This document contains sales, production, export, membrane switch, and raw material data for a company for the month of June 2012. It reports total sales of 259.10 million for June across OEM, retail, export, and fleet segments. Production capacity was 0.83 million sets and utilization was 61%. The export projects status update mentions material testing results for Honda and Yamaha projects. It also includes membrane switch production setup details and tracking of raw material development time, which averaged 3.9 days against a target of 3 days.

1. Mn. Rs
Month April May June July Aug Sept Oct Nov Dec Jan Feb Mar Total
Total Sales 238.08 255.07 259.10
Segment Sales April Sales May Sales June
OEM 207.63 228.10 229.91
Retail 21.22 17.50 19.95
Exports 7.42 7.23 8.14
Fleet 1.81 2.25 1.10
Total 238.08 255.07 259.10
1

2. Mn Rs.
Month April May June July Aug Sept Oct Nov Dec Jan Feb Mar Total
Budgeted Material
44.70 46.06
Consumption
Actual Material
48.33
Consumption 51.85
PO:

3. Pelhar April May June July August Sept Oct Nov Dec Jan Feb Mar
Installed
Capacity 0.76 0.83 0.83
( Million Sets)
Utilized
Capacity 0.33 0.45 0.50
(Million Sets)
% Utilization 43% 55% 61%
3

4. EXPORTS Projects
PROJECTS Status on JUNE 2012
HONDA A countermeasure was given to Honda ,where CSPL-TVF-3PLE-1 material is to be used. All the
materials available in Pelhar and Unit I were under deviation ,traced one roll at haridwar which was
without deviation and passes HES specs hence procured that from Haridwar, on which gloss
patches were printed . These patches passes in fuel oil resistance test where as fails in E10 and E20
solution for both Type 4 and Type 6 panels. Testing presently under process for original Honda Decal
for E10 and E20 solution reports will be submitted by July 1st week
MIO-PINK Printing done with following combination and test conducted results found as under,
(Yamaha Material used as
Indonesia) 1.PVC WB80 PA 10 11LLY
2.PVC WB80 PA T1 11LLY
3.CSPL-WVF-3P-1
4.CSPL-WVF-3P-2
Printed OC with following combination
1.V3 + 45% Non silicon 8228 OC
2.V3 + 8600 OC
3.V3 + SIEKO 5412 UV
All the material printed with V3 + Sieko 5412 UV fails in WOM after 400hrs,where as material printed
with other two OC passes in WOM till 400 hrs and is continued for 900hrs
KUBOTA Approved Drawing submitted (K7564-65231,K7311-65206,K7721-65801,K2581-65205) on 14.6.2012
and 18.6.2012. Awaiting for the release of the P.O
3/18/2013 4

5. Membrane Switch Projects
TYPE OF MEMBRANE STATUS IN JUNE 2012
SWITCH
LG samples will be submitted by 11-07-12
LG
LG quote submitted on 2.7.2012 ,awaiting feedback from
Mktg
Location finalized for MS assembling (In dial post curing
Membrane switch area) .Layout to be finalised
production set-up
Testing equipments (MS tester, life tester & Hipot tester)
Membrane Switch ordered, expected by mid July 2012
Equipments
Hot air oven will be ordered after positive feed back from LG
2 man power to be taken from production for involving in
Manpower MS start up production activities. Existing 2 persons
3/18/2013 5

6. RAW MATERIAL TRACKING SHEET
3/18/2013 6

7. Month
2010-11
Apr May Jun Jul Aug Sep Oct Nov Dec Jan Feb Mar Average Target
No. of
Samples 67 40 44
dispatched
Development
3.76 3.3 3.7
time (days)
5
4.5
4
TARGET 3.9 DAYS
3.5
3
2.5
2
1.5
1
0.5
0
Apr May Jun Jul Aug Sep Oct Nov Dec Jan Feb Mar

8. No. of samples No. of production No. of production
Segments Clients dispatched from this months sdr. previous months sdr. Ftr
OEM TWO WHEELERS HERO 7 0 4 4
BAJAJ 4 0 0 0
YAMAHA 5 0 1 1
SUZUKI 1 0 0 0
MAH. & MAH. 8 1 2 3
M&M SWARAJ 2 0 1 1
JOHN DEERE 3 0 0 0
TAFE 10 0 2 2
MARUTI SUZUKI 1 0 0 0
OEM FOUR WHEELERS TATA MOTORS 4 0 0 0
& OTHERS ESCORT TRACT. 2 0 0 0
HAZARA 1 1 0 1
AUTOGRAPHIX ROYAL ENFIELD 1 0 0 0
OTHERS 4 0 1 2
AUTOGRAPHIX 4 0 4 4
SAUD BHAWAN 2 0 0 0
EXPORT ALJ 1 0 3 3
BANGLADESH 1 0 0 0
TOTAL 61 2 18 20
INTERNAL CUSTOMER HERO HONDA 15 15

