mrm4 advanced cluster teemag_v1
DESCRIPTION
TRANSCRIPT
Supplier name :MRM -1 at (supplier name) on (Date)
Teemag Enterprises Pvt Ltd Unit - 4
MRM - 4 at DEEYEM CNC Machining Pvt. Ltd. on 20.06.2012
BOSCH ADVANCE CLUSTER 20122
Bosch Advanced Cluster Programme 4th MRM Presentation
By : Teemag Enterprises Pvt LtdBy : Teemag Enterprises Pvt Ltd
Venue : DEEYEM CNC Machining Pvt. Ltd.
Supplier name : Teemag Enterprises Pvt. Ltd.
Place : Bangalore
Supplier name :MRM -1 at (supplier name) on (Date)
Teemag Enterprises Pvt Ltd Unit - 4
MRM - 4 at DEEYEM CNC Machining Pvt. Ltd. on 20.06.2012
BOSCH ADVANCE CLUSTER 20123
Company Introduction
• Company name : Teemag Enterprises Pvt Ltd.
• Year of Established : 1995
• Major customers : BOSCH, SKF India Ltd.,
Amado Tools (Aerospace)
• Major Products : DV Pins, Cam Follower, CNC Turned
Components
• Products supplying to Bosch : DV Pins
• Total number of employees : 25 Nos.
• Type of company : Private Limited
• Managing Director : Mr. Tom Thomas.
• Certifications done : TUV NORD TS 16949 & ISO 9001:2008
Supplier name :MRM -1 at (supplier name) on (Date)
Teemag Enterprises Pvt Ltd Unit - 4
MRM - 4 at DEEYEM CNC Machining Pvt. Ltd. on 20.06.2012
BOSCH ADVANCE CLUSTER 20124
Organization structure
CEO – Tom Thomas
Manager – A K Kutty
Unit I Unit II Unit IV
Sharieff Cherian
Anthony Yesudas
Dennis John
Shivkumar
Sharieff Balraj
Prasanna Hanumanth
Finance / AccountsJames / Jayasourya
Supplier name :MRM -1 at (supplier name) on (Date)
Teemag Enterprises Pvt Ltd Unit - 4
MRM - 4 at DEEYEM CNC Machining Pvt. Ltd. on 20.06.2012
BOSCH ADVANCE CLUSTER 20125
Actions taken and status of points from previous MRMs
Click the link below to view in detail
Teemag_MOM
Supplier name :MRM -1 at (supplier name) on (Date)
Teemag Enterprises Pvt Ltd Unit - 4
MRM - 4 at DEEYEM CNC Machining Pvt. Ltd. on 20.06.2012
BOSCH ADVANCE CLUSTER 20126
Part ‘A’
CEO’sCEO’s Presentation Presentation
Supplier name :MRM -1 at (supplier name) on (Date)
Teemag Enterprises Pvt Ltd Unit - 4
MRM - 4 at DEEYEM CNC Machining Pvt. Ltd. on 20.06.2012
BOSCH ADVANCE CLUSTER 20127
Attendance Details
ATTENDED
PARTLY ATTENDED
ABSENT
CEO’s Presentation
MRM REFERENCE 01 02 03 04 05 06 07 08 09 10 11 12
CEO
CO-ORDINATOR
DY.COORDINATOR
Supplier name :MRM -1 at (supplier name) on (Date)
Teemag Enterprises Pvt Ltd Unit - 4
MRM - 4 at DEEYEM CNC Machining Pvt. Ltd. on 20.06.2012
BOSCH ADVANCE CLUSTER 20128
Peri
od
in
M
on
ths
Topics
12
11
10
9
8
7
6
5
4
3
2
1
Deliverables
Quality Circles,
7 QC Tools , Poka-yokes
Sustainability
Environment Management System (EMS)
Advance 5S, Safety
Suggestion / Kaizens
Daily work Management, Waste elimination , Safe workplace
Reduction in Absenteeism
Total Employee involvement
Quality MIS
Reduction in in house rejection
Zero Customer Returns & Complaints
Lead time reduction.
