kishor/ Shaikh At the time of Joining & Monthly 05
  35. 35. OEE: Action Plan Q2 (Jun & Jul-Sep) Target : ● Current OEE :80%  85% Details Who When 1 Training and new appointments Mr. Gosavi JULY/AUG Line balancing to be done by 100% PreM/c of 384/834 Mr. Gosavi / Patil D.B. July.1st Week Forging batch Qty will have to increase. Problem: shot man power. Proposed Solution Mr. D.B. Patil 735-July / 742-Aug. 1 Root Cause: absent operators. Problem: running load problem – 384/834 2 Root Cause: stock of material not available Problem: 742 and 735 shortage. 3 Root Cause: Less receipt from vendor 06
  36. 36. Output /Man & Hrs 07 OUTPUT/MAN Low Light of 2012-13 ●No consistency & sustenance in OUTPUT/MAN ACTION PLAN Q2 (Jul-Sep) ●How to achieve 3.4 in next Qtr On Next Slide OUTPUT/Hr Low Light of 2012-13 ● Below Benchmark line ACTION PLAN Q2 (Jul-Sep) ●How to achieve 500 in next Qtr On Next Slide
  37. 37. Output /Man & Hrs : GAP Analysis (2012-13) What went wrong : Learning from 2012-13 Issue / Problem/Cause Proposed Solution Problem: Operator performance not ok Who When Training to be given about CTQ and CTP At the time of joining. Machine fixed component wise 1 Mr. Shaikh/ Mr. Gosavi Mr. Gosavi/ Kishor/ Aamte Monthly cell wise/ M/C wise. New machine installed Mr. M.D. rawke 10/08/20 13 Root Cause: New operators Problem: Setting time 2 Root Cause: Frequently job changed 3 Problem : No capacity for other component. Root cause : M/c divided cell wise. 08
  38. 38. Output /Man & Hrs : Action Plan Q2 ● Output/Man : 3.22 k3.4 k ● Output/Hr : 464 500 nos./hr Details Who 1 Training and new appointments 2 Attendance Bonus to be increased Mr. Gosavi / M.D.Rawke JUN/JULY Line balancing done to be done by Pre-M/c of 384/834 Mr. Gosavi / Kishor July Forging batch Qty will have to increase. Problem: shot man power. Proposed Solution When Mr. D.B. Patil / M.D.R. DONE 1 Root Cause: absent operators. Problem: running load problem – 384/834 2 Root Cause: stock of material not available Problem: 742 and 735 shortage. 3 Root Cause: Less receipt from vendor 09
  39. 39. Customer Complaint PPM Observation ● C.C.PPM improvement ( 97%) ● C.C.Ph improvement (80 %) ● C.C.Occr. Improvement (83%) Action plan Next Slide Assessment year 2012-13 TPM Declaration Parameter C.C. Occ. C.C. PPM C.C. Ph. UOM No PPM (k) Nos 2012 Assessment year 2013-14 2013 2013 BM TRGET Mar’13 OCT NOV DEC JAN FEB MAR % impr Mar'14 Q1'13 (Apr-Jun) Apr (act) May (Trgt) 6 0 1 1 2 1 1 1 83% 0 0 3 1 2978 0 5 0 116 5 606 1 576 3 2415 2 244 1 81 1 97% 0 0 80% 0 0 (act) Jun Jul (Act) (Prj) 2 300 291 147 3 1 2 0 0 0 10
  40. 40. C.C. PPM : Phenomenon/QTY : JUN ● R: Repetitive Phenomenon Categor y (R/N) Jan N: New Feb Mar Apr May June Gear-670 depth u/s New 0 0 21 0 0 0 2 Gear 561 OD burr REP. 0 0 0 21 49 0 3 Pinion Dia 15.005 + 0.012 u/s New 0 0 0 0 30 0 4 M.Bkt. - ID Bush U/s New 0 0 0 0 0 23 5 M. Bkt (Old)– CD Shift New 0 0 0 0 0 22 1 11