9. Month
2010-11
Apr May Jun Jul Aug Sep Oct Nov Dec Jan Feb Mar Actual Target
No. of
Samples 67 40 44
dispatched
FTR 67 40 44
% FTR
100% 100% 94.4%
( days)
% FTR
120%
100%
80%
60%
40% % FTR
20%
0%
Apr May Jun Jul Aug Sep Oct Nov Dec Jan Feb Mar
No. of production from this
Clients No. of samples dispatched months sdr. Ftr
MAH. & MAH. 8 1 1
HAZARA 1 1 1
9

10. S. No
Dial Name Hand Over Date
1
HDT Daimler dial 10 nos each
NGC Dial & Diffuser 180 nos each
2
HDT Daimler dial 10 nos each
3
Bajaj JL dial & John Deere dial 5 Nos each
5
TATA Prima dial (New option) 10 nos
6
TATA Prima dial (New option) 20 nos
10

11. List of jobs of JUNE 2012
Custom DATE Status
SR No. JOB Things gone Right
er Received Sales status
1 Classic Inshop- repeat order (2 FTR approved
artwork)
ITC 2-Jun PRODUCTION DONE, 11-Jun
repeat size ( 17.3" x 17")
new size ( 22" x 14")
Royal Onshop, 3'X6' Clear and well file
2 ITC 9-Jun Awaiting feedback
information
Gold Flake red Onshop Vinyl, 3'X6'
Background : approved Brandboad : Clear and well file
3 ITC 1-Jun
approved information
Gold Flake red Onshop PC, 3'X6'
Background : approved Brandboad :
4 ITC 1-Jun Clear and well file
approved information
Flake Filter BRANDBOARD
1) flake BB straight Printing Background : approved Brandboad :
5 2) flake BB reverse Printing ITC 19-Jun
approved Clear and well file
information
6 NAVY CUT ACP, 59cmx 89cm ITC 22-Jun Awaiting feedback
As per the instructions
received by Nandini
kindly stop all the sample
NAVY CUT Reverse printing 17" x
developments on clear acrylic.
7 ITC 22-Jun
22" We will not be using
3mm clear acrylic henceforth.
We are going to try some
alternate base material
11

12. Sr. No JOB Customer
Costing Sampling
KUBOTA (225 RFQ)
39 RFQ Submitted on PC
1 KUBOTA 22 RFQ Submitted on PVC
22 RFQ Submitted on PVC
Total 83 RFQ Submitted
KUBOTA (225 RFQ)
39 RFQ Submitted on PC
2 KUBOTA 22 RFQ Submitted on PVC
30 RFQ Submitted on PVC
Total 91 RFQ Submitted
3 Sample Development KUBOTA 30 pcs. Each submitted
Dt. 28-06-2012
4 Sample Development KUBOTA
Sample Development KUBOTA
Sample Development KUBOTA HOLD for Customer Inputs
Sample Development KUBOTA
12

13. In Lac
Month
Apr May Jun Jul Aug Sep Oct Nov Dec Jan Feb Mar Total Actual
2010-11
Purchasing
817 1073 1122
Value
Target 57 75 79
Actual Savings 5.1 89 15.5
% 9% 118% 20%
100
90
80
70
60
50 Actual Savings
40 Target
30
20
10
0
Apr May Jun Jul Aug Sep Oct Nov Dec Jan Feb Mar
PO:

14. Inventory Analysis (Material Rx Vs Consumed)
April to Mar 2013
May- Mar-
Month Apr-12 12 Jun-12 Jul-12 Aug-12 Sep-12 Oct-12 Nov-12 Dec-12 Jan-13 Feb-13 13 Total
Matl
Recd(in L) 817 1073 1122 3012
Matl
Issued(in L) 1083 1363 1325 3771
1600
1400
1200
1000
800
600 Matl Recd(in L)
400 Matl Issued(in L)
200
0
PO:

15. Inventory Valuation
April to Mar 2013
May- Aug- Nov- Jan- Feb- Mar-
Month Apr-12 Jun-12 Jul-12 Sep-12 Oct-12 Dec-12 Total
12 12 12 13 13 13
Local
&Import ( 1280 1365 1356 4001
Lacs)
Target 1527 1628 1845 2080 2228 2316 11624
2500
2000
1500
Local &Import ( Lacs)
1000 Target
500
0
April May June July Aug Sep Oct Nov Dec Jan Feb Mar
PO:

16. Months Apr-12 May-12 Jun-12 Jul-12 Aug-12 Sep-12 Oct-12 Nov-12 Dec-12 Jan-13 Feb-13 Mar-13
Inv Turns 10 12 12
Target 11 11 11 11 11 11 11 11 11 11 11 11
12.50
12.00
11.50
11.00
Inv Turns
10.50
Target
10.00
9.50
9.00
PO:

17. Total
Month April May June July Aug Sep Oct Nov Dec Jan Feb Mar
Last year ( 11- 2.40 1.78 0.0 0.0 0.0 1.9 0.0 0.3 0.0 0.0 1.9 2.35 10.6
12)
2.37 1.98 0.6 4.95
This Year (12-13)
Target Rs in
Lakhs 4.0 4.0 4.0 4.0 4.0 4.0 4.0 4.0 4.0 4.0 4.0 4.0 48.0
4.50
4.00
3.50
3.00
2.50 Last year ( 11-12)
2.00 This Year (12-13)
1.50 Target Rs in Lakhs
1.00
0.50
0.00
April May June July Aug Sep Oct Nov Dec Jan Feb Mar
PO:

18. Description Apr-12 May-12 Jun-12 Jul-12 Aug-12 Sep-12 Oct-12 Nov-12 Dec-12 Jan-13 Feb-13 Mar-13
Base Film 49 49 49
Application
32 31 31
Film
Ink 24 24 24
Grand Total 105 104 104
Target 105 102 101 98 95 93 91 88 85 81 78 75
120
100
80
60
Grand Total
40
Target
20
0
PO:

19. 10
12
14
16
0
2
4
6
8
Avg. 13.48
13.66
(11-12)
9.48
Apr-12 9.88
10.07
10.22
May-12 10.70
10.69
10.92
Jun-12 13.44
12.08
Jul-12
Aug-12
Sep-12
Oct-12
Nov-12
Dec-12
Jan-13
Feb-13
Mar-13
Sales (Rs.Crs.)
Actual Prod (Rs.Crs.)
Budget Prod (Rs. Crs.)

20. Target
Actual
99.56
99.35
99.23
99.15
100
100
100
100
100
100
100
100
100
100
100
100
100
100
95
90
% OTD
85
80
75
70
Avg. Apr-12 May-12 Jun-12 Jul-12 Aug-12 Sep-12 Oct-12 Nov-12 Dec-12 Jan-12 Feb-12 Mar-12
(11-12)

21. New models AACA New Models
& K06A AANA & AAGA
Target Total Freight cost (%) on sale Premium Freight (%) on sale
0.7 0.63 0.62
0.6 0.54
0.5 0.46
0.4
0.3
0.22 0.20
0.2
0.10
0.1 0.07
0
Avg. 11- Apr-12 May-12 Jun-12 Jul-12 Aug-12 Sep-12 Oct-12 Nov-12 Dec-12 Jan-13 Feb-13 Mar-13
12

22. Capacity Planning for July’ 12 to Sept’ 12
Capacity Planning - July' 12 to Sep' 12 - Pelhar Plant
Sales Budget
Jul-12 Aug-12 Sep-12
(Sets) Total
HMCL 389100 362625 387385 1139110
BAL 90900 90400 90400 271700
Yamaha 32700 45000 43600 121300
Suzuki 30000 31500 31500 93000
M&M 4200 4200 4500 12900
Total 546900 533725 557385 1638010
Production
Budget (Sets) 601590 587098 613124 1801811
Planned
Utilization (%) 78 76 86 80

23. Dial Capacity Planning July’ 12 to Sept’ 12
Capacity Planning - Jul' 12 to Sep' 12 - Pelhar Plant
Sales Budget -
Jul-12 Aug-12 Sep-12
Dials Total
PRICOL 107850 132050 156150 396050
CONTI 39300 45300 47300 131900
TOTAL 147150 177350 203450 527950
Total Prod Budget 183938 221688 254313 659938
Capacity - Dials 452603 452603 417787 1322992
Planned %
41 49 61 50
Utilization

24. Sales & Production Plan – June ’12
Sales & Production Plan -Jul 12
Actual Opening Stk
Stocking Product Schedule
Customer Sales Plan
Norms BSR Depot Total ion Plan Value
HMCL 10.000 5.000 0.000 5.560 5.560 9.560 10.120
BAL 0.800 0.400 0.007 0.290 0.297 0.800 1.210
Yamaha 0.300 0.150 0.002 0.194 0.196 0.254 0.292
Suzuki 0.200 0.100 0.020 0.008 0.028 0.272 0.017
M&M 0.050 0.025 0.025 0.000 0.025 0.050 0.051
Godrej 0.020 0.010 0.000 0.000 0.000 0.035 0.025
Pricol/Conti
. 0.200 0.100 0.003 0.001 0.004 0.270 0.174
Export 1.150 0.000 0.000 0.000 0.000 1.150 0.530
Total 12.720 5.785 0.057 6.053 6.110 12.391 12.419
24