Single component flow
Breakdown reduction
Set-up time reduction
Productivity improvement
Material Traceability
Handling Damage reduction
Improved Inventory turn ratio
Improved VAPCO
Stability in Process, Continuous Improvement
Energy conservation and waste managementCell design through flow manufacturing
TPM- Step 1 2 3
SMED
Low Cost Automation
Material Handling Improvement
Inventory Management
Bosch Advanced Cluster Programme – 12 month Cluster
Status: Planned; In Progress; Observation/Check; Completed/Further Improvement
Status
Supplier name :MRM -1 at (supplier name) on (Date)
Teemag Enterprises Pvt Ltd Unit - 4
MRM - 4 at DEEYEM CNC Machining Pvt. Ltd. on 20.06.2012
BOSCH ADVANCE CLUSTER 20129
Customer Complaints (PPM) Desired Trend ↓ Delivery Performance (%) Desired Trend ↑
OEE (%) Desired Trend ↑ Breakdown (Hrs) Desired Trend ↓ Desired Trend ↑Inventory Turn Ratio - ITR
VAPCO Desired Trend ↑ Electricity consumption
0
10
20
30
40
201020112012 YTD Jan Feb Mar Apr MayJune Jul Aug Sep Oct Nov Dec
Nu
mb
er
ITR Target
0.00
2.00
4.00
6.00
8.00
10.0 0
2010 2011 2012YTD
Jan Feb Mar Apr May June Jul Aug Sep Oct Nov Dec
Nu
mb
er
VAPCO Target
0
20
40
60
80
100
201020112012 YTD Jan Feb Mar Apr MayJune Jul Aug Sep Oct Nov Dec
Hrs
Breakdown(Hrs)/month Target
0102030405060708090
100
201020112012 YTD Jan Feb Mar Apr MayJune Jul Aug Sep Oct Nov Dec
%
OEE (%) Target
0.0
20.0
40.0
60.0
80.0
100.0
201020112012 YTD Jan Feb Mar Apr MayJune Jul Aug Sep Oct Nov Dec
%
De livery Fulfillmeent Target
0
2
4
6
8
10
12
14
201020112012 Y TD Jan Feb Mar A pr MayJune Jul A ug S ep Oct Nov Dec
PP
M
PPM Target
Internal Rejections (PPM) Desired Trend ↓
0
10000
20000
30000
40000
50000
201020112012 YTD JanFebMarAprMayJuneJulAugSepOctNovDec
PP
M
Internal Rejections PPM
0
100
200
300
400
500
600
700
800
900
1000
0
2000
4000
6000
8000
10000
12000
14000
16000
18000
20000
2010 2011 2012YTD
Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec
un
its
in
KW
hr
KWhr consumption/month KWhr per lac of sales
Supplier name :MRM -1 at (supplier name) on (Date)
Teemag Enterprises Pvt Ltd Unit - 4
MRM - 4 at DEEYEM CNC Machining Pvt. Ltd. on 20.06.2012
BOSCH ADVANCE CLUSTER 201210
Absenteeism Desired Trend ↓ Kaizens – Overall Desired Trend ↑ 5S Score % Desired Trend ↑
Safety Tag Campaign – Overall Accident Frequency Desired Trend ↓ Poka Yoke – Overall Desired Trend ↑
0.00
2.00
4.00
6.00
8.00
10.00
201020112012 YTD JanFebMarAprMayJuneJulAugSepOctNovDec
%
Absenteeism(%) Target
0
5
10
15
20
No
. of
Acc
iden
ts
Major Accidents Minor Accidents
0369
1215
No
.
Tags Identified Tags Removed
0102030405060708090
100
201020112012 YT D JanFeb M arAprM ayJun Jul AugSepOctNovDec
%
Overall 1S Score 2S Score3S Score 4S Score 5S Score
0
10
No
.
Poke yoke Identified
0
5
10
15
No
.
Kaizens Identified Kaizens Implemented
Supplier name :MRM -1 at (supplier name) on (Date)
Teemag Enterprises Pvt Ltd Unit - 4
MRM - 4 at DEEYEM CNC Machining Pvt. Ltd. on 20.06.2012
BOSCH ADVANCE CLUSTER 201211
Status : Planned; In Progress; Observation/Check; Completed/Further Improvement
CEO Strategy# Gap / Improvement Area Strategy Due Date Status
1Kaizens- To get more no. of suggestions.
Operators are being asked to explain the difficulties faced during their work. Points received from them are being converted into suggestions
continuous
2 5S SustenanceMonthly audit and motivation for the personal involvement by all.
continuous
3 AbsenteeismPlan to discuss with like minded CEO’s of the cluster member companies for a common strategy.
End May
End June
4 In process Rejections
1. Working with BOSCH for reconditioning of existing Multispindle autos
2. Quality circle has been formed and they will work on this issue.
End Aug
End May
End June
5 Delivery Fulfillment 100% (Additional capacity available) -
6 VAPCOTopic covered on 10-05-2012 and will be followed
Supplier name :MRM -1 at (supplier name) on (Date)
Teemag Enterprises Pvt Ltd Unit - 4
MRM - 4 at DEEYEM CNC Machining Pvt. Ltd. on 20.06.2012
BOSCH ADVANCE CLUSTER 201212
Benefits from the Cluster Programme
Tangible (cumulative till End Feb.12)
1) Disposed unwanted items – savings Rs. 5800/-
2)Total Money Earned / Recovered from 1S in Rs : 5800/-
3)Total Money Saved (yearly) Thro Kaizens in Rs : Nil
Intangible
1) Change in Environment (Clean & Green Environment) : Yes (Car parking area marking done)
2) Employees Involvement : Yes (Suggestions came up to prevent oil spillage on the floor)
3) Employees are coming forward with more and more suggestions for improvement on better house keeping.
Supplier name :MRM -1 at (supplier name) on (Date)
Teemag Enterprises Pvt Ltd Unit - 4
MRM - 4 at DEEYEM CNC Machining Pvt. Ltd. on 20.06.2012
BOSCH ADVANCE CLUSTER 201213
CEO Review
Meeting No. : 04
Date : 08.06.12
Venue : Training Hall
Agenda : Review of cluster activities Necessity of Quality circles and the progress made by the team.