  41. 41. C.C. PPM : Action Plan ● C.C.PPM : 147 k0 Details (Top 5) Problem: Gear 5 th pinion Depth u/s 1 Root Cause: Forging defect and scaling issue Problem: Gear 561 burr placed on OD dia. 2 Root Cause: Die wear out Problem: Pinion Dia. 15.005+0.012 mm U/S 3 Root Cause: Checked by digital micrometer Problem: M.Bkt – ID Bush U/S 4 Detailed Action plan for Each Issue Attached here In ● 6W2H format ● Effectiveness & Sustenance format Proposed Solution Who Strict inward inspection to be done and forging parameters to be fixed for forging checking. Mr. Shaikh Immediate Die Grinding frequency fixed by supervisor ( after 2500 nos.) Close monitoring. Mr. Bharmbe Immediate/ Monitoring newly development part OD grinding operation added ( 12 micron ) Air gauge ordered for pinion instead of digital micrometer. Mr. shaikh 30 June Bracket Bush Fitting Pin ø to be increased by 30 micron Mr.Gosavi July -2nd Week / Under Montor. Reaming operation introduced for answering PCD Guage Mr.Patil / Giri Jun-Last Week / Under Montr. Root Cause: Bush fitment Fixture Pin U/s Problem: M. Bkt(Old) CD Shift - Spare 5 Root Cause: Reaming to be done When 12
  42. 42. In house Rej PPM Observation ● In House Rej PPM : 75% improvement in yr 2012-13 ● How to ach. Q2 trgt 0 (zero) Action plan Next Slide Assessment year 2012-13 TPM Declaration Parameter In house Rej Occurrences In house Rej PPM In house Rej Phenomena 2012 Assessment year 2013-14 2013 2013 BM TRGET Mar’13 OCT NOV DEC JAN FEB MAR % impr Nos 14 0 7 6 6 5 5 4 PPM (k) 4512 200 1188 1491 1598 1441 1169 Nos 12 0 8 8 7 7 5 UOM Mar'14 Q1'13 (Apr-Jun) Apr (act) May (Trgt) 71% 0 0 7 10 1145 75% 200 0 1410 5 58% 0 0 3 (act) Jun Jul (Act)) (Prj) 9 0 1152 1125 0 4 4 0 13
  43. 43. In house Rej: Phenomenon / Qty: JUN ● R: Repetitive Phenomenon N: New Category (R/N) Jan Feb Mar Apr May June 1 ID o/s – (LAY SHAFT / YOKE ) Repetitive 72 53 126 113 93 62 2 Parallelism – (BSC-384 ) Repetitive 32 22 26 18 19 15 3 Total Length u/s – ( LAY SHAFT & YOKE ) Repetitive 42 31 35 38 30 27 4 Cutting u/s – ( YOKE ) Repetitive 48 72 58 60 56 37 14
  44. 44. In house Rej : Action Plan: Q2 ● IHR .PPM : 1125 k0 Details (Top 5) Problem: ID o/s ( Lay shaft / YOKE ) 1 Detailed Action plan for Each Issue Attached here In ● 6W2H format ● Effectiveness & Sustenance format Proposed Solution Who When New tool under monitoring / Back boring Tool for ID M/c. Mr. Gosavi Under Monitoring BSC -384 Cutting blank given for facing and ID boring ( Pre machining ) Mr. D.B. Patil Started 15/06/2013 100% from July. Properly training given to operator about job resting and jaw cleaning.. Mr. Gosavi 1/06/2013 Pipe cutting operators proper training given to insure no burr at resting face. Mr. Shaikh 2/06/2013 Root Cause: B type defect / Burr Revolving in ID Problem: Parallelism more 2 Root Cause: Due to U drill force Problem: Total length u/s ( Lay shaft and yoke) 3 Root Cause: Resting not properly done Problem: Cutting u/s (Yoke ) 4 Root Cause: burr placed on resting face 18
  45. 45. Cost 19
  46. 46. Cost Assessment year 2012-13 TPM 2012 Declaration Parameter UOM BM Assessment year 2013-14 TRGET Mar’13 2013 2013 OCT NOV DEC JAN FEB MAR % impr Mar'14 Q1'13 Apr May Jun Q2-13 (Trgt) (Apr-Jun) (act) (act) (act) (Trgt) Power Cost Rs/unit 1.06 1.73 1.67 1.43 1.17 1.22 1.59 -50% 1.75 1.82 1.90 1.73 1.82 1.92 Rework Cost Rs/unit 0.3 0.29 0.25 0.25 0.24 0.24 0.24 20% 0.20 0.25 0.27 0.25 0.23 0.20 Rs/unit 2.08 2.98 2.91 2.24 2.69 2.65 3.65 -75% 4.00 4.08 4.87 3.83 3.53 3.50 Consumable cost 20
