110203 mai chacan fact -files backup

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Fact - File SBC

Production in Chakan plant

1H10

2H10 Total10

Jan-11

Feb-11

Mar-11

2Q11 2H11 Total11

PRODUCTION ( Mio Pieces)Budget ( MioPieces)

0.4 12.2 12.6 2.4 3 3 7.9 16.8 33.1

Production ( MioPieces)

0.56 12.55 13.1 1.4 - - - - -

Forecast ( MioPieces)

- - - 2.46 2.72 3.05 8.84 17.95 35

MANPOWERStaff Budget 4 6 6 6 6 6 6 6 6

Staff Actual 3.5 5 5 5 - - - - -

Operatives Budget 2 6 6 10 10 10 12 12 12

Operatives Actual 1 6 6 6 - - - - -

SCRAP RATIO ( %)

Scrap RatioTarget ( %)

0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5

Scrap RatioActual ( %)

0.38 0.2 0.29 - - - - -

EXTERNAL PPMPPM Target 2 2 2 10 10 10 10 10 10PPM Actual 0 0 0 - - - - - -

Capacity coating system SBC: > 50 Mio pieces/year



SBC PRODUCTION 2010/11

SS/Operations06/22/11 3



SBC OPERATIVE MANPOWER

• Only Operative Team

• Common Staff Like

Maintenance /

Logistic / Quality

function are divided in

equal proportions.

• Mubea + Contactor employees considered

Operative ManpowerDetails




SBC STAFF MANPOWER

• Only White collar


Maintenance /

Logistic / Quality


equal proportions.

Staff manpower Details




SBC PPM

06/22/11 7SS/Operations



Fact - File VS

Production in Chakan plant

1H10 2H10 Total10 Jan-11 Feb-11 Mar-11 2Q11 2H11 Total11

PRODUCTION ( Mio Pieces)Budget ( MioPieces)

1.9 4.25 6.15 0.8 1.3 1.5 4.4 8 16

Production ( MioPieces)

2.22 4.39 6.6 0.6 - - - - -

Forecast ( Mio

Pieces)

- - - 0.6 1.3 1.4 4.1 9 16

MANPOWERStaff Budget 7 8 8 8 8 8 8 8 8

Staff Actual 6.5 7.5 7.5 7.5 - - - - -

Operatives Budget 3 7 7 7 10 10 10 10 10

Operatives Actual 3 7 7 7 - - - - -

SCRAP RATIO ( %)

Scrap RatioTarget ( %)6% 6% 6% 2% 2% 2% 2% 2% 2%

Scrap RatioActual ( %)

1.49%

1.34% 1.41% 1.2% - - - - -

EXTERNAL PPMPPM Target 2 2 2 2 2 2 2 2 2PPM Actual 0 0 0 0 - - - - -

Capacity VS line: 1piece / Sec; GEFF 75 %; 21 WD;16.5 Mio pieces/year



VS Production 2010/11




VS STAFF MANPOWER

06/22/11 10

• Only White collar


Maintenance /

Logistic / Quality


equal proportions.

Staff manpower Details

SS/Operations



VS OPERATIVE MANPOWER

06/22/11 11

• Only Operative Team


Maintenance /

Logistic / Quality


equal proportions.

• Mubea + Contactor employees considered

Operative ManpowerDetails

SS/Operations



VS SCRAP %

06/22/11 12

Action – UPS Back up provided

SS/Operations

http://e/D%20Drive/D%20Drive/Dr%20Mhur%20Visit%20preperation/60%20KVA%20UPS.jpg

http://e/D%20Drive/D%20Drive/Dr%20Mhur%20Visit%20preperation/60%20KVA%20UPS.jpg



VS PPM




Continuous improvment and Trainee

Programm s Chakan Plant

Trainee program for coling process.

2 Trainee´s to Bedano from week 7 to week 15 2 Trainees Under Hot presetting machine ( Under Mr Prasad)

Continuous improvment results (last 8 weeks) :

reduction HPS setting time from 1.5 hour to 0.5hour due to standard

setting sytem

better pipe system to avoid stopage of line. Achieved Zero rejection of Fall down spring ( Before – After -



Forcast Stock of SBC

All values in millions Revised forecast date 02.02.2011

SBC INVENTORY ANALYSIS

Feb Mar Apr May1Forecast Sales 2.86 3.10 3.25 2.59 Slow Moving 0.44 0.55 0.48 0.56

Moving 2.42 2.55 2.77 2.03

2ORDER / TANSIST 1.9 0.56 0.2

3Total Stock ( Chakan +CGN)

13.55 12.59 10.05 7.00

Slow Moving 5.68 5.24 4.69 4.21

Moving 7.87 7.35 5.36 2.78

4Closing Stock 12.59 10.05 7.00 4.40 Slow Moving 5.24 4.69 4.21 3.65

Moving 7.35 5.36 2.78 0.75

Actions For Inventory Reduction

Weekly Order strategy -Implemented

Slowing inventory to be sold other required Mubea locations- Under

progressClear DSI implementation



Investigation DSI Target ´s for VS

DSI total (sales base 4.Q11)= 33 DSI DSI transit = 6 DSI DSI inhouse = 27 DSI

Actual DSI: 34

Lead time in total; wire ordering to shipping FG VS to EU: 114 days (5,7 month)

Detailed steps of suplier- chain

days DSI related

Average time order and processing VS-W 50 NO

Suncall/Japan 80%; Suzuki-Garphytan/China 20%

Transit /Shipping Japan/China – India 20 NO

Customs/Clearance & Transit Mumbai pune 9 YES

Stock raw material Chakan 20 YES

Production 5 YES

Stock FG Chakan (incl. monthly Container fill up) 10 YES



Investigation DSI Target ´s for SBC

DSI total (sales base 4.Q11)= 60 DSI transit = 27 DSI inhouse = 33

Actual DSI : 74 days

Lead time in total; order uncoated SBC to domestic indian customer (north): 94 days

Detailed steps of supplier chain days DSI related

Average time order and processing SBC uncoated 26 NO

MUB-Taican60%; MUB Attendorn 40%

Average Transit /Shipping from China/Germany - India 24 YES

Customs/Clearance 5 YES

Transit Mumbai-Pune 2 YES

Stock raw material Chakan 20 YES

Production 2 YES

Stock FG Chakan (35% Volumes) 10 YES

Transit FG Dehli (65% Volumes) 5 YES

Stock FG Delhi (65% Volumes) 10 (target) YES



Project Plan Stab Bar




Layout for Stab Bar project

(project plan see extra chart )

Stab bar production• end heating (Oven LPG)• end punching (Press)• bending ( Pulzer )• correction (Correction Work Station)• process flow from backside to front



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