Points Addressed
1)Cluster activity points was discussed.
2)Necessity of Quality circles to reduce our internal rejections.
3)Interaction with quality circle team leader.
4)Improvement in 5S activity required.
Supplier name :MRM -1 at (supplier name) on (Date)
Teemag Enterprises Pvt Ltd Unit - 4
MRM - 4 at DEEYEM CNC Machining Pvt. Ltd. on 20.06.2012
BOSCH ADVANCE CLUSTER 201214
Actions for CEO Review
Sl. No.
Point / ActionProposed Action Responsibility Planned
Date for Completion
Actual
Date of completion
1 Dividing ZonesDividing factory in to different zones and provide zonal boards
Hanumanth 27-02-2012 27-02-2012
2 Gangway Yellow Line Putting yellow line for gangway Hanumanth 28-02-2012 28-02-2012
3 Red tag Red tag campaign Hanumanth 16-02-2012 20-02-2012
4 Putting Safety tagsInitiate action to eliminate unsafe conditions
Hanumanth 18-02-2012 08-03-2012
5Formation of Quality Circle
Identify one of the internal defect discuss, identify the causes, initiate actions, reduce rejections.
Cheriyan
Hanumanth31-05-2012 23-05-2012
6
Evaluate effectiveness of the action initiated as per Quality circle.
Record daily rejections follow upCheriyan
Hanumanth30-06-2012
Supplier name :MRM -1 at (supplier name) on (Date)
Teemag Enterprises Pvt Ltd Unit - 4
MRM - 4 at DEEYEM CNC Machining Pvt. Ltd. on 20.06.2012
BOSCH ADVANCE CLUSTER 2012
Part ‘B’
Coordinator’s PresentationCoordinator’s Presentation
• Overview of all Cluster Initiatives
• Key Indicators and Plans for Improvement
15
Supplier name :MRM -1 at (supplier name) on (Date)
Teemag Enterprises Pvt Ltd Unit - 4
MRM - 4 at DEEYEM CNC Machining Pvt. Ltd. on 20.06.2012
BOSCH ADVANCE CLUSTER 201216
Left view
Front view
Back view
Right view
Company Photos
Supplier name :MRM -1 at (supplier name) on (Date)
Teemag Enterprises Pvt Ltd Unit - 4
MRM - 4 at DEEYEM CNC Machining Pvt. Ltd. on 20.06.2012
BOSCH ADVANCE CLUSTER 201217
Employee Suggestions
0.0
0.1
0.1
0.2
0.2
0.3
2010 2011 2012 YTD
Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec
No
s
Suggestions per Employee/month Target
Desired Trend ↑
Note : 1) YTD – Update cumulative value, up to the corresponding MRM
Supplier name :MRM -1 at (supplier name) on (Date)
Teemag Enterprises Pvt Ltd Unit - 4
MRM - 4 at DEEYEM CNC Machining Pvt. Ltd. on 20.06.2012
BOSCH ADVANCE CLUSTER 201218
Kaizens – Overall
0
2
4
6
8
10
12
2010 2011 2012YTD
Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec
No
.
Kaizens Identified Kaizens Implemented Target
Desired Trend ↑
Note : 1) YTD – Update cumulative value, up to the MRM month
Supplier name :MRM -1 at (supplier name) on (Date)
Teemag Enterprises Pvt Ltd Unit - 4
MRM - 4 at DEEYEM CNC Machining Pvt. Ltd. on 20.06.2012
BOSCH ADVANCE CLUSTER 201219
Kaizens – Zonewise Benefits
# Zone Name Identified Implemented Pending BenefitsValue recovered
INR Per Annum
1 Zone A Hanumanth Ramu NilSafe storage and
better appearance Nil
2 Zone A Hanumanth Hanumanth Nil Better house keeping Nil
3 Zone A Hanumanth Hanumanth Nil Better house keeping Nil
4 Zone B Prasanna Hanumanth NilEliminated UNSAFE
condition.Nil
Supplier name :MRM -1 at (supplier name) on (Date)
Teemag Enterprises Pvt Ltd Unit - 4
MRM - 4 at DEEYEM CNC Machining Pvt. Ltd. on 20.06.2012
BOSCH ADVANCE CLUSTER 201220
TEEMAG Teemag
Enterprises Pvt Ltd.
Kaizen No Month/year P Q C D S M
3 05/12
Theme: Unsafe conditionImplemented Area:
Unit 4 - Zone B
Problem Description Before Improvement Suggested by: Anthony Kumar
Guard is not existing which may lead to accidents
Implemented by: Hanumanth
Result/Benefit (also in monetary terms):
Safe condition and prevented accidents
Root Cause Identification After Improvement Standardisation Implementer’s Photo
Guard was damaged during shifting and was not replaced
Root Cause: Guard does not exist
Solution Idea: Fabricate a new guard and install Horizontal Deployment
NilAction Taken: New guard installed.
