Work Plan Review || Cummins

1. 1
WELCOM
E
Team Cummins
about
Agenda
Table
Of
Content

2. about
Agenda
Table
Of
Content
Presented By :-
Sonu Tyagi
Assistant Manager
Talbros Automotive Component limited

3. about
Agenda
Table
Of
Content
2022
Work Plan
Review
Date:- 14-03-2023

4. 4
about
Agenda
Table
Of
Content
Table Of Content
Proactive Measures- 2023
Cummins Plant Wise MNC Bifurcation 2022
Talbros- Organization Chart
Diversified Customer - OEM
Cummins KPI’s- 2022
Strategic Pillar For Improvement
Bifurcation Of Defect
Talbros Group – Products & Global Partners
Talbros Group – Key Milestones
Overview Of Talbros Group

5. 5
2,500 + (ON ROLLS)
EMPLOYEES
INR 24,000 Million (USD
400 Million )
GROUP SALES LOCATIONS
14 Manufacturing and 3
Distribution sites
RESEARCH &
DEVELOPMENT
TECHNOLOGY CENTERS IN
GURGAON AND FARIDABAD
KEY INDUSTRIES
SERVED
Automotive, Light Commercial, Heavy-Duty
Truck, Off-Highway, Agricultural, Rail and
Industrial
Payen Talbros incorporated in
collaboration with Coopers
Payen UK
1979 – Renamed as Talbros
Automotive Components Ltd.
1980 – Maiden IPO
1984 – Establishment of QH Talbros
Ltd. as a JV with Quinton Hazell, UK
Technical agreement with Nippon
Leakless, Japan to manufacture Non-
Asbestos Gaskets
Establishment of
T&T Motors Ltd.
• JV with Nippon Leakless
Corporation, Japan for
Automotive Gaskets
• Diversification into Forging
business commenced
• 2008 – Technical Agreement
with Sanwa Japan
• Diversification into Forging
business commenced
JV with Magnetic Marelli, Italy for
Suspension Components
JV with Marugo Rubber, Japan for
Anti-Vibration and Hoses
1956
1979 -
85 1997 1998 2005
2008 -
09 2011 2012
 Overview Of Talbros Group
 Talbros Group – Key Milestones

6. 6
QH TALBROS
STEERING/ SUSPENSION
TALBROS AUTOMOTIVE FORGING
DIVISION
FORGINGS
MAGNETI MARELLI TALBROS CHASSIS
SYSTEMS PVT. LTD.
SUSPENSION SYSTEMS & MODULES
TALBROS MARUGO
RUBBER
RUBBER PARTS & ENGINE MOUNTS
TALBROS AUTOMOTIVE GASKETS
DIVISION
HEAT SHIELDS AND SEALING
SYSTEMS
 Talbros Group - Products  Talbros Group – Global Partners

7. 7
Faridabad - Delhi NCR
Sitarganj (Uttarkhand)
Pune (Maharashtra)
Pune Customers
Delhi NCR Customers
OEMs and After
Market
• Locations: Total 3
Faridabad, Pune & Sitarganj
• Area (Sq. Ft): 650862.34
• Employees : 1250
• Engineering: 24
• Quality Assurance: 42
 Warehousing Facility
 Manufacturing Locations

8. 8
 Gasket with Electrical Controls
 Company Product - Gaskets
2,707
37,342
99,233 92,986
-
100,000
200,000
FY 19-20 FY 20 -21 FY 21-22 FY 22-23 ( Feb)
Sale Qty.

9. 9
2 Wheeler Passenger HCV/LCV/ENGINES Agri & Off Loader Exports
 Diversified Customer - OEM

10. 40 43
23
29
62
72
83
0
10
20
30
40
50
60
70
80
90
FY 17-18 FY 18-19 FY 19-20 FY 20-21 FY 21-22 FY 22-23 (P) FY 23-24 (P)
Growth With Cummins – INR in CR
10
TATA CUMMINS
27%
HERO
23%
VOLVO
14%
TATA MOTORS
13%
SIMPSON
3%
ASHOK LEYLAND
2%
ESCORTS
2% MSIL
2%
KOEL
2%
OTHER
12%
Leading Top customer SOB
TATA CUMMINS HERO VOLVO TATA MOTORS
SIMPSON ASHOK LEYLAND ESCORTS MSIL
KOEL OTHER
277
305
262 263
353
416
465
0
250
500
FY17~18 FY18~19 FY19~20 FY20~21 FY21~22 FY22~23 P FY23~24 P
Business Growth Overall – Gasket Division
FY17~18 FY18~19 FY19~20 FY20~21 FY21~22 FY22~23 P FY23~24 P
 Industry Mix  Business Growth

