Shriram Piston
Shriram Piston
Shriram Piston
SLIDE NO. 1
Presenter : J.P.Garyali
Date : 19th March 2008
SLIDE NO. 2
SLIDE NO. 3
2. BRIEF HISTORY
Major Milestones
1993
DIVERSIFICATION INTO MANUFACTURE OF
TPM Milestones
2000
1995
2004
2005
2007
2006
FOR
SLIDE NO. 4
RINGS
14 12
(Million Nos.)
9.5 4.7 3.7 7.0
12.0
GOOD
(Million Nos.)
70 60 50 40 30 20 10 0
(Million Nos.)
36 23 30
(Million Nos.)
54
65
GOOD
10 8 6 4 2 0
2000
2002
2004
2006
Year
2008 Plan
2000
2002
Year
2004
2006
2008 Plan
PINS
ENGINE VALVES
14 12
(Million Nos.)
7.0 4.7 3.7
12.0 9.5
GOOD
(Million Nos.)
25 20 15 10 5 0
(Million Nos.)
15.5 10.0 4.7 3.5 2000 2002 2004 2006
20.0
GOOD
(Million Nos.)
10 8 6 4 2 0
2000
2002
Year
2004
2006
2008 Plan
Year
2008 Plan
SLIDE NO. 5
4. FOREIGN COLLABORATIONS
PISTONS
1. 3.
KOLBENSHMIDT -GERMANY
(Collaboration since 1972)
PISTONS
2.
ENGINE VALVES
4.
FUJI OOZX JAPAN
(Collaboration since 1993)
HF
HONDA FOUNDRY JAPAN
(Collaboration since 1989)
SLIDE NO. 6
5. CERTIFICATIONS RECEIVED
2007 GLOBAL CUSTOMER SPECIFIC QUALITY SYSTEMS
TS 16949
2003
OHSAS 18001
2001
ISO 14001
1999 1994
QS 9000
ISO 9001
SLIDE NO. 7
KIA MOTORS
RIKEN
SLIDE NO. 8
JOURNEY TOWARDS
SLIDE NO. 9
SLIDE NO. 10
Plant
Plant Steering Committee
Pillar Sub-committees
Planned Maintenance Quality Maintenance Initial Control Education & Training Office TPM Safety Health & Env.
Plants
Plants
Office
R&D
J.H. Circles
J.H. Circles
J.H. Circles
J.H. Circles
SLIDE NO. 11
President
Company Wide TPM Steering Committee Medium & Long term Goals
Pillar Sub-committees
Strategic Projects
New OEM Business in India with Tata Motors New Type Product (Gears) for Global OEM Productivity increase In Piston Line - 5 New International OEM Business Salt core technology for Pistons for Euro IV Engine ERP Implementation New Design for Future Emission norms
J.H. Circles
Kobetsu Kaizen Jishu Hozen Planned Maintenance Quality Maintenance New Equipment Initial Control Education & Training Integrated O TPM Safety Health & Env. R&D (New Product) Information Management Logistics Rationalization of Marketing Network
Plant
Plant Steering Committee Plant TPM Secretariat
Head Office
Head Office Steering Committee
Marketing
Marketing Steering Committee Marketing TPM Secretariat
Plants
. Plants Office
R&D
CPMS
A/cs.
Adms.
O&P
OE Sales
Exp. Mkt.
J.H. Circles
J.H. Circles
J.H. Circles
J.H. Circles
J.H. Circles
J.H. Circles
J.H. Circles
SLIDE NO. 12
Consistency between medium & Long term goals and TPM goals
Level- 4
Corporate Goals : 2007
Vision
World Class Supplier Status World Class Quality at Lowest Cost in India Rs./Mil Turnover :9000 G. Profit :1600 Rs./Mil Turnover :12000 G. Profit :2200
Corporate Goals
Rs./Mil
Rs./Mil
8 Pillars
12 Pillars
12 Pillars
12 Pillars
TPM PART 1
TPM PART - 2
2007
2010
2012
TPM PART 3
TPM PART - 4
YEAR
SLIDE NO. 13
5.