Supplier name :MRM -1 at (supplier name) on (Date)
Teemag Enterprises Pvt Ltd Unit - 4
MRM - 4 at DEEYEM CNC Machining Pvt. Ltd. on 20.06.2012
BOSCH ADVANCE CLUSTER 201221
Poka Yoke – Overall
0
0.5
1
1.5
2
2.5
3
3.5
4
4.5
2010 2011 2012YTD
Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec
No
.
Poke yoke Identified Poke yoke Implemented Target
Desired Trend ↑
Note : 1) YTD – Update cumulative value, up to the MRM month
Supplier name :MRM -1 at (supplier name) on (Date)
Teemag Enterprises Pvt Ltd Unit - 4
MRM - 4 at DEEYEM CNC Machining Pvt. Ltd. on 20.06.2012
BOSCH ADVANCE CLUSTER 201222
Status: Planned; In Progress; Observation/Check; Completed/Further Improvement
Actions for improving Poka Yoke / Kaizens / Suggestions
# Corrective Actions Responsible Due Date Status
1Kaizens- Discussed among the operators and asked to come out with their ideas to improve house keeping and quality.
Hanumanth Continuous
2
3
4
5
Supplier name :MRM -1 at (supplier name) on (Date)
Teemag Enterprises Pvt Ltd Unit - 4
MRM - 4 at DEEYEM CNC Machining Pvt. Ltd. on 20.06.2012
BOSCH ADVANCE CLUSTER 201223
Vendor No Part No.
Vendor name Part Description
Machine description Operation No.
Project start Date Operation Description
Project end Date Target due Date
Identify the Level of Poka-Yoke Project
Safety Quality Cost Delivery
√
Description of problem (with photo/sketch): Solutions implemented to eliminate failures (with photo/ sketch):
Part is milled more than once.
Root Cause analysis:
Productivity increase Projected yield in INR or PPM
No. of workstations to install Status
Other Information:Defective parts do not reach coustomer& Reduction in internal rejection .
Signature
POKA – YOKE
Introduce sensor to prevent
milled part getting loaded again
Others (Specify)
30
Complited
Level 2 – Prevention Level 3 - Elimination
CEOImplementer Supervisor Process Planner
Mill Flutes
Level 1 – Indication
Improvement in : (Check in relevant
boxes)
3/12/2012
3/30/2012
Productivity
Milling SPM
Completed
Project No: PY No: YYYY/MM/SN
F002B73 217
Valve ConeTeemag Enterprises PVT LTD
4
Milled part not ejected after operation
97008211
Supplier name :MRM -1 at (supplier name) on (Date)
Teemag Enterprises Pvt Ltd Unit - 4
MRM - 4 at DEEYEM CNC Machining Pvt. Ltd. on 20.06.2012
BOSCH ADVANCE CLUSTER 201224
5S Audits – Zone wise – Target > 85 %
R GScore < 70% 70% ≥ Score < 80% 80% ≥ ScoreStatus >> Y
# Zone Name 5S Score % Status
1 Zone A (Production) 67
2 Zone B (Production) 69
3 Zone C (Inspection Area) 72
4 Zone D (Garden) 87
5 Zone E (Office) 77
Lowest score 67
Supplier name :MRM -1 at (supplier name) on (Date)
Teemag Enterprises Pvt Ltd Unit - 4
MRM - 4 at DEEYEM CNC Machining Pvt. Ltd. on 20.06.2012
BOSCH ADVANCE CLUSTER 201225
5S Score % Desired Trend ↑
0
10
20
30
40
50
60
70
80
90
100
2010 2011 2012 YTD
Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec
%
Overall 1S Score 2S Score 3S Score 4S Score 5S Score Target
Note : 1) YTD – Update average score, up to the MRM month
2) Refer previous slide and consider lowest score for plotting graph
Supplier name :MRM -1 at (supplier name) on (Date)
Teemag Enterprises Pvt Ltd Unit - 4
MRM - 4 at DEEYEM CNC Machining Pvt. Ltd. on 20.06.2012
BOSCH ADVANCE CLUSTER 201226
Actions for Improving 5S# Description / Problem Corrective Action Responsible Due Date Status