11. 11
Suresh Sharma
President
Vikash Narula
GM- Purchase
Pankaj
Bhardwaj-
R&D
K c Jangra
HS
Paranvir
Rubber
Dilip
Sec Gasket
Anil Bar
CHG
Upender
Yadav
Head SCM
Manohar
Thakur
AGM- T/R
Naveen
Sharma
GM- Maint.
Sushant
sindwani
GM- sales
Ajay
Sharma
DGM- QA
Nitin Thakur
Plant Quality
Sonu Tyagi
CR
Harneet
NPD
Kuldeep
Kumar
Plant Head
S C Shukla
Mentor
Anshu
Mehra
GM-HR
Ajay Singh
VP –Engg,NBD&
Tech.
Manish Khanna'
CFO
Steering Committee
 Talbros- Leadership Organization Chart
Harneet Ahuja
NPD

12. 12
Cummins KPI’s- 2022
B Targets for 2021-2022 - Reactive Measures
# Quality Measure 2021 Performance 2022 Performance 2023 Remark
Target Actual Target Actual Target Actual Status(R/Y/G)
1 PPM (Overall) 400 95 50 115 50
PPM (PSBU) 400 6 50 559 50
PPM (EBU -TCL ) 300 104 50 126 50
PPM (CTT) 300 NA 50 NA NA
PPM (Export) 50 0 50 0 0
2 OEM /BIS(Overall) 0 2 0 0 0
3 Disruption Score 500 Points 1170 300 850 300 Points Disruption score attached in sheet
4 NCMR (Overall) 12 27 12 27 6 Major MNC are due to disciplinary issue
5
SCAR _Response 30 Days 28 Days < 10% 30days < 10%
SCAR _ Past due < 10% 0 < 10% 0 < 10%

13. 13
632
469
95 115
0
250
500
750
1000
1250
1500
2019 2020 2021 2022
Over All PPM Target 50
0
1307
6
559
0
250
500
750
1000
1250
1500
2019 2020 2021 2022
PPM (PSBU)
0 0 0 0
0
250
500
750
1000
1250
1500
2019 2020 2021 2022
PPM (CTT)
0 0 0 0
0
250
500
750
1000
1250
1500
2019 2020 2021 2022
PPM (Export)
Cummins KPI’s- 2022
Target 50 Target 50
Target 50

14. 14
0 0
1170
850
-100
100
300
500
700
900
1100
1300
1500
2019 2020 2021 2022
Disruption Score
658
21
104 126
0
250
500
750
1000
1250
1500
2019 2020 2021 2022
PPM (EBU -TCL )
0 0
2
0
0
1
2
3
4
5
6
7
8
9
10
2019 2020 2021 2022
OEM /BIS(Overall)
82.5 80
70
80 80 80 80 80 80 80 80
100 100
0
20
40
60
80
100
2022
Jan-22
Feb-22
Mar-22
Apr-22
May-22
Jun-22
Jul-22
Aug-22
Sep-22
Oct-22
Nov-22
Dec-22
Quality Score Card
Cummins KPI’s- 2022
Target 50 Target 0
Target 300 Target 100

15. 15
13 6 2 1 1 1 1 1 1
48
70 74 78 81 85
93 96
0
10
20
30
40
50
60
70
80
90
100
0
1
2
3
4
5
6
7
8
9
10
Packaging- Box
damage/Rusty/
Non Std Packing
Appearance -
Stamp Miss/ Step
Mark
Foreign material Part Mix @
Cummins Line
Groumet Loose Release Paper
Miss
Washer damage Burr Short Moulding
18
11
27 27
0
5
10
15
20
25
30
2019 2020 2021 2022
Total MNC
TCL 2, 10
TCL 1, 8
CIL, 7
TCL 3, 2
MNC -2022
Type Of Defect
Handling:- Rusty , material
Un fill, Damage ,
Handling 5 nos’
100
 Cummins Plant Wise MNC Bifurcation 2022
4983020
4318978
3924389
3929792
4959090