25. 60
64
66
68
70
74
76
62
72
66
73
Avg. (11-12)
65
75
Apr-12
65
75
May-12
65
75
Jun-12
75
Jul-12
75
Aug-12
Target
75
Sep-12
75
Oct-12
Average
75
Nov-12
75
Dec-12
75
Jan-13
75
Feb-13
75
Mar-13

26. Avg. (11- Sep- Nov- Dec- Mar-
Apr-12 May-12 Jun-12 Jul-12 Aug-12 Oct-12 Jan-13 Feb-13
Month 12) 12 12 12 13
Description
Total Loading Time (min.) 204595 162714 184178 201729
Total Down Time (min.) 61233 58657 59206 61105
Total Down Time (%) 30.00 36.05 32.15 30.29
Reasons of Down Time
13681 20864 12757
Planned Shut Down 13638
4568
4655 3609
Screen Related 3571
30045 37828
38824
Process Related 39305
Ink Related 3474 3140
2894 3561
Maintenance Related 1180 665 913
1030
26

27. Traget % OT Cost (Support) to Production (Production)
% OT Cost % OT Cost % OT Cost (Total)
1.20 0.97
1.00
0.80
% OT
0.60 0.59 0.39
0.27
0.40 0.13 0.14 0.20
0.20 0.01 0.32 0.19
0.00
Avg. (11- Apr-12 May-12 Jun-12 Jul-12 Aug-12 Sep-12 Oct-12 Nov-12 Dec-12 Jan-13 Feb-13 Mar-13
12)
Month
• New Model AAGA – Super Splendor processed on short lead time.
• Increased changeovers in SPD due to Brand Migration at HMC
• M/C Allocation for ITC Sampling
27

28. Actual Target
Machine April May June July Aug Sept Oct Nov Dec Jan Feb Mar
(Avg) (Avg)
REBOLINI -1 91 87 87
REBOLINI -2 82 82 94
BHARAT BIG -1 83 72 98
BHARAT BIG -2 89 89 81
BHARAT
SMALL -1
82 78 91
BHARAT
SMALL -2
76 76 70
28

29. Rejection %
10.00%
6.00%
8.00%
0.00%
1.00%
2.00%
3.00%
4.00%
5.00%
7.00%
9.00%
Avg. (11-
12)
5.96%
Apr-12
May-12 6.85%
5.10%
Jun-12
5.13%
Jul-12
Aug-12
Sep-12
Month
Oct-12
Nov-12
Dec-12
Jan-12
Feb-12
Mar-12
29

30. 10.00
9.44
9.00
8.00 8.00 8.13
7.00 7.19
6.00
5.00 Unit 1
4.00 Pelhar
3.00 Haridwar
2.00
1.00
0.00
Jul
Target
Aug
Nov
Jan
Feb
Dec
Mar
May
Sep
Apr
Oct
Jun
30

31. DIAL Rejection trend
Nov Dec Jan Feb Mar April May June July Aug Sept Oct
Pricol 16 15 20.71 10.54 14.58 9.5 9.56
Continental 50 24 52.38 30.83 34.08 28 31.44
Diffuser 0 0 41.82 64.77 43.04 27.94 39.25
70
60
50
40
Pricol
30 Continental
Diffuser
20
10
0
Nov Dec Jan Feb Mar April May June July Aug Sept Oct

32. 8
7
6
5
4
3
2
1
0
Apr
Oct
Jun
Dec
Mar
Jul
Nov
A: 11-12
A: 10-11
Jan
Feb
May
Aug
Sep
Pelhar Target
Internal Actual Actual
April May June July Aug Sept Oct Nov Dec Jan Feb Mar Target
Rejection 11-12 10-11
Pelhar 4.05 3.63 3.85 4.0% 4.0 5.7

33. 13000
12000
11000 Line Rejection – BAL (2011-12)
10000 W&C
9000
8000
7000
6000
5000
4000 Target
3000
2000
1000
0
Nov
Apr
Aug
Dec
Jun
Jul
Feb
May
Actual:
Oct
Mar
Jan
Sep
11-12
Line rejection ppm from Varroc - Pantnagar
TARGET ACHIEVED TARGET APRIL MAY- JUNE-12 JULY-12 AUG- SEP-12 OCT-12 NOV-12 DEC-12 JAN-13 FEB-13 MAR-
2011-12 2011-12 2012-13 12 12 12 13
3000 11909 3000 6001 11986
33