1 Identification Sign Board to be fixed on all doors, lights, switches and machine items.
Hanumanth 30.04.2012
2 Parking area not earmarked. Marking to be done. Ramu 05.03.2012
3 Floor marking Yellow lines for Gang ways Hanumanth 10.02.2012
4 Identification for LightNumbering for Light and Switches
Hanumanth 15.03.2012
5Tray to be provided below the machine to prevent oil spillage
To be procured Hanumanth31.05.2012
30-06-2012
6Rain water flows towards the entrance of the workshop
Construct small wall to direct the rain water towards the back of the workshop
Ramu 30.04.2012
Status : Planned; In Progress; Observation/Check; Completed/Further Improvement
Supplier name :MRM -1 at (supplier name) on (Date)
Teemag Enterprises Pvt Ltd Unit - 4
MRM - 4 at DEEYEM CNC Machining Pvt. Ltd. on 20.06.2012
BOSCH ADVANCE CLUSTER 2012
27
Worst Point Photos
BEFORE
AFTER
Red Tag Area Inspection station
10.04.1210.04.12
Supplier name :MRM -1 at (supplier name) on (Date)
Teemag Enterprises Pvt Ltd Unit - 4
MRM - 4 at DEEYEM CNC Machining Pvt. Ltd. on 20.06.2012
BOSCH ADVANCE CLUSTER 201228
Fixed Point Photos
STORE - OIL STORE - MATERIALS
CHIPS SCRAP AREA INSPECTION AREA
Supplier name :MRM -1 at (supplier name) on (Date)
Teemag Enterprises Pvt Ltd Unit - 4
MRM - 4 at DEEYEM CNC Machining Pvt. Ltd. on 20.06.2012
BOSCH ADVANCE CLUSTER 201229
Safety Tag Campaign – Overall
0369
1215
2010 20112012 YTDJan Feb Mar Apr May
No
. of
Tag
s
Tags Identified Tags Removed
Supplier name :MRM -1 at (supplier name) on (Date)
Teemag Enterprises Pvt Ltd Unit - 4
MRM - 4 at DEEYEM CNC Machining Pvt. Ltd. on 20.06.2012
BOSCH ADVANCE CLUSTER 201230
Safety Photos
BEFORE
AFTER
Supplier name :MRM -1 at (supplier name) on (Date)
Teemag Enterprises Pvt Ltd Unit - 4
MRM - 4 at DEEYEM CNC Machining Pvt. Ltd. on 20.06.2012
BOSCH ADVANCE CLUSTER 201231
Accident Frequency
0
5
10
15
20
2010 2011 2012YTD
Jan Feb Mar Apr May Jun July Aug Sept Oct Nov Dec
No
. of
Ac
cid
en
ts
Minor Accidents Major Accidents Target
Desired Trend↓
Note : 1) YTD – Update cumulative value, up to the MRM month
Supplier name :MRM -1 at (supplier name) on (Date)
Teemag Enterprises Pvt Ltd Unit - 4
MRM - 4 at DEEYEM CNC Machining Pvt. Ltd. on 20.06.2012
BOSCH ADVANCE CLUSTER 201232
Actions for Improving Safety (Reducing Accident Frequency)
# Description / Problem Corrective Action Responsible Due Date Status
1Safety Goggle near the Pedestal Grinder M/c
Provide space for safety Goggle.
Hanumanth 10.03.2012
2Safety Guard for Bar Feeder of MSA Auto M/c
Prepare & fix safety guard Hanumanth 10.04.2012
3Rubber mat for near the Electric Panel Board.
Provide Rubber mat Hanumanth 10.03.2012
4No safety guard for compressor
Provide guard Hanumanth 30-04-2012
Status : Planned; In Progress; Observation/Check; Completed/Further Improvement
Supplier name :MRM -1 at (supplier name) on (Date)
Teemag Enterprises Pvt Ltd Unit - 4
MRM - 4 at DEEYEM CNC Machining Pvt. Ltd. on 20.06.2012
BOSCH ADVANCE CLUSTER 201233
Absenteeism Desired Trend↓
0.00
2.00
4.00
6.00
8.00
10.00
201020112012 YTD Jan Feb Mar Apr MayJune Jul Aug Sep Oct Nov Dec
%
Absenteeism(%) Upper Limit
Supplier name :MRM -1 at (supplier name) on (Date)
Teemag Enterprises Pvt Ltd Unit - 4
MRM - 4 at DEEYEM CNC Machining Pvt. Ltd. on 20.06.2012
BOSCH ADVANCE CLUSTER 201234
Actions for reducing Absenteeism
# Description / Problem Corrective Action Responsible Due Date Status
1 To minimize absenteeism
Plan to discuss with like minded CEO’s of the cluster member companies for a common strategy.
