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CARRIER ENGINEERS PVT. LTD.

Corporate Office :- Plot No. 21, Sector-27A, Faridabad – 121003 Haryana (India)

Phone : 0129 4101673-74

Email : carepl@airtelmail.in, Web : www.carrierengineers.com

Presentation On

SUCCESS STORY

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• Established in year : 1995

• No. of Employees : 120

• Products : High Pressure Hydraulic Fittings

& Transmissions Components.

• Production Facilities :

(In-House) Band Saw Cutting

Rough Turning

CNC Turning

VMC Machining

Cylindrical Grinding

Straightening

Induction Hardening

Automation Drilling

Crimping & MPI Testing

JCB India & United Kingdom

CLAAS India, Germany & France

Terex Equipment Pvt. Ltd.

Telco Construction

• Key Customers :

Unit - I

Unit - III

Unit - II

Export – 30%

Transmission – 35%

Agriculture – 30%

Others – 5%

Company Profile

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Problem Identification

62.0%

3.0%

87.5%

10.8% 72%

22 Nos./Year5.1%

52 Hrs./Mc

18%

010

2030

405060

7080

90100

Product

Efficency

Quality (In-

house)

Delivery Absenteeism Awarness Complaints Rework M/c Breakdowm

(Hrs.)

Non Value

Activity

2009

Awareness

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Productivity:- Productivity was low so we have installed more

machines but we were not able to achieve 100% Delivery.

Process Time:- More Process time required due to lack of knowledge of

advance technique & process capability study.

Absenteeism :- Absenteeism was high as our workforce was plagued with

Low Morale.

Awareness :- Low awareness in our employees for better working culture

& continuous improvement.

Rejection/Rework :- Rejection & rework was high as our operators were

lacking proper training.

Breakdown:- Breakdown was high due to improper monitoring.

Wastage :- More wastage due to not aware to control Non Value Activity &

various types wastage i.e. Oil, Air, Water, Coolant, Energy etc.

Before Joining Cluster Program

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One of our Major Customer M/s

JCB India Ltd. Started a Cluster

Program with CII (Confederation of

Indian Industry) and they have

selected us as one of the participant

in that Cluster Program .

Our 1st visit was held on May-

2010 & Our mentor Mr. Amit Sanghvi

(CII) describe the lot of scope for

improvements in our organization.

On that day our mind set has been

change drastically .

Inspiration of Journey

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Activities started during JCB CII Cluster Program &

create Seven Zones with their Zone Leaders

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Distinctive TEI Initiatives

All activities started during JCB CII Cluster Program

CEO Weekly Contact Program for Operators

In-house Training

Suggestion Day Celebration

Kaizen Day Celebration

Best Working Culture Development

Quality Forum Activity

KENT RO Drinking Water

Safety Awareness Activities

Talent Development Program

Reward & Recognition

CEO Monthly Gate Meeting

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Distinctive TEI Initiatives

All activities started during JCB CII Cluster Program

KENT RO Plant

CEO Monthly Address

Gloves used for

Safety

In-House Training

Facility

Self Safety Culture

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Safety Culture Develop

Safety

Instruction

Safety

Goggles &

Apron

Safety

Gloves

Fire

Extinguisher

(210 Accident Free Days From Jan-2012 to till date )

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CEO Gate Meeting Program

Distinctive TEI Initiatives

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CEO Weekly Contact Program for Operators

Distinctive TEI Initiatives

12 Birth Day Celebration of Employee

Distinctive TEI Initiatives

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Distinctive TEI Initiatives

Best Suggestion Award Celebration of Employee

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Distinctive TEI Initiatives

Best Kaizen Award Celebration of Employee

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Initial Cluster Program Organize on 13-04-2011

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Initial Cluster Program Organize on 13-04-2011

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Advance Cluster Program Organize on 25-06-2012

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Advance Cluster Program Organize on 25-06-2012

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Improvement Journey During Cluster Program

ONE Gms. RM Saving Project – : 266 Kaizen Implemented &

Saving per year Rs. 2.23 Lacs.

ONE Sec. Cycle Time Saving Project – : 478 Kaizen Implemented &

Saving per year Rs. 3.65 Lacs.

Reduce Setting Time Project (SMED) – : 321 Kaizen Implemented total

saving per year Rs. 4.28 Lacs.

Cutting & Hydraulic Saving Project – : 28 Kaizen Implement total

annual saving Rs. 0.71 Lacs.

Energy Saving Project – : 51 Kaizen Implemented total

saving per year Rs. 0.63 Lacs.

Loading/Unloading Time Reduce Project – : 249 Kaizen Implemented &

Saving per year Rs. 1.24 Lacs.

Quality Improvement Project – : 342 Kaizen Implement & total

saving Rs. 2.72 Lacs. per year.

WIP Process Time Reduce Project – : 41 Kaizen Implemented and

total saving Rs. 1.56 Lacs. Per

year

Process Time Reduce Project – : 356 Kaizen Implemented &

Saving Rs. 3.6 Lacs. Per Year

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CEPL KAIZEN TREE

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AFTER

Converted into Slot

type forging – Raw

material required 320

Gms/Pc

86 Sec. Processing

time required . Total Benefit Achieved (Raw Material + Cycle Time Reduce) = Rs. 2.32 Lacs Per Year

BEFORE

Use Flat Type forging –

Raw Material required 380

Gms/Pc

140 Sec. processing

time required for Slot

cutting.

380

320

0

50

100

150

Before After

Forging Weight

140

110

0

50

100

150

Before After

Cycle Time ( Sec.)

1 Gms Saving Project – Forging Process Improvement TOTAL KAIZEN IMPLEMENTED – 197 Nos.

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AFTER

Chuck mounted on

Rotary Table converted

into Horizontal Milling

process.

Benefit Achieved Reduce process Time Rs. 3.65 Lacs

BEFORE

Low Productivity & more

Loading / Unloading time

required due to Vertical

Milling Process.

One Second Saving Project - Productivity Improve

Horizontal Deployment

in Three Components

TOTAL KAIZEN IMPLEMENTED – 378 Nos.

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Employees at all levels are effective problem-solvers and are able to utilize Root Causes Analysis and Corrective Action to solve many operational challenges. Such efforts support the continuous improvement process and have become a routine part of everyone's job function.

Problem-Solving Capability

Best Manufacturing Practices

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PERFORMANCE INDICATORS

SUMMARY

S. No. Key Indicator Name UOM Jun-2010 Jun-2012

1 Customer Complaints Nos. 8 1

2 Customer Return PPM 297 67

3 In-Process Rejection PPM 3759 1132

4 Inventory Turnover Ratio (ITR) Ratio 16.9 24.5

5 VAPCO Ratio 3.8 5.7

6 Delivery Schedule Adherence % 93.9 100

7 Machine Breakdown Hours Hrs. 337 87

8 Absenteeism % 11 2

9 Employee Involvement in

Kaizen

% 34 95.3

10 Sales Turnover (Month Wise) In Cr. 0.88 1.61

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Major Achievements During Cluster Program

Best Quality Award From Our Esteemed

Customer JCB on 09-12-2011

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Best Quality Improvement Award From

Our Esteemed Customer JCB on 20-09-2011

Major Achievements During Cluster Program

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Certification of CII Yr. 2011

Major Achievements During Cluster Program

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For sparing your

valuable time

Our Journey towards Improvement Will be Continue.....