34. Vendor Rating - Bajaj
CSPL (Vendor) Rating from BAJAJ [2012-13]
Standa
Customer APRIL MAY JUN JUL AUG SEP OCT NOV DEC JAN FEB MAR
rd
BAL – WC < Level
(100487) 2 2 3 3
BAL – < Level
Haridwar 2 2 2 2
(111407)
34

35. Line PPM feedback from M&M FES
Actual 2012-13
Line ppm:
Actual
MM FES Apr May Jun Jul Aug Sep Oct Nov Dec Jan Feb Mar
11-12
TARGET LR
PPM <250 618 258 13
ppm
% GR
3 0 0
Rejection = 0
M&M FES - Line ppm [12-13]
Target: 250 ppm
700
600
500
400
300
200
100
0
Actual 11-…
Nov
Aug
Apr
Jul
May
Dec
Sep
Feb
Oct
Mar
Jun
Jan
35

36. Line PPM feedback from Tafe
Line ppm: Actual Actual 2012-13
Tafe 11-12 Apr May Jun Jul Aug Sep Oct Nov Dec Jan Feb Mar
TARGET <100
865 250 0 0
ppm
1000 Past trend Target Actual
900 865
800
700
600
500
400
300 250
200
100
0
36

37. 4. Summary of Complaints
Apr May Jun Jul Aug Sep Oct Nov Dec Jan Feb Mar
No. of Complaints 3 2 6 1
Nature of Complaints
low Gloss 1
Complaints by Customer
Varroc – Chakan 1
37

38. 5. Summary of Corrective actions - June
Sr.No Customer Complaint Description Root Cause Corrective Action
1] Work instruction amended for the method
IYM- Levelling of blade on one side of die
1 Graphic Cut in 1CK2 of visual checking of deepcut,
Surajpur found out to be uneven.
2] job training provided to the inspectors.
Uncoated metallic particles have less
Coated metallic particles to be used. Bill of
IYM- Ink peel off in Yamaha cohesive force as compared to coated
2 material amended and also the process
Surajpur Emblem (5KAB CRUX) metallic particles used in ink
routing changes in SAP.
preparation.
IYM- New material was used - inadequate PPAP methodology to be followed for new
3 Air Bubbles in 1CK3
Surajpur validation material introduction
Disc. 125 ST Shade
Variation in deposition of metallic
Bajaj - Variation found in Flame red Uniform stirring during ink issue also stirring
4 partcile on base film during printing in
Waluj for batches 446052012 & prior to pouring ink on the screen.
single batch.
70062012
Smoke Variation found in Setup Sheets/Dials to be crossed completely
Setup sheet is not identified at printing
HDT Diamler in 1 pieces in using permanent marker in printing stage
stage before proceeding for further
Continental- lot size of 300 of batch itself.
5 operation leading to mixing of setup
Bengaluru number 2021211 at customer Illumination inspection to be done on Cluster
sheets/dials with Ok sheets/dials at final
assembly line at Continental, instead of light table.
inspection.
Bangalore on 20/06/2012.
Green and white dots found Before commencing printing a pc sheet with
Leakage in screen due to removal of
in HDT Daimler in 59 pieces lamination and/or rough pc sheet will be
emulsion coating from non image area
Continental- in lot size of 300 of batch printed and checked for ink leakage and
6 leading to green and grey ink transfer
Bengaluru number 2021211 at customer same will be done after every 100th and for
on image area while printing 5th Colour
assembly line at Continental, last sheet and leakages if any will be touched
and 6th colour respectively
Bangalore on 20/06/2012. up by PVA

39. HMC-G– Quality Failure Report
Plant SL Material Material Problem Analysis Action Type Reason Counter Measures
No. Code Description
HMC-G 1. 240512 CBZ Stripes Incomplete -Samples -Process lapse -Yet to be
back cut sent to plant received
2. 5940312=0 KWAH Front Incomplete -Samples -Process and -Yet to be
9 Cowl Blk back cut(10- sent to plant inspection lapse received
Blue 12%)
2470512=0 KVEG CVG -Incomplete -Samples -Process and -Yet to be
9 back cut(25- sent to plant inspection lapse received
30%)
3160612=0 KWAH Front -Incomplete -Samples -Process and -Yet to be
9 Cowl cover back cut(3-5%) sent to plant inspection lapse received
BHG

40. HMC-D – Line feedback
Customer Issue Batch No. Observation CAPA / Comments
HMC-D 1.Craters observed in model 5560412 -Observed after -Yet to be received from plant
splender plus AAEA lacquering process. -IPA cleaning introduced prior to
-Reduces after lacquering and after that no
cleaning with IPA. problem has been reported.
2.Skinning observed in stripes 2640512 -Observed in 10- -Yet to be received from plant .
of model AAEA SBK 15% stripes
-model AAEA P.maroon 0320120376 -obsd. In 20-25% -do-
pcs.
3.Top film removal hard 3100512 -Observed in 30- -Yet to be received from plant.
observed in stripes of model 40% stripes
AADA BLK Sil
-Splendor pro color SBK 0520120425 -observed in 30- -Yet to be received
40% stripes
4.Hole punching in stripes - -Repeated problem -Inform to all concerned with
& Observed in the compiled data.
materials belonging
to march 12
5.Incomplete back cut at tab
location in side cover color 0520120425 -Observed in 30- -Yet to be received.
SBK 35% pcs.