  47. 47. DSM Assessment year 2012-13 TPM Declaration 2012 Assessment year 2013-14 2013 2013 UOM BM TRGET Mar’13 OCT NOV DEC JAN FEB MAR % impr % 100z 100 100 100 100 100 100 100 Major Accidents Nos 0 0 0 0 0 0 0 Minor Accidents Nos 0 0 1 3 0 0 Green Bed Area % 0 0 0 0 0 0 kaizens Emp/mnth - 0.5 Training Hr/emp 1.0 SOB With Varroc % Act With Varroc Apr (act) (act) Jun (Act) Jul (Prj) 100 100 100 100 0 0 0 0 0 0 0 0 0 1% 0 0.2 0.14 0.2 0 1.50 1.5 1.5 2.0 90% 98% 98% 95% 95% 95% 100% 98% 98% 98% 98% 98% 0 100% 100% 100% - - - 1 1 0 100% 100% 100% - - - 1 1 0 100% 100% 100% - - - 1 50 100 0 100% 100% 100% 100 100 0 100% 100% 100% - - - - Mar'14 Q1'13 (Trgt) (Apr-Jun) 100 100 100 0 100 0 0 0 0 0 100 0 0 0 0 0 5% 1% 0.06 0.08 0.08 0.08 0.03 0.03 25% 0.5 0.05 4.00 1.50 1.50 1.50 1.50 1.50 1.50 50% 4.0 98% 98% 98% 98% 98% 98% 98% 98% 100% % 96% 95% 98% 98% 98% 98% 98% 98% Nos - 9 0 0 0 2 1 Nos - 9 0 0 0 2 Nos - 8 0 0 0 1 On Time Development % 100 0 0 0 First Time Right % - 100 0 0 0 Parameter Delivery Product Under Development Samples Submitted In Time Sample Accepted First Time May 1.5 - 21
  48. 48. Loss Analysis ● TOTAL LOSS IN HRS : ● LOSS IMACT : 944.52 960.00 ● Total Loss till date (Jan-Jun) : 5235 hrs . (436Shift) 940.00 920.00 888.40 900.00 880.00 856.90 867.57 823.38 840.00 820.00 ● Monetary Loss : 1650 Rs ● Opportunity Loss : 855.05 860.00 719813 lacs 800.00 780.00 760.00 JAN FEB MAR APR MAY JUN ● LOSS TREND TOP 3 399.6 396.6 ● TOP 3 LOSSES 374.5 334.4 274.9 272.1 270.3 360.93 9.7 JAN FEB 241.68 123.7 Management 31.4 loss 42.8 MAR APR % cont 1. Set up & adjustment 2161 526 2. Due to operator 1567 261 3. Management loss 249.28 Due to operator 17.6 Time (Hrs) (Jan-Jun) 691 115 295.22 120.4 252.0 *Note : Monetary loss : Operation cost + Manpower cost. Opportunity cost :- Could have produced component in lost time MAY JUN 22
  49. 49. Loss Analysis: Detailed (Loss in Hrs) 450.0 400.0 350.0 399.6 396.6 374.5 360.93 334.4 295.22 300.0 274.9 272.1 270.3 280.0 270.0 260.0 250.0 252.0 240.0 150.0 Set up & Adjustment 100.0 50.0 JAN 241.68 Due to operator JAN FEB 43.8 45.0 MAR APR MAY JUN 40.8 24.0 30.0 28.70 26.97 20.0 Equipment Failure loss 10.0 JAN Tool Change Loss 10.0 5.0 149.8 Due to material 93.5 80.0 47.1 46.9 43.3 60.0 40.0 28.1 21.8 40.0 37.2 4.8 FEB MAR APR MAY JUN JAN FEB MAR APR MAY JUN 15.8 15.0 10.0 3.5 20.0 55.9 20.6 25.0 20.0 Other 28.2 30.0 100.0 JUN 0.0 140.0 120.0 MAY 120.0 20.0 JAN FEB MAR APR MAY JUN APR 60.0 0.0 0.0 MAR 137.4 80.0 15.4 15.0 20.0 160.0 25.0 0.0 100.0 30.0 37.0 40.0 9.7 FEB 42.8 140.0 32.55 32.55 35.0 42.5 50.0 17.6 160.0 39.2 40.0 60.0 31.4 JAN 40.0 20.0 50.0 67.1 70.0 80.0 60.0 230.0 FEB MAR APR MAY JUN Mngmnt loss 100.0 220.0 0.0 80.0 120.0 249.28 250.0 200.0 120.4 123.7 140.0 5.0 Trial, inspection & Dev. 0.0 0 3.51 0.0 0.0 JAN FEB MAR APR MAY JUN -5.0 JAN FEB MAR APR MAY JUN 23