16. 16
Discipline :- Hole miss, Tape stick on part, stamp
miss, extra flashes, Release paper missing
Handling:- Rusty , material Un fill, Damage ,
Process:- Burr in mounting hole, Dowel hole
oblong , Short mold.
Packaging:- Damage Box , non standard
packaging. Mix up of IPO & Old model
 Bifurcation Of Defect
Process-3 No’s
Handling-5 No’s
Discipline -9 No’s
Packaging -9 No’s
3978072
3973509 5568829
2884896
5620682
5620682 3978072
4983020
4318978 3924389 3929792 4959090
5610751 5625715 5716994
4959090 5447591

17. 17
Proactive Measures- 2022
C Targets - Proactive Measures
# Area Details Requirements Action Status Link
1 SPQR
Specific details required from supplier -
Index of tooling life for all parts, Welding
validation reports (Once / 6 months), Mistake
proofing index with validation plan.
Monthly Data to be sent SQI on or before 05th
of every month. Delay or no submission shall
result into deduction of score which can not be
rectified manually.
SPQR regularly send on or before 5th of
every month On going
2
MQV
(Identified
parts)
Part Number - 5625715 (Oil pan Gasket
Part Number - 5621842 ( Gasket Filter Head)
May-22
-Laser fixture implemented
-Gauge implemented for 100 % inspection
Done
3 Failsafe
List of fail safeing with validation plan to be
prepared.
Reference - Discussion during process audits
on site.
Part Identified and fail safe implemented On going
4
Process
Audit
Mar-22 Audit observations to be closed within 2 months Action Plan submitted Done
5
Layout
Inspection
(identified
parts)
Part List - Attached. Plan to be shared on or
before March 2022
Layout report to be submitted along with action
plan for non-conformance & along with Material
test certificate. Salt Spray test required for any
of coating on part.
Annual layout plant has been
prepared and monthly reports has
Been submitted before 5th of every
Month.
On going
6
Special
Project
Strategy to eliminate disciplinary complaints.
Foreign material in between layers, rust, paint
defect, packaging & transportation damages.
Plant Re Layout On going
7
Amaze
Projects
Amaze Projects launched at Talbros in 2029
,Good amount of work & efforts being put for
improvements identified under AMAZE Drive.
Graduation completed in 2020 ,
Improvements to be driven with same zeal.
Now effectiveness need to monitored in 2022
Continue effectiveness monitoring of action
taken.
Done

18. 18
Proactive Measures- 2022
C Targets - Proactive Measures
# Area Details Requirements Action Status Link
8
New Product
Development
Disciplinary issue need to control , specially in
new developed parts and quality team need to
involved in new product development as QAND
function
Quality Representative need to involved in NPD parts
List Attached & QA
representative is fixed .
Done
9
Special Project -
IATF Certification
IATF Certification Scope need to update as per
8.3 clause (Design and Development of product
& services) from the scope of IATF certification.
01-02-2022
Successful added the
design scope in IATF
audit
Done
10 5S & SAFETY
Safety culture need to improve in shop floor ,
operators and inspector need to use PPE
Immediate
Safety Audit Conducted
on monthly basis to
improve the safety culture
in shop floor
Done
11
Tool Monitoring
System
Tool monitoring required for all tool (Press,
Mould & Gauges ) used for TCL / PSBU
/EXPORT
Monthly Data to be sent SQI on or before 05th of every
month. Delay or no submission shall result into
deduction of score which can not be rectified manually.
All tool monitoring data
update in software.
Done
12
Packaging &
dispatch ; VMI site
Quality Control
Observed concerns related to packaging in 2022
Quality Control SOP for material handling &
preservation at VMI at Phaltan to be released.
Compliance to be ensured.
Adherence of Plan vs
Actual
Done
13
Firewall Station and
CSL2
Major MNC reported due to Discipline issue and
ineffective PDI .
Talbros Need to Develop Separate Pre dispatch
inspection and Firewall station to inspect parts supplied
to TCL and Cummins
CSL2 need to Implement if Final PDI inspection no
yield into result
Fire Wall Implemented for
Cummins Part
Done