CEO
Status : Planned; In Progress; Observation/Check; Completed/Further Improvement
Supplier name :MRM -1 at (supplier name) on (Date)
Teemag Enterprises Pvt Ltd Unit - 4
MRM - 4 at DEEYEM CNC Machining Pvt. Ltd. on 20.06.2012
BOSCH ADVANCE CLUSTER 201235
Customer Complaints (PPM)
0
2
4
6
8
10
12
14
2010 2011 2012YTD
Jan Feb Mar Apr May June Jul Aug Sep Oct Nov Dec
PP
M
PPM Upper Limit
Desired Trend ↓
Note : 1) YTD – Update cumulative value, up to the MRM month
Supplier name :MRM -1 at (supplier name) on (Date)
Teemag Enterprises Pvt Ltd Unit - 4
MRM - 4 at DEEYEM CNC Machining Pvt. Ltd. on 20.06.2012
BOSCH ADVANCE CLUSTER 201236
Actions for reducing Customer Complaints
# Description / Problem Corrective Action Responsible Due Date Status
Status : Planned; In Progress; Observation/Check; Completed/Further Improvement
No Customer Complaints
Supplier name :MRM -1 at (supplier name) on (Date)
Teemag Enterprises Pvt Ltd Unit - 4
MRM - 4 at DEEYEM CNC Machining Pvt. Ltd. on 20.06.2012
BOSCH ADVANCE CLUSTER 201237
Internal Rejections PPM
0
5000
10000
15000
20000
25000
2010 2011 2012YTD
Jan Feb Mar Apr May June Jul Aug Sep Oct Nov Dec
PP
M
Internal Rejections PPM Upper Limit
Desired Trend ↓
Note : 2) YTD – Update cumulative value, up to the MRM month
Supplier name :MRM -1 at (supplier name) on (Date)
Teemag Enterprises Pvt Ltd Unit - 4
MRM - 4 at DEEYEM CNC Machining Pvt. Ltd. on 20.06.2012
BOSCH ADVANCE CLUSTER 201238
Pareto of Internal Rejections
0 1000 2000 3000 4000 5000 6000 7000 8000
D1D2D5D8D9
D10D11D13D14D15D16D17D18D19D20D22D23D24D25D26D27D28D29D30D31D32D33D34D36
PPM 2011 2012 Jan-12 Feb-12 Mar-12 Apr-12 May-12 Jun-12 Jul-12 Aug-12
Supplier name :MRM -1 at (supplier name) on (Date)
Teemag Enterprises Pvt Ltd Unit - 4
MRM - 4 at DEEYEM CNC Machining Pvt. Ltd. on 20.06.2012
BOSCH ADVANCE CLUSTER 201239
Actions for reducing Internal Rejections
# Description / Problem Corrective Action Responsible Due Date Status
1Visual defects on turned components
To be finalized by quality circle team members
Cheriyan End April
2Visual defects on turned components
Quality circle has been formed to identify the causes for defect – lines on head dia – and initiate actions.
Cheriyan /
Hanumanth
End May
End June
3 ValidationObserve the effectiveness of the actions taken
Cheriyan /
HanumanthEnd June
4 Visual DefectsRecondition existing machines after receiving a substitute machine from BOSCH
CEO End 2012
5 Visual DefectsForm one more quality circle to analyse one more major defect and initiate actions.
Cheriyan /
SanilEnd Aug 12
Status : Planned; In Progress; Observation/Check; Completed/Further Improvement
Supplier name :MRM -1 at (supplier name) on (Date)
Teemag Enterprises Pvt Ltd Unit - 4
MRM - 4 at DEEYEM CNC Machining Pvt. Ltd. on 20.06.2012
BOSCH ADVANCE CLUSTER 201240
DIR ( Do It Right )
DIR Meeting every day at 10:00 am
Topic discussed : Previous days rejections
Team Members
All the employees in first shift
Supplier name :MRM -1 at (supplier name) on (Date)
Teemag Enterprises Pvt Ltd Unit - 4
MRM - 4 at DEEYEM CNC Machining Pvt. Ltd. on 20.06.2012
BOSCH ADVANCE CLUSTER 201241
DIR ( Do It Right ):
DIRDate 19/06/2012
Attendance: Yesudas SadasivanBharathanSanil
Sl No Part No Defect Actions Responsibility DueRemark
(Scrap /Repair) Status
1F002B73271
Etc.Short Pins
Change feed finger and collet on spindles where bar feeding is not OK.
Sharieff / Sanil 23/06/2012 Scrap
2F002B73271
Etc.Inscription
unclearOver check machine
settings
Try setting as explained by stamp supplier
Modify work instruction accordingly
Cheriyan 30/06/2012
Sharieff
Yesu / Sadasivan
21/06/2012
Scrap
Daily Meeting Minute
Tom Thomas A. K Kutty
Status : Responsibilities & actions initiated Completion of actions All actions complete &Target date fixed new standard achieved
Supplier name :MRM -1 at (supplier name) on (Date)
Teemag Enterprises Pvt Ltd Unit - 4
MRM - 4 at DEEYEM CNC Machining Pvt. Ltd. on 20.06.2012
BOSCH ADVANCE CLUSTER 201242
Quality Circles
March 2012
April 2012
May 2012
June 2012
Q √ Hanumanth
C Cheriyan
P Prasanna
D Bharathan
S Anthony kumar
Sanil
QC Theme
QC members.