41. Customer Line feedback-Yamaha SP
Customer Issue Batch No. Observation CAPA / Comments
IYM-SP 1.Ink peel off in yamaha -Ink peel off while removal -Submitted on
emblem model 5KA of top application film 23.04.2012
5470412 -Problem repeated -Submitted on
26.06.2012
-Fresh batch yet to
be delivered
2.Craters in stripes of model 0120120743 -Problem observed at edges -Submitted on
1CK3 in different locations after 26.06.2012
lacquering -Fresh batch after
c/m yet to be
received

42. Major Highlights (Quarter-1)
• April12: First Surveillance Audit inline with
TS:16949/2009 conducted by Bureau Veritas.
• May12: Supplier Surveillance Audit (QAV-1)
conducted by Mahindra 2 Wheeler.
• May12: Visit of John Deere to Pelhar Plant.
• June12: Green Vendor Development Program
(GVDP), certificate received by HMCL Gurgaon.
• June12: Supplier Development Audit conducted
by Royal Enfield.

43. Ink Lab – Issues report for June
OC Peeloff Problems
Job Details Issue Root Cause Corrective Action
AANA GLM CARB CB OC & Ink peel off Uncoted silver particles in CSPL 057 (CSPL 2285) New Accurate
RED ABS PART & KTRM (accurate silver) Silver by Coated Stapa VK
Glm. FI CB RED ABS 903/904 ECN raised
part ( HMCL)
KVEG CBZ EXTREME - OC & Ink peel off
SG 700 Base coat Eliminate
HMCL
SG 700 Conc White HD White
CSPL 1007 (425 OC) CSPL 2120 (8228 OC)
ECN raised
VK901 in CSPL 438 Pastel Gold
YAHAHA Emblem OC & Ink peel off Shade Used Stapa 801 silver particles
CSPL 1007 (OC 425) CSPL 1007 (OC 425)
ECN raised
43

44. Ink Lab – OC Wastage for June
Wastage % Wastage
PO no. Machine Description Qty. 8600 OC Average
Qty.Kg OC
100068194 SPS-XP KWAH BLK H. GREY F/COWL (T-3) [4 SETS] 2000 8.8 1.781 20.20%
100068200 SPS-XP BAJAJ DISC 125ST BLK RED SEAT/FR.COWL(1S 2000 16 3.6 22.50%
100068001 SPS-XP KTPJ C.B.RED T-2 FUC 'A', BC 'A' (1SET) 2600 11.2 2.544 22.70%
100068691 SPS-XP BAJAJ DISC 125ST BLK RED SEAT/FR.COWL(1S 1860 6.4 1.384 21.50%
100068615 ATMA-6 EXPORT 1000 5.8 1.19 20.50%
100070565 ATMA-6 EXPORT 500 4.5 1 22.20% 21.65%
CSPL 2120 Wastage % Wastage
PO no. Machine Description Qty. Average
of Nazdar Qty.Kg OC
100067055 SPS-XP AACA PASSION PRO BLK H.GREY SC (2SETS) 2272 10.5 2.44 23.20%
100068298 SPS-XP AAFA SPL.NXG BLK RED ABS PARTS(1SET) 3000 16.8 4.27 25.40%
100067415 SPS-XP AACA[PASS.PRO]BLK H.GREY ABS (1SET) 2300 11.2 3.5 31.25%
100068271 SPS-XP BAJAJ PULSAR 135 RED ABS(4SETS) 600 3.5 1.2 34.20%
100068001 SPS-XP KTPJ C.B.RED T-2 FUC 'A', BC 'A' (1SET) 1100 5.6 1 17.80%
100068604 SPS-XP KWAH BLK RED/BLUE /H.GREY R/COWL(5SETS) 2500 14.4 3.4 23.60% 26%
44