GROSS PROFIT
Cost Structure
TOTAL COST
O.E.E
WORKS EFFICIENCY
RAW MATERIAL COST
VARIABLE COST
FIXED COST
AVAILABILITY RATE
PERFORMANCE RATE
ENERGY COST
PERSONNEL COST
ADMN. COST
FINANCE COST
STARTUP LOSS
SPEED LOSS
INSPECTION LOSS
YIELD LOSS
ENERGY LOSS
OFFICE LOSS
INVENTORY LOSS
IMPROVEMENT THEMES
IMPROVEMENT THEMES
SLIDE NO. 14
5.2 Development & application of NEW PRODUCTION SYSTEM Shriram New Production System (SNPS)
Energy Cost
Labour Cost
Minimum Minimum Improve Reduce Inventory Inventory Process Customer of Raw of work in Capabi- Complaint Process Material -lity
Redesign Reduce Packag- TranspFor Reduce ortation Lower Purchase -ing Yield Cost Cost Cost Loss Product weight
Reduce Online ProcurrSupply ement Cycle of time Raw of Material Raw Material
Single Cellular Multis- Reduction Clubbing Online Elimin- InspecPiece Produc- killing in set Flow tion tion up/adjus. ation of line Tment operation time
For Control Shining Better of Shop Field Hazarfloors Perfordous mance chemicals
SLIDE NO. 15
1.
Focus Market
4. Sequence/Timing
Speed of expansion? Sequence of initiatives?
4.
Sequence/ Timing
5.
Sales & Profit Growth & Leadership
2.
How to get There
3.
How to Win
3. How to win?
Image? Technology? Customization? Product Quality? Reliability? Relationship? Response Time? Price?
SLIDE NO. 16
NS Gears New Type of Products in New Area Strategic New Product development (NPD) Connecting Rods Aluminum Castings Pistons
New Products
Rings
Engine Valves
SLIDE NO. 17
a Ro
SLIDE NO. 18
HO and Marketing
SLIDE NO. 19
5.7 Overall integration of company activities from Suppliers to Customers for smooth operations
On Time Supply
240 Nos.
BACKWARD INTEGRATION
Suppliers Purchase
Information
PRODUCTION
FORWARD INTEGRATION
Marketing
Information
On Time Delivery
31 Countries 10 Companies 38 Nos. 250 Customers
Production Control
Exports OEMs
25 Nos.
Vendors
750 No. of Suppliers/ Vendors Production Value
(Million Rs./Year)
Quality Assurance
Logistics
After Market
6000 6000
Production Value
5190 4312
800 800
1000
4.4
Operating Profit
(Million Rs./Year)
Marketing Cost
(as %age of Sales)
5.0 5
(Million Rs./Year)
595
500
400 400
500
Operating Profit
(Million Rs./Year)
2000 2000
265 1827 205 2001 2002 2003 2004 2005 2006 2007
3.0 3
2 2.0
200 200
00
250
250 0
00
2000
1 1.0
TPM Part 1
Evaluation System
No Formal Evaluation System Formal Evaluation System Introduced
TPM Part 2
Point Based Evaluation System
OEE DOL Maintenance Quality Control Guidance on 5 S Self Certified Suppliers Direct On Line
70 60 50 40 30 20 10 0
TPM Part 1
Rank Based System
TPM Part 2
Deliveries Trend
100%
(%)
20 20 20 40 30 30 30 30 40 40 40 10 10
2000 2002 2004 2006
Vendor Guidance
Incoming Quality Inspection Vendor Quality Audit Quality Certificatio n
No Formal Guidance
All Components No Mechanism for Audit No Quality Certification
Online Inspection
Self Certified/ DOL Supplies (%) 60 Self Certified 0
2003 2004 2005 GOO D
Delivery Frequency
Monthly Deliveries
Weekly Deliveries
Daily Deliveries
Online
75%
50
Online Daily
Weekly
50%
25%
50
50
0%
10
2007
Selected Components
Random Sampling
30
2006 2007
DOL
Segment-wise Sales
7000 6000 5000 4000 3000 2000 1000 0
(Million Rs.)
