how standards help in business growth
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National Seminar on “Standards for Quality and Empowerment”. How Standards Help In Business Growth. Case Study by Tata Motors. Founded in 1868, India’s largest & most respected Business Group Diverse businesses in 7 sectors & Operations in over 80 countries - PowerPoint PPT PresentationTRANSCRIPT
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Founded in 1868, India’s largest & most respected Business Group
Diverse businesses in 7 sectors & Operations in over 80 countries
Products & services exported to 85 countries
Group Revenue FY 2010 – Rs 319,534 Cr / $67.4 bn
International Income - 57% of Group revenue
Largest employer in private sector – over 395,000 employees
TATA
GRO
UP
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Industry Pioneers
1902 Taj Palace Hotel- Luxury hotels
1907 Tata Steel- Asia’s First Steel Plant
1910 Tata Power- Hydro Power
1932 Tata Airlines- Civil Aviation
1968 Tata Consultancy Services- Software
1998 Tata Motors- India’s first indigenous car
Industrial Practices Firsts 1912 Eight hour working day 1915 Free Medical aid 1917 Schooling facilities for Children 1920 Leave with pay, workers’ PF
Scheme
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7 Business Sectors
Tata Motors
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No. 3 in Passenger Car Vehicles in India
Jaguar Land Rover part of portfolio
Over 5.9 million vehicles on Indian Roads
Strong Subsidiaries / Associates - Tata Daewoo, Hispano, Telcon, Tata Technologies, European Technical Centre in UK and Tata Motors Thailand
Established in 1945, India’s largest automobile company
Revenue Rs 123,133 cr in 2010-11
Leadership position in Commercial Vehicles
Global no. 3 in M&HCV Trucks, 2 in Buses
TATA MOTORS
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Passenger Car Business Unit (PCBU)
Passenger Cars
Utility Vehicles
Commercial Vehicles Business Unit
(CVBU)
Goods transportation
Passenger transportation
Product Range : A Vehicle for Every Need
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April’09 - OHSAS 18001:2007 certification May’09 – Eastern Complex Prodn commencedJune’09 – NABL AccreditationNov’09 – CII Energy efficient award
Peak Production in 90’s achieved
Nov’94 -Crown & Pinion Prodn started (Parts Business)
Aug
1983Land identified by Late Mr. S Moolgaonkar
1994 2001
20-Oct-92 - 1st vehicle - Model - LP 1210 / 52 (MCV BUS) rolled out
Mar’01 CNG Chassis rolled out
Feb’02 - RE Bus rolled out
April’02 – FBV Business started
Dec ’03 - Certification of ISO 14001 & TS 16949 Oct ’04 - Ace Gear Box launched
Mar’05 - Low floor bus launched July’05 - OHSAS 18001 Aug’05 - ERC Set-up Dec’05 - HCBS prototypeMay’06 - Expansion Project initiated Nov’06 - Zero PPM in ACE Gear Box
Feb’07 - 100000th Ace Gear Box Mar’07 - 100th Module– Integral BusesSep’07 - TMML DTC Bus unveiledOct’07 - 200000th VehicleJan’08 100th DTC VehicleNov’08 - 1st tender for DTC Buses completedDec’08 – IMEA Gold AwardDec’08 - The Trial run of BIW Shop
Turnaround Domestic Growth International Growth
Key Mile Stone
1997
Phase -1 – Start upPhase -1 – Start up Phase -2 – Bus FocusPhase -2 – Bus Focus Phase -3 – New Generation Buses & TrucksPhase -3 – New Generation Buses & Trucks
Revenue in million US$
2000 2005 2006 2007 2009 201020081993
Who are we..