45. Machine Total Downtime Avg. Downtime Avg. MTBF Avg. MTTR
(mins.) per day (mins.) (mins.) (mins.)
Sakurai-01 465 18.6 21367.65 465
Sakurai-02 115 4.6 7408 38
SPS-01 205 8.2 8599 51.25
SPS-02 60 2.4 21570 60
SPS-03 0 0 43200 0
SPS-04 30 1.2 14390 15
SPS-XP 320 12.8 8576 80
Others 430 35.33 2177.62 57.63
TOTAL (JUN’ 12) 1700 68.00 1507.73 95.86
TOTAL (MAY’ 12) 1960 40.80 1579.80 42.70
TOTAL (APR’ 12) 982 40.80 1579.80 42.70
TOTAL (Mar’ 12) 2429 83.29 879.40 51.68
MTBF – Mean Time Between Failures; MTTR – Mean Time To Repair
Downtime for Rolt is not considered as there are some manufacturing defects which lead to
downtimes.
45

46. 3500
Downtime 2011-12
Monthly 3147
Downtime Limit Downtime 2012-13
3000 is 2000 mins.
2580 2582
2448 2429
2500
2201 2148
1957
2000
1735
1653
1517 1506
1500
1000
500
0
May
July
Mar
Dec
June
Jan
Feb
Oct
Nov
Sept
April
Aug
46

47. CYLINDER PRESS DOWNTIME FOR LAST 12 MONTHS (mins)
Machine/ SPS-01 SPS-02 SPS-03 SPS-04 SPS-XP SK-01 SK-02
Month
June12 205 60 0 30 320 465 115
May12 0 245 0 200 0 20 130
Apr’12
40 65 0 0 40 0 110
Mar’12
75 70 00 113 223 345 15
Feb.’12
144 155 128 337 200 200 30
Jan’12 202 375 86 147 182 87 30
Dec’11 130 192 30 405 90 0 0
Nov’11 0 175 285 145 270 20 110
Oct’11 5 428 20 198 80 5 220
Sept’11 115 0 165 40 105 0 25
Aug’11 110 119 30 125 30 0 75
July’11 240 145 0 105 410 70 240
TOTAL 1266 2029 759 1845 1950 1212 1100
Average 105.5 169.08 63.25 153.75 162.5 101 91.66

48. Electricity Units 2010-
800000 11
Sudden increase is due
to increased HVAC load
700000
and machine load.
589080
600000 560790 566430 564000 555180 547590 551910559709
527070 521501 504090
513840 506576
493710 496020 492535
500000 475710
492390
488250
435450 430266 425790 437071
400000
300000
200000
100000
0
May
July
Mar
June
Dec
Jan
Feb
Oct
Nov
Sept
April
Aug
48

49. MAINT. BREAKDOWNS & PREVENTIVE ACTIONS
Breakdown Down
Machine Corrective Action Preventive Action
Reason Time
SPS XP Machine 320 Damaged Cable PLC’s input ,output function
wasnot running mins. replaced with the ‘Check Point’ will be
due to faulty New Cable. checked in ‘Preventive
cable of PLC Maintenance’.
input Contacts..
SK-1 Shear Key of 465 Shearkey replaced Shear Key Check Point
the Gear-box mins. with new Shearkey. included in the ‘Preventive
was broken. Maintenance’.
SK-2 Timer Belt 165 Timer Belt replaced Timer Belt will be replaced
damged of the mins. with new one. once in a year.
Vaccum Pump.

50. 500
Sales (Rs.) per Electrical Unit
2011-12
450 Sales (Rs.) per Electrical Unit
2012-13
400
Monthly Target for
Sales (Rs.) per Elec.
350 Unit is Rs. 300.
300
250
200
150
100
50
0
May
July
Mar
Oct
June
Nov
Dec
Jan
Feb
Sept
April
Aug
50

51. 800000
Electricity Units 2011-12
Sudden increase is due
700000 Electricity Units 2012-13
to increased HVAC load
and machine load.
600000
500000
400000
300000
200000
100000
0
May
July
Mar
Jan
Dec
June
Oct
Nov
Feb
Sept
April
Aug
51

52. 9000 Units consumed by DG
8200 Sets 2011-12
8000 7657 Units consumed by DG
Sets 2012-13
7000
6000
5412 5370
5000
4238
4000 3797
3000 2576
2378
1836
2000
1275
998
1000 555 501
337
0
0
11
2
4
1
3
5
6
7
8
9
10
12
52

53. As on As on
Sr. No Description March March April May June July Aug Sept Oct Nov Dec Jan Feb Mar
2011 2012
1 No. Of Staff 87 106 100 99 94
No. Of Company
2 94 118 119 117 117
Workmen
No. of Contract
3
Workmen
423 432 381 405 398
Total Manpower 604 656 600 621 609