5277
1099
6300
1260
3709
688 3465 2947 1972
2109
327 968 872
2000
2518
375 1263 1048
2004
Quarterly Audit
12
879
2002
1231
1575
2006
2007
0
2001 2002 2003 2004 2005 2006
0.5
2007
Logistics / Marketing
Certified Suppliers/Vendors
(%)
100% 75% 50% 25%
550 725 345 250 225 200 0 0 25 0 20 5 35 8 22 10 25 10 20
TS 16949 QS 9000
Training
Fundamental Skills
Advanced Skills
ISO 9000
100 80 50 40 35
ISO 9000
0%
2001 2002 2003 2004
Uncertified
2005
2006
Control Method
Supplier /
100%
Quality Penalty
20
25 20
30
75%
25
A Rank
50% 25% 0%
30 15 20 25 40 35 15
2005 2006 2007
Online Packing
15
(Days)
(Nos./Year)
4000 4000
750
750
702
4.0 4
RSOs established
for faster handling of customer enquiries
12
0
2000 2001 2002 2003 2004 2005 2007
Ontime Supplies
(%)
GOOD
On Time Supplies
Fortnightly Supplies
Weekly Supplies
Daily Supplies
100
DOL Supplies
Suppliers 80
100 95 Vendors
75
70
50
2000 2001 2002 2003 2004 2005 2006
Piston
Assembly
Piston
Piston
Kit
Piston
Sub-assembly
Connecting Rod
Rings
Rings
Pin
Rings
Pin
80%
Assembly
2007
Component
Finishing Operations
Semi Finished Operations Intervening Operations Initial operations like Parting/ Shearing Intervening Operations Initial operations like Parting/ Shearing
Semi Finished Operations Intervening Operations Initial operations like Parting/ Shearing
6.5
0.6
1.8 1.2
Logistic Support
Field Godowns
Units
Customers
6 5.5 5 4.5
0.3
2003
0.38
2004
0.45
2005
0.5
2006
Pistons
4
2003 2004 2005 2006 2007
Marketing Cost
GOO D
600 600
4.9
SLIDE NO. 20
JIPM Steps
Intensification of Jishu Hozen Activity Step -5 Step -4 Step -3 Step -2 Step -1 Autonomous Inspection
JIPM Steps
SLIDE NO. 21
5.9 Implementation Approach for New Steps Approach for New Step-1
General Inspection of Equipment from Quality Perspective . ( Vibrations, Leveling & Static Accuracy)
SLIDE NO. 22
SLIDE NO. 23
Zero Leakage
Zero Defect
Zero Accident
SLIDE NO. 24
New Approach
Maintenance skill
RESTORE DETERIORATION & IMPROVE WEAKNESS EVALUATE EQUIPMENT & GRASP PRESENT STATUS
SLIDE NO. 25
Example
1. Reduction in set up time. 2. Reduction in cycle time. 3. Line balancing by de bottlenecking. Approach in Piston Plant for Doubling Production 4. On line inspection. 5. Challenging the lunch hour. 6. Outsourcing the rough operations etc.
SLIDE NO. 26
WIP WIP Process C
Inspect ion Packing
Batch Process
Process A
Machine
WIP
WIP
Line Process
Process A
Machine
Inspect ion
Packing
WIP
WIP
Packing
Process A
Machine
Process B
Process C
Inspect ion
SLIDE NO. 27
7. People Development
Classroom Trainings On Job Trainings
OEE Focused Equipment Structure Jishu Hozen OEE Tree Equipment
O.E.E. IN %
Kaizen Ability Quality Monitoring Setup & Adjustment OEE Focused Equipment Structure Jishu Hozen
Vibration Pen
AVAILABILITY
100
AVAILABI LITY IN %
O.E.E. CHART
100 95 90 85 80 75
GOOD 88 85 79 86 89 88 90 91 91
TARGET
90%
70
70 65 60 55 50 45 40 35 30 25 20
(BENCHMARK)
56
36
36%
2007
JAN-00
2000
2001
2002
2003
2004
2005
2006
Apr-07
May-07
Jun-07
Jul-07
(TARG ET )
MONTH
Function Chart
PERFORMANCE RATE
TARGET
PER FORM AN CE R ATE IN %
95 90 85
95 92
96
98
97
96
96
95
95
96
95
96%
80 78 78% 75 70 65 (BENCHMAR K) 60
JAN-00 2000 2001 2002 2003 2004 2005 2006 Apr- 07 May-07 Jun-07 Jul-07
GOOD
87 82 73
90
92
93
93
95
95
96
TARGET 98.9 99.48 99 .83 99. 97 9 9.95 99.9 6 99 .96 99 .98 99.99 99.99 9 9.98 99.99 100 %
95%
98 96 94 92 90 88 86
98.9%
GOOD
GOOD
2007
(T ARGET)
MONTH
(TAR GET)
2007
2001 2002
2003
2004
(BENCHMARK)
JAN- 00
2000
2001
2002
2003
2004
2005
2006
Apr-07
May-07 Jun- 07
Jul-07
2007
(TARGET)
MONTH
MONTH
Set Up Time
14 0 12 0 10 0
I N M N. I
EQUIPMENT FAILURE
10 0 50 0
80
REJECTION DATA
1 00
100
100
100
100
100
100
100
100
100
100
0.5
129
80
GOOD
288
%
80 70 60 50 40
GO OD
B/ D IN M IN.
T IM E IN M IN.