  50. 50. Action Plan : Losses June ●Set up & Adjustment : 295hrs 0 Causes / Problem Problem: No raw material planning Detailed Action plan for Each Issue Attached here Proposed Solution who when Immediate Mr. Gosavi Immediate New sleeve boring bar purchased . Root Cause: Material shortage Mr. Gosavi Setting change planned As per raw material availability , Training given to supervisor about setting problems and tool adjustment. 1 Line balancing done to reduce set up change loss, raw material planning discussed with Mr Gajanan, Material Requirement planned . Mr. Gosavi Immediate ● Management loss : 123 hrs 0 Causes / Problem Problem: Material short (BSC-834 ) 1 Root Cause: Delivery late Problem: Material short (BSC-384 ) 2 Root Cause: Material come from Ludhiyana Proposed Solution who when New vendor added for BSC-384 , Dia 83 20 MNCr5 raw material procured from Mukund Ltd. ( delivery time only 2 days ) Mr. D.B. Patil 20/07/2013 Forging batch Qty at Mahesh industry increased from 2200 to 4000, Ample Qty. Available at pre m/cning and CNC machining stage. Mr. D.B. Patil DONE 25
  51. 51. Action Plan : Losses June ● Due to operator : 241.0 hrs  Causes / Problem Detailed Action plan for Each Issue Attached here In ● 6W2H format ● Effectiveness & Sustenance format Proposed Solution who when Problem: Lack of man power 1 Root Cause: New operators Problem: unclean job 2 Root Cause: No man for job cleaning Skilful and trained operators designated for machine shop , minimum 6 month experienced operators to be selected at the time joining. Mr. Gosavi Immediate Clean job provided. machine wise operator fixed. stock material, Allen key and insert provided on the spot. And extra casual provided for job cleaning. Mr. Patil Immediate 24
  52. 52. JH Status ● JH as On Today JH STATUS : ● JH: Scheduled Calendar TTL M/C JH Status 20 *JH ACTIVITY SCHEDULE * 20 Category 12 12 12 Name of M/c JH 1 JH 2 JH 3 Status Month JH2 Machining ● JH Plan Apr MAY JUN JUL Aug (Bal) (Done) (Plan) (Plan) (Plan) JH1 - - - - JH2 2 - - 2 JH3 2 - - 2 Done 10 Feb. Done 5 Feb. Done 8 Feb. Done 10 Feb. Done 10-Feb Done 25-Jun Done 25-Jun Done 10 APR. Done 5-Jul 5-Jul Done 10 APR. pending 15-Jul CNC-6 Done 25 Apr. Done 30-Apr Done 2-May CNC-7 Done 15-May Done 18-May Done 20-May Done 22-May Done 25-May Done 30-May CNC-9 JH3 8 Feb. CNC-8 JH1 Done CNC-5 0 Done 5 Feb. CNC-4 0 Month CNC-2 10 Status CNC-3 10 Month CNC-1 12 Status Done 28-May pending 20-Jul Remark Done Pending Pending CNC-10 Done 29-May Done Done - VMC-1 Done 15 Dec. Done 20 Dec. Done 22 Dec. - VMC-2 Done 25 Dec. Done 30 Dec. Done 2-Jan - Done 1-Jul Done 12 10 10 Pending 0 2 2 Total 12 12 12 26
