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- Daiso has 2400 retail stores adding 30 per month with sales of $3 billion across 15 countries and variety of 70,000 items per outlet priced at 100 yen or less.
- The textile supply chain in Gujarat has manufacturing cycle times ranging from 12 to 49 days for different processes while delivery lead times range from 25 to 49 days.
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Remodelling the manufacturing business for msm es in india 29 july17 cii anandManish Kothari
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https://youtu.be/a0sh4I30mcg
This seminar was targeted at Singapore SMEs to encourage them to built up their IP so that they can be export orientated rather than remain stay as ASEAN trading companies. Even though this was developed in 2009, it is still relevant today.
Productivity Improvement of a Laboratory Equipment Manufacturing Company thro...akshay hebbar
The Small Scale Industrial sector plays a significant role in the industrial development of any country.
In India, the survival and growth of small scale industry largely depends on its ability to innovate, improve operational efficiency and increase productivity.
To maintain business arena in Small Scale Industries it is of most important to win hearts of customer by delivering products according to the requirement of the customer, quality, time and cost of the product of service.
Using the concepts of ERP, inventory classification scheduling, Likert scale to minimize the Tech-Ed company’s problems in the area of purchase, production and service
The main purpose of this project is to bring lean concepts in small scale industries in India, where industries are working on very old and obsolete techniques of manufacturing and there is no any working culture available and even they are not thinking to develop it.
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Visit : https://www.avirahi.com/blog/tata-group-dials-taiwan-for-its-chipmaking-ambition-in-gujarats-dholera/
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The Parable of the Pipeline a book every new businessman or business student ...
Pankaj chandra
1. Returning Competition to the
Factory Floor
Pankaj Chandra
Indian Institute of Management
Ahmedabad
ICRIER’s Silver Jubilee Conference, November 6-7, 2006
2. Large Volume Operations
• Nokia’s factory Chennai
• AMUL’s operations in Gujarat
• ORPAT’s factory in Morbi
• Daiso’s 100 Yen retail outlets in Japan
3. • NOKIA’s Factory in Chennai
– 1 million handsets per month
– 1200 operators
• AMUL (GCMMF)
– 12 plants
– 11, 962 Village Societies, 2.5 million farmers
– Daily Milk collection: 6.3 million litres per day
•Mehsana: 1.342 million litres per day
– Sales Turnover: Rs 3773.6 crores
4. • ORPAT’s factory at Morbi
– 5000 wall clocks per day
– More than 4000 operators
– Sales turnover: Rs 300 crores
• DAISO’s 100 Yen Retail Stores
– 2400 retails stores; 30 stores per month
– Sales turnover: US$ 3bn.
– 380 stores outside Japan in 15 countries
– 10th
fastest growing company in global retail industry
– Variety: 70,000 items per outlet
– All products sell outside Daiso at a price greater than
100Yen !
6. The Textile Supply Chain in Gujarat
MCT DLT
Ginning & Pressing 12 25
Spinning 8 38
Weaving 23 40
Processing 11 21
Garmenting 15 49
Customs - 10
Transport (overseas) - 35
** MCT= Manufacturing Cycle Time (days)
DLT = Delivery Lead Time (days)
7. Skills Dilemma
•Indian Textile & Apparel Sector
– Export target US$ 50 bn. by year 2010
– Expected Investment in the Indian Textile
& Apparel sector – Rs. 1400 bn.
8. • Manpower required to run the additional
plant & equipment –
Textile sector: about 70,000 supervisors
and 1.05mn operators
Apparel sector: about 112,000
supervisors and 2.8mn operators in the
apparel sector
(Not to mention auxiliary services &
NATURE OF SKILLS)
9. Scale
• Chinese Capacity Strategy – capacity
leading the demand (credit issue in India?)