2011
Increase in Volumes
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Global Market presence
Different customer preferences
Different stages of market maturity Different cultures Different time zones Different regulations
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Jamshedpur – Commercial Vehicles
Pune – Commercial and Passenger Vehicles
Lucknow – Commercial Vehicles
Pantnagar – Commercial Vehicles
Sanand – Tata Nano
Dharwad – Buses
South Korea –Heavy and Medium Trucks
Spain – High Capacity Buses Morocco – High Capacity Buses
Thailand – Pickup trucks
UK – Jaguar Land Rover
India
Overseas
Decisions on setting up plants and where to make what
products
Global Manufacturing Base
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Global Vendor Base
Increased No of vendors Global Sourcing
Uniformity for bidding(e-bidding, RFQ preparation)
Different regulations across countries
Periodic up-dation of standards are necessary
AllisionParker
VoithZf
RGB- Brazil
TACO
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Changing Customer Preferences – In Trucks
SE 1613 ChassisScenario Before FY 2000
TML was supplying Truck chassis
LPT 2515/3118 Fully builtScenario 2000-07TML started supplying multi axle vehicle for more pay load & Body built with various options
4018TC/3518TC
Brief Technical Specifications –130 BHP Engine, Leaf spring suspension, Synchromesh Gear Box, Rigid front axle, Rear Live axle, Semi forward cabin design
Scenario 2007 Onwards
TML started supplying Less & high loading capacity
Brief Technical Specifications –150/180 BHP Engine, Leaf spring suspension, Synchromesh Gear Box, Rigid front axle, Rear Live axle, Multi axle with more loading capacity and in fully build condition with various options
Brief Technical Specifications –ACE : Up to 1 Ton loading Capacity
HCV : 180 BHP Engine, Leaf spring suspension, Synchromesh Gear Box, Rigid front axle, Rear Live axle, More no of axles with more loading capacity and in fully build condition with various options
Customer preferences changed from low to High engine Horse power along with load carrying capacity distribution to low & high capacity
Current Indian Market ScenarioIndividual of Customer preferences
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LP 1512 TC ChassisBefore FY 2000
TML was supplying only chassis for buses
LP 1512 TC BusScenario 2000-07
TML started supplying Customized Body built buses
1612/1618 RE Bus
Brief Specifications –120 BHP Engine, Leaf spring suspension, Synchromesh Gear Box, Rigid front axle, Rear Live axle
2007 Onwards
TML started Low Floor & Rear Engine Buses
Brief Specifications –120 BHP Engine, Leaf spring suspension, Synchromesh Gear Box, Rigid front axle, Rear Live axle, Standard body building AC & Non AC
Brief Specifications –120/ 180 BHP Engine, Pneumatic Suspension, Independent suspension, Auto Transmission, AC & NON AC, Low floor,
Brief Specifications –240/230 BHP Engine, Pneumatic Suspension, Kneeling mechanism with Independent suspension, Auto Transmission, AC & NON AC Saloon , Low floor & Ultra low floor, Multiplexing advanced W/H, Fuel Options– Diesel/CNG, Advanced seating Comfort and Features equipped with high end Technology
1623CGL /1624 TC2009 Onwards
TML started Luxury Coach RE Buses with high end Technology
Customer preferences changed from low to High Passenger comfort& Capacity along with Rear Engine, Pneumatic Suspension, Low Floor, AC Saloon, Seating Comfort & Advanced Technical features which are already available in European Market
Current Indian Market Scenario
Changing Customer Preferences – In Buses
Customer preferences
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Complexity
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Improvement
Standards
Standards
How Standards help
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Organisational Pyramid for System and Process Management
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Strategy Level
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Strategy Level
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Leadership systemLeadershipStrategy Level
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System & Process Level
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System & Process Level
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System & Process Level
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System & Process Level
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System & Process Level
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System & Process Level
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System & Process Level
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System & Process Level
Six Sigma SPC Why Why Analysis CFT DOEKaizen Quality Circles
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Implementation Level
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Implementation-Product
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Implementation -Product
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Implementation-Process
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Implementation-Process
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SOP depicting the OCP for handling and storage of Diesel, Paint and Thinner
Implementation: Process
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SA8000 is an international standard for improving working conditions around the
world. It is based on international human right instruments and ILO conventions.
Tata Motors Lucknow is going for SA 8000 - 2008 Accreditation Program.
ØSA 8000 is a global standard for improving working conditions around the
world.
ØStandard and verification is compliance based, creditable, comprehensive and
efficient tool for improving workplace.
ØSA 8000 is First auditable international standard on workers' rights, it provides
definitions and parameters
to ensure conformance to universal human rights.
