1. Manish Engineering Works
TPM REVIEW
17.07.2013
01

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.  NPD / In-Organic Growth
VEPL – WP7
20 %
Gear - 735
VEPL – PP3
50 %
YOKE - Suzuki
Gear - 742

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. Product Information Max 2 Slides
Category wise
02

6. Esteemed Customers
02

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. TPM Progress Status

9. Methodology Followed for TPM Implementation

10. PQCDSM – Plant Targets
02

11. • 1S 2S Zone Mapping & Leaders

12. • 1S Top 3 Examples & Results

13. • 2S Top 3 Examples & Results

14. • Yoke Cell level Targets as explained by DTJ
• 2012 Tgt vs Act , 2013 Tgt Vs Act

15. • Yoke Cell Layout before & After ( Block
Diagram or sketeches ) with movie of after
stating lead time reduction

16. • Yoke Manufacturing Flow Stage & Photo

17. • P – Trend of P 1 , P2 , P3 , P4

18. • P – Approach OEE , Output / Man , Output /
Man

19. • Kaizens P 1 , P2 , P3 , P4

20. • Q – Trend of Q1 , Q2

21. • Q – Approach

22. • Q – Kaizens of Q1 , Q2

23. • Same way for C , D , S , M

24. • Summary of Results PQCDSM 2013 Tgt vs
MOM Act

25. • IPO of Yoke Cell for Sustenance of IHR Stage
wise IPO sheets with hyperlink

26. • Linkage of IPO to JH , PM , TBM Sheets ( small
window of IPO & big window of JH , PM or
TBM sheets

27. • Horizontal Deployment in other cells

28. • Plant level Results vs TPM Tgt PQCDSM

29. • Future Plan

30. • The Journey Continoues….

31. PQCDSM - Targets
02

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. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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. Cost
19

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. 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. 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. 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. 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. 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. 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. 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. 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. 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. Business Plan & SOB
28

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. 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.  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. 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. 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. Summary

63. Journey Continue….
32