  53. 53. Moral-Employee Involvement 0.70 Tgrt 0.5 kaizen/Emp/Month 0.50 0.30 0.10 0.24 0.06 0.08 0.10 0.08 0.04 0.20 0.18 0.04 -0.10 -0.30 3 4 4 5 2 2 12 9 3 4 4 5 2 2 12 9 10 JAN FEB MAR APR MAY 100 90 80 70 60 50 40 30 20 10 0 JUNE -0.50 Tgrt 25 kaizen/Month OCT Category JH KK PM QM SHE 5S OTHERS Total NOV OCT DEC NOV DEC 1 2 1 JAN FEB 1 1 1 APR 1 1 MAR 2 2 3 3 2 2 2 1 1 1 1 1 1 1 1 MAY June TTL % Contr 10 13 7 1 1 Nos of Emp kaizen/Empl/Mnth 0.06 1 1 1 3 50 1 1 7 3 3 1 2 5 3 1 1 3 4 50 4 50 5 50 2 50 2 50 12 50 9 50 10 50 48 450 0.08 0.08 0.10 0.04 0.04 0.24 0.18 0.20 0.11 Kaizen Required 25 25 25 25 25 25 25 25 25 -22 -21 -21 -20 -23 -23 -13 -16 -15 -177 1. Theme : To reduce IHR QM Benefit: 1 ) Rework time saved by 30 min. 2 ) IHR reduce by 13 nos. 3 ) Production increased by 51 nos. 2. Theme : To increased productivity KK Benefit: 1 )Productivity increased by 45 nos. 2 ) Cycle time reduced by 35 sec per job. 3 ) Insert life increased 4 ) Cost saved 225 Kaizen Short fall TOP 2 Kaizen Of The month 27
  54. 54. Plant layout improvement BEFORE BEFORE Entry CNC 1 VMC VMC CNC 10 CNC 2 CNC 9 CNC 3 CNC 8 CNC 4 Premachining CNC 7 Traub 2 Traub 1 Sawing Inspection RM Storage Dispatch BSC CNC 5 CNC 6 Press for Yoke Dimple For Powder Coating on 2nd Floor RM Storage Yoke
  55. 55. Plant layout improvement AFTER 2nd Lift - For Floor for Powder Coating RM Storage BSC VMC CNC 7 Sawing CNC 2 VMC Insp Table CNC 3 CNC 2 CNC 1 Dispatch CNC 6 Premachining CNC 4 Press for Yoke Dimple Traub 2 CNC 5 Traub 1 CNC 9 CNC 8 RM Storage Yoke
  56. 56. Business Plan & SOB 28
  57. 57. BUSINESS GROWTH PLAN 8.55 Growth Plan : Yr 2012-13 14 Yr 2013-14 ● New m/c added : 3 ( Mar’13) ● Expected : 3 Machines (Aug’13) ● CNC-4, VMC-1, Hy. Band s.-1 29
  58. 58. SOB & Turn Over SOB (12-13) Year wise Performance 16 Turn Over Values In Cr 14 20 16 12 10 12 7 8 5 8 8.55 4 6.64 4 4.72 2.88 0 0 Yr 10-11 Yr 11-12 Yr 12-13 Status :Yr 2013-14 6 6 4 4 Yr 2013-14 Performance 2 3 Yr 13-14 4 4 3 2.88 2 0 0 Apr-Jun Jul-Sep Oct-Dec Jan-Mar 30
  59. 59.  Summary of Business Growth Plan 63 % Customer VEPL - PP3 VEPL - WP5 OLC- WP-5 (Gears) VEPL - WP7 VEPL - WP1 Birla & Other Qty Targeted ( In Lacs ) FY 13-14 Business Targeted ( In Crs ) FY 13-14 YOKE - ( ø48 - Black ) -10 140 YOKE Enfield (RE)- 29 520 YOKE Pulsar- 21 520 YOKE - SUZUKI BSC - VMC Profile -1043384 4.20 1.50 10.00 1.50 3.00 1.82 0.65 3.08 0.44 2.77 BSC - Cross Hole -1043834 Adler Gear Gear - 1005 / 06 Gear - DD Gear - 670 Gear - 561 Gear - 735 Gear - 742 Drive Shaft Assy - 15 350 0.50 0.50 0.25 3.50 2.00 3.50 1.00 0.70 2.00 0.67 0.06 0.03 0.20 0.11 0.05 1.21 1.20 0.19 M.Bkt. Assy. Comp. - 15 340 2.00 0.86 D.Shaft Assy.(Old) 0.13 0.01 0.12 0.20 36.60 0.05 0.70 14.10 Part Name - 15 150 M.Bkt. Assy. (old) - 15 350 B.H. - 521 / other Gross Sale @ 14.00 Crs
  60. 60. New Initiatives – Employee Involvement ● Star performer award started for operators Category : 1- Attendance incentives , 2 - Productivity award 3 - Best Kaizen award, ● Quality campaign carried out. 1 - Gauges handling and setting 2 - Product knowledge 3- Defect wise monitoring ● Safety training campaign arranged. - Safety Aids - Both cell safety alarm provided and Training to all operators ( mock drill ) 31
  61. 61. New Initiatives Best KAIZEN Award GO GREEN ACTIVITY Best Productivity on Yoke Cell Sr.No. ACTIVITY TARGET 1) Pre-Treated Water for Toilet & Garden Aug 2) No utilization of Poly Bags Aug 31
  62. 62. Summary
  63. 63. Journey Continue…. 32

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