Implementation- Process
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April’09 - OHSAS 18001:2007 certification May’09 – Eastern Complex Prodn commencedJune’09 – NABL AccreditationNov’09 – CII Energy efficient award
Peak Production in 90’s achieved
Nov’94 -Crown & Pinion Prodn started (Parts Business)
Aug
1983Land identified by Late Mr. S Moolgaonkar
1994 2001
20-Oct-92 - 1st vehicle - Model - LP 1210 / 52 (MCV BUS) rolled out
Mar’01 CNG Chassis rolled out
Feb’02 - RE Bus rolled out
April’02 – FBV Business started
Dec ’03 - Certification of ISO 14001 & TS 16949 Oct ’04 - Ace Gear Box launched
Mar’05 - Low floor bus launched July’05 - OHSAS 18001 Aug’05 - ERC Set-up Dec’05 - HCBS prototypeMay’06 - Expansion Project initiated Nov’06 - Zero PPM in ACE Gear Box
Feb’07 - 100000th Ace Gear Box Mar’07 - 100th Module– Integral BusesSep’07 - TMML DTC Bus unveiledOct’07 - 200000th VehicleJan’08 100th DTC VehicleNov’08 - 1st tender for DTC Buses completedDec’08 – IMEA Gold AwardDec’08 - The Trial run of BIW Shop
Turnaround Domestic Growth International Growth
2008- Frost & Sullivan –Indian Manufacturing Excellence (IMEA) Gold
2009 - Confederation of India Industries (CII) Energy Efficient unit award
2010 – Rajiv Gandhi National Quality Award for 2009 under “Best in All” category
Key Mile Stone
1997
Phase -1 – Start upPhase -1 – Start up Phase -2 – Bus FocusPhase -2 – Bus Focus Phase -3 – New Generation Buses & TrucksPhase -3 – New Generation Buses & Trucks
Revenue in million US$
@Rs 44/US$
2000 2005 2006 2007 2009 201020081993
Who are we..
2011
Results
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EBIDTA (Rs Cr)
66
92.4
Quality Index49
1216 GROWTHQUALITY
SPEED
Number of New Models introduced YoY2009-102002-03 2003-04 2004-05 2005-06 2006-07 2007-08 2008-09
Abili
ty to
Inno
vate
Low
Life
Cy
cle
Cost
Sol
utio
ns
(Cos
t of O
wner
ship
)
Growth Focus
Safety
OHS
ICR-2
OHSAS OHSAS:2007
Speed & Agility KTLIntegrated NPI
approach
KM
BSC
Integrated IT Systems
BSC Digi BSC Digi P2
CoP
Safety CommitteeAlert CardEL-11-07
Daily Insp
Safety Kaizen Behaviour Based SafetyPoint Leaders
Expansion Project
TMML
Quality Focus
TS 16949Six Sigma
WCMCTQ
IQA NABLLM
Safety BM OHS Policy
IBF
Eastern Complex
Matrix Structure
ERM
Review Structure CFT, CLT, CPT
Benchmarking
Evacuation DrillSQDCM
SQDCM Quality Tools
Innovation
Standardized Processes and Team Work gave us results
Our Journey towards Excellence
Who are we…
EPM Version 1 EPM Version 3 EPM Version 6 EPM Version 8 EPM Version 10
2010 - 11
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FY 08-09 India Manufacturing Excellence Award (IMEA)
FY 10-11 Rajiv Gandhi National Quality Award (RGNQA) in the “Best of All Category”
The Engagement EffectRecognition of Our Efforts
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Excellent Energy Efficient Unit Award by CII at the 11th National Award for Excellence in Energy Management 2010 on 1st & 2nd September 2010 at Chennai
National Energy Conservation Award by Bureau of Energy Efficiency on 14th December
2010 at New Delhi
Silver Award by GreenTech Foundation at the 11th
Global GreenTech 2010 Excellence Award at Hyderabad on 12th December 2010
Tata Motors Lucknow received the Best Assessee Award (Samman Patra) from Central Excise in
2010
Lucknow Plant bagged the NABL accreditation for its Material
Engineering Lab in November 2010
Tata Motors Lucknow bagged the Second prize at Annual Regional
Convention of INSSAN - Eastern India Chapter on 23rd -24th April 2010
Tata Motors Lucknow won the Second prize in the regional
convention of INSSAN for Excellence in Mitigating
Climate Change conducted by INSSAN - Eastern India
Chapter at Jamshedpur in April’2010
Recognition for Our Efforts
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