No of QC Teams Formed
% Employee ParticipationTotal
Employees
20 Nill 30% 40%
Supplier name :MRM -1 at (supplier name) on (Date)
Teemag Enterprises Pvt Ltd Unit - 4
MRM - 4 at DEEYEM CNC Machining Pvt. Ltd. on 20.06.2012
BOSCH ADVANCE CLUSTER 201243
Quality Circles
Sl. No. Name of QC Team
No of members
Problem Selected
Current Status
Upper limitExpected Benefits
Planned date of completion
2 Team - 2 5 Aug End 2012
Productvity increase
30-05-20121 Team -1 6 Internal Rejection. 737 500 ppm
Supplier name :MRM -1 at (supplier name) on (Date)
Teemag Enterprises Pvt Ltd Unit - 4
MRM - 4 at DEEYEM CNC Machining Pvt. Ltd. on 20.06.2012
BOSCH ADVANCE CLUSTER 201244
Delivery Performance
0.0
20.0
40.0
60.0
80.0
100.0
2010 20112012 YTD Jan Feb Mar Apr May June Jul Aug Sep Oct Nov Dec
%
Delivery Fulfillmeent Target
Desired Trend ↑
Note : 1) YTD – Update cumulative value, up to the MRM month
Supplier name :MRM -1 at (supplier name) on (Date)
Teemag Enterprises Pvt Ltd Unit - 4
MRM - 4 at DEEYEM CNC Machining Pvt. Ltd. on 20.06.2012
BOSCH ADVANCE CLUSTER 201245
Actions for improving Delivery Performance
# Description / Problem Corrective Action Responsible Due Date Status
Status : Planned; In Progress; Observation/Check; Completed/Further Improvement
Already at 100 %
Supplier name :MRM -1 at (supplier name) on (Date)
Teemag Enterprises Pvt Ltd Unit - 4
MRM - 4 at DEEYEM CNC Machining Pvt. Ltd. on 20.06.2012
BOSCH ADVANCE CLUSTER 201246
OEE % Desired Trend ↑
0
10
20
30
40
50
60
70
80
90
100
201020112012 YTD Jan Feb Mar Apr May June Jul Aug Sep Oct Nov Dec
%
OEE (%) Target
Supplier name :MRM -1 at (supplier name) on (Date)
Teemag Enterprises Pvt Ltd Unit - 4
MRM - 4 at DEEYEM CNC Machining Pvt. Ltd. on 20.06.2012
BOSCH ADVANCE CLUSTER 201248
Machine Breakdown (Hrs)
0
100
200
300
400
500
2010 2011 2012YTD
Jan Feb Mar Apr May June Jul Aug Sep Oct Nov Dec
Hrs
Breakdown(Hrs)/month Upper Limit
Desired Trend ↓
Note : 1) YTD – Update average value, up to the MRM month
Supplier name :MRM -1 at (supplier name) on (Date)
Teemag Enterprises Pvt Ltd Unit - 4
MRM - 4 at DEEYEM CNC Machining Pvt. Ltd. on 20.06.2012
BOSCH ADVANCE CLUSTER 201249
Actions for reducing Machine Breakdown
# Description / Problem Corrective Action Responsible Due Date Status
1 Motor confirmed defective Spare motor procured Management Mar 12
2 General Machine conditionPreventive maintenance / Total refurbishing planned
Production deptContinuous / Dec ‘12
Status : Planned; In Progress; Observation/Check; Completed/Further Improvement
Supplier name :MRM -1 at (supplier name) on (Date)
Teemag Enterprises Pvt Ltd Unit - 4
MRM - 4 at DEEYEM CNC Machining Pvt. Ltd. on 20.06.2012
BOSCH ADVANCE CLUSTER 201250
Inventory Turn Ratio - ITR
0
2
4
6
8
10
12
14
16
2010 2011 2012YTD
Jan Feb Mar Apr May June Jul Aug Sep Oct Nov Dec
No.
ITR Target
Desired Trend ↑
Supplier name :MRM -1 at (supplier name) on (Date)
Teemag Enterprises Pvt Ltd Unit - 4
MRM - 4 at DEEYEM CNC Machining Pvt. Ltd. on 20.06.2012
BOSCH ADVANCE CLUSTER 201251
Inventory Control – Red, Grey, Green Inventory Red Grey Green Inventory
Supplier name :MRM -1 at (supplier name) on (Date)
Teemag Enterprises Pvt Ltd Unit - 4
MRM - 4 at DEEYEM CNC Machining Pvt. Ltd. on 20.06.2012
BOSCH ADVANCE CLUSTER 201252
Actions for improvement of ITR
# Description / Problem Corrective Action Responsible Due Date Status
1Excess stock due to high fluctuation in customer demand.
Customer should provide monthly requirement
CEO / Production Department /
BOSCHEnd June
Status : Planned; In Progress; Observation/Check; Completed/Further Improvement
Supplier name :MRM -1 at (supplier name) on (Date)
Teemag Enterprises Pvt Ltd Unit - 4
MRM - 4 at DEEYEM CNC Machining Pvt. Ltd. on 20.06.2012
BOSCH ADVANCE CLUSTER 201253
VAPCO
0.00
2.00
4.00
6.00
8.00
10.00
2010 2011 2012YTD
Jan Feb Mar Apr May June Jul Aug Sep Oct Nov Dec
No
.