• New organizational forms
– TAMA, Tokyo region, Japan
– Wenzhou, Zhejiang Province, China
– Rajkot, Gujarat, India
• Evolution of “coordinating specialist firms”
10. • Formation of “Cluster:” TAMA
Technology Advanced Metropolitan Area
• TAMA Association formed by MITI in
1996
• Includes adjoining areas of Saitama, Tokyo
and Kanagawa prefectures
– Along Route 16 & Ken-O-Do Expressway
– Inland industrial area covering 74
municipalities
11. – Number of workers: 4 million
– Value of shipped goods: $214 billion (1998)
– Total Value add (in Million $): 1,083,883
(Japan), 81,862 (TAMA), 63, 890 (Holland)
– Total Value add($)/worker: 116,447 (TAMA),
110,184 (Japan), 94,970 (USA), 58,260
(Germany)
– TAMA has twice the shipment value of
Silicon Valley
12. Some Performance Indicators
• No. of New Products in the Market in the last 3
years: 22 (against 4 by non-member SMEs)
• % of firms cooperating with research universities: 65
(an increase of 55% over last five years)
• Patents: 62.9% of TAMA firms held patents as opposed
to 29.6% of all SMEs in Japan
• R&D Expenditure/Sales: 5%(PDS),2%(PPS)
• Profit/Sales ratio: 2% for PDS (1% All Japan SME
median)
13. DNA of TAMA
• Linkages between firms: “creation of new technologies, new
products and new businesses by combination of different
technologies and knowledge”
• R&D units of large enterprises (about 15)
• University & Colleges with science, engineering &
management departments (34)
• Product Developing SMEs (about 300)
• Product Processing SMEs (about 16262)
• All are R&D oriented
14. Strategy
• Managerial strategy for large number of
operators on the shop floor or configuring
quick throughput lines
• Role of Small and Large enterprises
16. Debate on Manufacturing
must Refocus on
• Operational Productivity
• Capabilities - built by individual firms
– manufacturing ability will define success – new
tools of production
– inter-firm linkages (GPNs) will help learn &
reduce risks
– quick throughput lines
• Quality and Quantity of Manpower
17. • New Organizational Forms
• Attract world-class producers of goods
& machinery to setup manufacturing &
R&D facilities in India
I will not talk about Infrastructure or trade barriers or tariffs – even labour laws – their roles are well known in developing a robust manuf environment. I would like to bring the acitivties of the shop floor to the centre of policy & strategy discussion. Bring the role of operations management in building large volume manuf capabilities.
Slide 2: Role of these examples is to set the stage for the kind of large vol operations that we are talking and to show that such shop floors exist in India.
After Nokia, AMUL, ORPAT:question- how do you execute an operational strategy that delivers at low cost and short cycle times?
Slide 4: DAISO: Products include goods like wicker baskets, candle stands, wrapping paper, ice cube trays, salt & pepper shaker, belts, curios, cutlery, utensils, stationery,stickers, glasses, spectacles, food items, cosmetics, books, CDs etc.
Variety is crucial (about 70,000 items per outlet) and so is turning the stock daily!
Purchase a product that retails for 500 Yen at a volume where it now starts to cost less than 100 Yen !(How does volume operations makes it cost less than 100 Yen?)
Located in upscale/fashionable/busy areas, in the vicinity of large malls (like JUSCO)
Key:
Scouting for new products, large volume imports (purchasing power), distribution effectiveness & reach, high sales efficiency
Increase the value of product on offer
There is a need to change the frame through which manufacturing policy needs to be looked – need to look at the the shop floor for building competitiveness – five challenges exit is addressing this issue – imp for developing a large vol strategy
Slide 6: story of a mid size textile supply chain; explain why LT is crucial – LT directly related to many parameters of competition e.g., quality – poor quality, longer LT; higher inventory or poor product mix, higher LT; focusing on LT will also help reduce the impact of other disadvantages – higher credit rated, reduce turnaround time for a project implementation, faster turnaround of capital; shorter LT, resources tied up for shorter period (incl power, credit, tech etc); Malaysian customs story
Skilled people needed to execute large vol strategy in a disciplined manner
Chinese large firms have 1.5times higher spinning capacity, 1.25 times denim (2 times gray fabric) and about 6 times more revenue in garment than their large Indian counterparts;
Chinese Capacity Strategy – capacity leading the demand (credit issue in India?) Example of Hakkai Creates and the firm in China
Scale needs to be understood as the supply chain scale and not always as a single plant scale – develop of a new org form for India which has a predominance of SMEs
Explain the importance of Product Processing SMEs
Two other networks with similar structure – Wenzhou and God’s Engg Land, i.e., Rajkot. Wenzhou – success linked to creating markets for components as opposed to finished goods alone; Rajkot – PP SMEs with strongly outsourced environment – not many are innovating with own processes.
Rajkot
Engineering cluster: low to mid-quality, SMEs, policy induced
Strong (innovative) processing capabilities (have not kept with new processes)
Collaborating on orders, processing, manpower – intense outsourcing
Local coordinators
Struggling for technical manpower – lack of training (issue of trust)
Large volume oper require focused mgr skills of coordinating high throughput lines with a strong delivery see through; along with labour rigidities & mindset of owners to resist investing in tech in their plants, perhaps Indian managers have not developed the managerial strategy required to create focused factories with disciplined workers or high throughput lines?
Domestic market should be used to complement the manufacturing demand of external markets – then vol grows
Integration of small and large to create scale and scope ; small for tech development & process development and large for product assembly & focused factories;
Technology & Productivity (Poor Policy Incentives) – low hp/fuel inefficient, limited application, free power & water politics
Sivassa to Baddi; Ahmedabad to Jammu/Baddi to Dehradun
Chinese exports to India:
Electrical Machinery: Cellular Telephones
Organic Chemicals mainly antibiotics (Penicillin)
Machinery: Parts & Accessories of Computers
Mineral Fuels mainly Coal
Silk
Jewelry
Indian exports to China:
Iron & Steel
Ores (mainly iron ore)
Organic Chemicals
Plastics & related articles
Building Stone
Cotton
Oil Cakes etc.