19. Strategic Pillar For Improvement - 2023
19
50
PPM

20. 20
C Targets - Proactive Measures
# Area Details Requirements Action Status Link
1 SPQR
Specific details required from supplier -
Index of tooling life for all parts, Welding
validation reports (Once / 6 months),
Mistake proofing index with validation plan.
CAPA Paynter chart
Monthly Data to be sent SQI on or before 05th
of every month. Delay or no submission shall
result into deduction of score which can not be
rectified manually.
SPQR regularly send on or
before 5th of every month
On going
2
MQV (Identified
parts)
Part Number - 2884896 - Gasket -PSBU
Part Number - 5716654 ( IWH) - EBU
MQV to be made for mention part no.
01/04/2023
01-03-2023
In process
3 Failsafe
List of fail safeing with validation plan to be
prepared.
Reference - Discussion during process audits on
site.
Two Project identified Done
4 Process Audit Apr 23
Audit observations to be closed within 2
months
Process Audit to be conducted
in month of Apr’23
In process
5
Layout
Inspection
(identified parts)
Part List - Attached. Plan to be shared on or
before March 2023
Layout report to be submitted along with action
plan for non-conformance & along with
Material test certificate. Salt Spray test required
for any of coating on part.
Annual layout plant has been
prepared and monthly reports
has
Been submitted before 5th of
every
Month.
On going
6 Special Project Strategy to eliminate disciplinary complaints.
Foreign material in between layers, rust, paint
defect, packaging & transportation damages.
Plant In process Refer Slide 12
7 Amaze Projects
1) Barcode Scanning process need to improve
for wrong barcode
2) ERP need to improve for part traceability as
per ZDM
3) Vision camera inspection for part missing
Target date to closed the project as per below
target date.
01-05-2023
01/06/2023
01/06/2023
All requirement to be
implemented after approval of
Capex.
In process Refer Slide 1
Proactive Measures- 2023

21. 21
Proactive Measures- 2023
C Targets - Proactive Measures
# Area Details Requirements Action Status Link
8
New Product
Development (PPAP
/APQP) & SR
1)Quality team need to involved in new
product development as QAND function
2) DQR and DVP& R process should follow
for all global and domestic projects
3 )FTR should be 100% for all PPAP and SR
.
4) PSDS and IMDS acceptance as per CES
10903 mandatory for all PPAP
CFT Team need to involve on all PPAP and
SR
List Attached In process
9 Facility upgradation
In-house Laser weld for Beagle project -
Export RMEP
New laser machine of weld for beagle
project need to commissioned
Target 2023
In process
10 5S & SAFETY
Safety culture need to improve in shop
floor , operators and inspector need to use
PPE
Immediate
Safety Audit Conducted on
monthly basis to improve the
safety culture in shop floor
Conduct on
every month
11
Tool Monitoring
System
Tool monitoring required for all tool
(Press, Mould & Gauges ) used for TCL /
PSBU /EXPORT
Monthly Data to be sent SQI on or before
05th of every month. Delay or no
submission shall result into deduction of
score which can not be rectified manually.
All tool monitoring data update in
software.
Closed
12
Packaging &
dispatch ; VMI site
Quality Control
Observed concerns related to packaging in
2023
Quality Control SOP for material handling &
preservation at VMI at Phaltan to be
released. Compliance to be ensured.
Adherence of Plan vs Actual
On going
Process
Refer Slide 12
13
Firewall Station and
CSL2
Major MNC reported due to Discipline
issue and ineffective PDI .
Talbros Need to Develop Separate Pre
dispatch inspection and Firewall station to
inspect parts supplied to TCL and Cummins
CSL2 need to Implement if Final PDI
inspection no yield into result
Fire Wall Implemented for
Cummins Part
Done Refer Slide 12

22. Q&A
Gaskets Heat Shields Forgings Chassis Systems Rubber Components Steering & Suspension 22