VAPCO Target
Desired Trend ↑
Note : 1) YTD – Update cumulative value, up to the MRM month
Supplier name :MRM -1 at (supplier name) on (Date)
Teemag Enterprises Pvt Ltd Unit - 4
MRM - 4 at DEEYEM CNC Machining Pvt. Ltd. on 20.06.2012
BOSCH ADVANCE CLUSTER 201255
0
100
200
300
400
500
600
700
800
900
1000
0
2000
4000
6000
8000
10000
12000
14000
16000
18000
20000
2010 2011 2012YTD
Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec
un
its
in
KW
hr
KWhr consumption/month KWhr per lac of sales
Supplier name :MRM -1 at (supplier name) on (Date)
Teemag Enterprises Pvt Ltd Unit - 4
MRM - 4 at DEEYEM CNC Machining Pvt. Ltd. on 20.06.2012
BOSCH ADVANCE CLUSTER 201256
I E D I E D I E D I E D I E D I E D I E D I E D I E D1 1 0 1 1 1 123456789
101112
Muri MuraMovement Processing DefectivesWaiting TransportationZone No. Description
Over production Inventory
I : Mudas IdentifiedE : EliminatedD : Documented
Muda eliminated is less than 60%
Cumulative till May.2012
Topic : 3M (Waste Elimination)
Supplier name :MRM -1 at (supplier name) on (Date)
Teemag Enterprises Pvt Ltd Unit - 4
MRM - 4 at DEEYEM CNC Machining Pvt. Ltd. on 20.06.2012
BOSCH ADVANCE CLUSTER 201257
Company Front view and Scrap Bin ViewScrap Bin View
Company Front View
Category Value, in Rs.
Process Scrap
Packaging Scrap
Process Reject
Total Value of Scrap generated
Total Value of RM Consumed
% Scrap value
No. of Kaizens done to reduce Scrap
Category Target Actual
Scarp Disposal Frequency per month 25
Scrap Yard Area, Sq. M
Last Month, Sq.m
Current Month, Sq. M
0
Hazardous Scarp Nil Nil
Mar-12
Not covered. Scrap yard not finalized
Due by July ‘12
Supplier name :MRM -1 at (supplier name) on (Date)
Teemag Enterprises Pvt Ltd Unit - 4
MRM - 4 at DEEYEM CNC Machining Pvt. Ltd. on 20.06.2012
BOSCH ADVANCE CLUSTER 201258
#Area / Machine / Tool No. of Setups
Before
No.of Setups After
Changeover
Time Before
Changeover
Time After
Status
1
2
3
4
5
6
7
Σ= All Zones Total
SMED – Quick Changeover
Status : Planned; In Progress; Observation/Check; Completed/Further Improvement
Not Covered
Supplier name :MRM -1 at (supplier name) on (Date)
Teemag Enterprises Pvt Ltd Unit - 4
MRM - 4 at DEEYEM CNC Machining Pvt. Ltd. on 20.06.2012
BOSCH ADVANCE CLUSTER 201259
Training and its Effectiveness
# Training Imparted Score % Covered%
EffectivenessImprovement Action Status
1 5S 60 100 60Monthly audit to be conducted on
20th of every month
2 Suggestions/ Kaizens 75 100 30 In CEO’s Mthly. Discussion agenda.
3 Safety 100 100 60Monthly audit to be conducted on
20th of every month
4 Poka Yoke 60 100 50 Tgt. 2/Qtr. If possible (less scope)
5 Basic Quality Tools 60 100 70 More areas being targeted
6 Quality control circle 60 100To be
evaluated
Team has been formed and activities under progress due end
May
7 Inventory Management 40 30To be
evaluatedTo be worked out
8 Energy ConservationNot
Covered
9 SMEDNot
Covered
Status : Planned; In Progress; Observation/Check; Completed/Further Improvement
Supplier name :MRM -1 at (supplier name) on (Date)
Teemag Enterprises Pvt Ltd Unit - 4
MRM - 4 at DEEYEM CNC Machining Pvt. Ltd. on 20.06.2012
BOSCH ADVANCE CLUSTER 201260
Zone wise - Total Employee Involvement
Zonal No
Name of AreaTotal employees - Nos
5S Score-
%
Suggestions – Nos Cum.
Accidents Nos– Cum.
Absenteeism- aver.
%
Training effectiveness - %
1 Production 18 74 7 Nil 4 60
2 Assembly NA NA NA NA NA NA
3 Store NA NA NA NA NA NA
4 Despatch NA NA NA NA NA NA
5 Office 2 60 Nil Nil Nil 60
6 Scrap yard NA NA NA NA NA NA
7 Quality 2 74 1 Nil Nil 60
8
9
Supplier name :MRM -1 at (supplier name) on (Date)
Teemag Enterprises Pvt Ltd Unit - 4
MRM - 4 at DEEYEM CNC Machining Pvt. Ltd. on 20.06.2012
BOSCH ADVANCE CLUSTER 201261
Sl. No
Learnings Courtesy
(name of company)
Implemented Pending
1 Separate Inspection Cell M/s Aditya Auto Components
Discussed and dropped
2 Work station design near the machines (display of drawings, statistics, storage of tools etc.)
ESBEE Precision Industries √
3 Improved component cleaning station DAS CNC √
4
5
Learnings from other cluster members
Supplier name :MRM -1 at (supplier name) on (Date)
Teemag Enterprises Pvt Ltd Unit - 4
MRM - 4 at DEEYEM CNC Machining Pvt. Ltd. on 20.06.2012
BOSCH ADVANCE CLUSTER 201262
ThanksThanks
to allto all
22nd June – 1st July 2012Palace Grounds
Bangalore Palace