GOOD
60
39
GOOD
%
70 60 50
%
GOO D
0. 8 2
GOOD
0.3
80 60 40 20
56 48 32 23 23 22 21 20 20 21 20
40 30 20 10 0 A g. v Y ar e 200 0 Avg. Year 20 01 Avg. Yea r 2 002 A g. v Y ar e 200 3 Avg. Year 20 04 Avg. Yea r 2 005 A g. A v pr-07 May -07 J un-07 J ul-07 Target Y ar e 200 6 Avg. Yea r 2 000 Avg. Yea r 2 001 Avg. Yea r 2 002 Avg. Yea r 2 003 Avg. Yea r 2 004 Avg. Ye ar 2 005 A g. Apr-0 7 Ma y-07 J un-07 Jul-07 Target v Ye ar 200 6
40
30 20 10 0
0.2
0 .13
20
19 12 0 11 0 0 0 0 0 0
50 0
Avg. Year Av g. Ye ar Avg. Year Av g. Avg. Ye ar Y ear 200 3 Av g. Avg. Ap r- 7 M ay- 07 Jun -07 Jul 07 Targe t 0 Ye ar Y ear 2005 2006
0.1
0.09 0. 4 0 0. 3 0 0.04
Year 2000
Year 2002
Year 2003
Year 2005
Year 2006
A vg. Y ear 20 01
A vg. Y ear 20 03
0.0 2
0. 1 0
0.01
0.0 2
0 .00
0.0
2000
200 1
2002
2004
MONTH
A vg. Ye ar A vg. Y ear A Year A vg. Ye ar A vg. Ye ar A vg. Y ear A . Yea r A pr-07 vg. vg 2000 200 1 20 02 2 003 200 4 200 5 2 006
Ma y- 7 0
Ju n-07
Jul -07
Targ et
Course Modules
I Operate
Dirty machine Leakages Scattered Chips
SLIDE NO. 28
GENERAL HEALTH
HEALTH CHECKUP CAMPS FOR EMPLOYEE & THEIR FAMILY MEMBERS
- Serious Diseases, Cancer, Tumor, TB etc detected at each stage , treatment at Govt. Hospital
SLIDE NO. 29
YOGA CLASSES
SLIDE NO. 30
HOLI
CULTURAL ACTIVITIES
(Celebrating all major festivals)
SLIDE NO. 31
SHRIRAM JAYANTI
SLIDE NO. 32
- Each function is also a communication forum where chief guest &CEO shares the views with the employees.
SLIDE NO. 33
SPORTS ACTIVITIES
- National & State level players in Shooting ball & kabaddi - District level cricket team
SLIDE NO. 34
REWARD & RECOGNITION Worker of the month Blood donors Best suggestor Best sportsman High performing children Best attendance
SLIDE NO. 35
- Direct participation of more than 400 employees - Representation from all plants
SLIDE NO. 36
COMMUNITY DEVELOPMENT
Development of park for children
SLIDE NO. 37
8.
50
TANGIBLE RESULTS
Overall Equipment Efficiency
GOOD
110 100
(% age)
85 54 86
63 % Increase
GOOD
88
Th.Parts/Man/Year
30
%age
25 19
29
32
35
90 80 70 60 50 40 30
87
20
10
20 10
B.M.-1 2000
B.M.-2 2004
Year
Actual 2006
Actual 2007
Target 2008
B.M.-1 2000
B.M.-2 2004
Year
Actual 2006
Actual 2007
Target 2008
82.1
70.5
(As
25
25
GOOD
Reduction by 76 %
20
%age
50 40 30 20
15
10
5
10 0
B.M.-1 2000
B.M.-2 2004
Year
Actual 2006
Actual 2007
Target 2008
B.M.-1 2000
B.M.-2 2004
Year
Actual 2006
Actual 2007
Target 2008
SLIDE NO. 38
(% age)
GOOD
GOOD
15
10.3
%age
10
Nos.
7.3
6.1
5.2
Reduction by 81 %
92 Actual 2006
2.0
78 Actual 2007
0 Target 2008
0
B.M.-1 2000
B.M.-2 2004
Year
B.M.-1 2000
B.M.-2 2004
Year
Actual 2006
Actual 2007
Target 2008
No. of Suggestions
20
(Nos./ Month)
2
(Nos/year/employee)
14.0
785% Increase
GOOD
GOOD
Nos./Year/Employees
15
17.0
Nos./ Month
11.0 10.6
1.5
10
0.58
0.5
1.92
0
B.M - 1 2000 B.M - 2 2004 2006 Actual
0
2007
0
Target 2008
B.M - 1 2000
B.M - 2 2004
2006
Actual 2007
Target 2008
Year
Year
SLIDE NO. 39
9.
INTANGIBLE BENEFITS
SLIDE NO. 40
SLIDE NO. 41
END OF PRESENTATION