54. Figures in Mn.Rs
Description April May-11 Jun-11 Jul-11 Aug-11 Sep-11 Oct-11 Nov-11 Dec-11 Jan-12 Feb-12 Mar-12
Total Production. 98.8 107.0 106.9
Salary & Wages to
% of Production. 7.33% 8.59% 7.74%
Mn. Rs.
Contract Wage Bill
3.16% 3.11% 3.03%
% to sales
On Roll Overtime
Cost to % of 0.06% 0.15% 0.12%
Production
Contract Overtime
Cost to % of 0.07% 0.44% 0.34%
Production.
54

55. Description April May-11 Jun-11 Jul-11 Aug-11 Sep-11 Oct-11 Nov-11 Dec-11 Jan-12 Feb-12 Mar-12 Total
ELECTRICITY/POWE
R EXPENSE -
2.81 2.88 2.85 3.96 5.44 5.29 5.40 5.90 6.17 5.99 5.60 5.76 58.06
MANUF
ACTUAL EXPENSES 4.25 2.91
FUEL EXPENSES -
- 0.08 0.08 0.08 -
MANUFACTURING - 0.08 - 0.08 0.08 - 0.08 0.56
ACTUAL EXPENSES - 0.12
REPAIRS & MAINT- 2.50 2.50 2.50 2.00 2.00 2.00 2.00 1.20 2.00 1.50 1.20 1.20 22.60
MACHINERY
ACTUAL EXPENSES 2.45 0.71
55

56. Description April May Jun Jul Aug Sep Oct Nov Dec Jan Feb Mar Total
CONSUMABLE
SUPPLIES 0.92 0.93 1.05 1.43 1.73 1.76 1.91 1.98 2.16 2.20 2.45 2.69 21.20
ACTUAL EXPENSES 1.11 0.49
DIE PURCHASES &
DEVELOPMENT 0.28 0.28 0.32 0.43 0.52 0.53 0.57 0.59 0.65 0.66 0.73 0.81 6.36
ACTUAL EXPENSES - 0.31
POSITIVE &
NEGATIVE
0.07 0.07 0.08 0.11 0.14 0.14 0.15 0.16 0.17 0.18 0.20 0.22 1.70
DEV.CHARGS
ACTUAL EXPENSES 0.02 -
PRODUCT
DEVELOPMENT
0.18 0.19 0.21 0.29 0.35 0.35 0.38 0.40 0.43 0.44 0.49 0.54 4.24
CHGS
ACTUAL EXPENSES 0.21 0.06
56

57. Description April May-11 Jun-11 Jul-11 Aug-11 Sep-11 Oct-11 Nov-11 Dec-11 Jan-12 Feb-12 Ma-12r Total
SCREEN MAKING
EXPENSES 1.01 1.02 1.16 1.57 1.90 1.93 2.10 2.17 2.38 2.42 2.69 2.96 23.32
ACTUAL EXPENSES 0.90 2.20
LABOUR CHARGES
4.46 4.46 4.48 4.83 5.35 5.99 6.02 6.50 6.85 6.77 6.99 7.04 69.73
ACTUAL EXPENSES 4.36 5.06
TRANSPORT
CHARGES BY ROAD-
0.17 0.18 0.20 0.27 0.33 0.33 0.36 0.38 0.41 0.42 0.47 0.51 4.03
OUTWARD
ACUTAL EXPENSES 0.03 0.11
TRANSPORT
CHARGES OTHERS-
0.55 0.56 0.63 0.86 1.04 1.06 1.15 1.19 1.30 1.32 1.47 1.61 12.72
OUTWARDS
ACTUAL EXPENSES 0.46 0.54
57

58. Description April May-11 Jun-11 Jul-11 Aug-11 Sep-11 Oct-11 Nov-11 Dec-11 Jan-12 Feb-12 Mar-12 Total
REPAIRS & MAINT-
0.18 0.18 0.18 0.18 0.18 0.18 0.53 0.53 0.53 0.53 0.53 0.53 4.20
BUILDING
ACTUAL EXPENSES -
MOTOR CAR /
CYCLE FUEL
0.20 0.20 0.20 0.20 0.20 0.20 0.20 0.20 0.20 0.20 0.20 0.20 2.40
EXPENSES
ACTUAL EXPENSES
0.12
SECURITY CHARGES 0.33 0.33 0.33 0.33 0.33 0.33 0.33 0.33 0.33 0.33 0.33 0.33 3.90
ACTUAL EXPENSES
0.24
GARDENING EXP 0.05 0.05 0.05 0.05 0.05 0.05 0.05 0.05 0.05 0.05 0.05 0.05 0.60
ACTUAL EXPENSES
-
HOUSE KEEPING
EXPENSES 0.35 0.35 0.35 0.35 0.35 0.35 0.35 0.35 0.35 0.35 0.35 0.35 4.20
ACTUAL EXPENSES
0.33
58