PowerPoint Presentation

AchieveExcellence in operations at PTP 1 and 2

1

Productivity improvement at PTP (II) i.e. from 5000 kg to 8000 kg (60 % improvement).More focus towards quality consistency and improvement at both plants . System introduction and addressing primary issues in thrashing plants.Customer Satisfaction and aiming for Customer Delight.Process facility PTP (I) and PTP (II) at par with each other and should have skill & system equilibrium. To achieve

Why to Have excellence in operations ?Assures decisions based on long term success of the enterprise Aligns manufacturing with business and corporate strategiesCreates an awareness of competition Assures long term product, capability and process differentiation from competitorsProvides clear communication between management levels Focuses improvement activities on long-term successPROVIDES A BASIS FOR FUTURE SUCCESS

Understanding Excellence in OperationsImproving Aim :OEs main objective is to reduce operation cost and improve productivity , without affecting quality , timely delivery with customer satisfactionElement 1Element 3Element 2

What is Manufacturing System Design ?Manufacturing system structure designManufacturing strategyDesigning and implementation of KPI Operating policyDesigning and developing various policies Partnerships (with customer)Initiatives towards building and developing relationship with customerOrganization structure detailsClear and visible job description of each individual in organization (Plant)Manufacturing system infrastructure designBuildings, location, capacityContinual improvement initiativesProcess auto Automation / plant modernization / Machine selection / Layout changesSystematic approach towards above all

Element 1We are here

We discuss these tools separatelyKeep in mind that these two are connected. I had to force myself to separate the two items as such. There is no manufacturing system design without a infrastructure design. As you will see most of the tools will imply that. Especially the framework we have come up with

What is Manufacturing Strategy?A game plan for the manufacturing organization to keep itself aligned with the Corporate strategy

It consists of :Long term objectivesStrategiesProgramsInitiatives

To help the business build and maintain a competitive advantage for future successProduct performance, quality & cost Low risk participation, steady businessCustomers BusinessReturn of investmentStockholdersEmployment stabilitySatisfactory salary, working conditionsPromotion opportunitiesEmployeesHourlyManagementPrimary NeedStakeholder

Element 1

Team WorkElement 2And Element 3LeadershipConsidering all above three Elements --- KPI for each in PTP-2 factory are designed as followsTeamwork holds a highly valuable place in organizations, with teamwork among employees every bit as important as collaboration among members of a sporting team..Leaders have an important role to play in coordinating and integrating the activities of these individuals and teams, ensuring that they are aware of the institution's priorities and that they are working towards them.

KPI for PTP (2)Key performance indicatorsAll four Managers at PTP(2) has given objective basis of above Hence forth Performance will be reviewed based on following deliverables.

KPI Improved Productivity

Customer Focus

9

KPI Reduction in over all cost

10

KPI Quality improvement

11

KPI System improvement

KPI System improvement

Responsibility chart and Further line of Actions:Individual MANAGER :After finalizing the objective with respective KPI with each Manager , they have to form a team of their subordinatesEach objective will be further divided in to sub objective depending up on the skill set they have.They will own up entire responsibility till control phase.Factory Team Periodic review mechanism will be introduce for present status and support in there action implementation.Monthly report generation on each KPI will be monitored by ConcernDesigning and developing various policies and framing Initiatives towards building and developing relationship with customerDrafting entire blue print for infrastructure / Layout ,Process auto Automation / Plant modernization / Machine selection / Layout changes

Oct 2013Oct 2013Nov 2013Nov - Dec 2013Jan 2014March 2014

Individual TeamPrasadSpillage ControlYield ImprovementMukhtiarQA MannualReddyWarehouse FIFOVijayaPPCFactory teamFor KPI reviewMK / PBS / BVSSupport BVS sir/ Ratanam sir / Raja sir/ Raghu sir/MK / U Rao / PBS Designing and developing various policies and framing Initiatives towards building and developing relationship with customerDrafting entire blue print for infrastructure / Layout ,Process auto Automation / Plant modernization / Machine selection / Layout changes For AuditMK / UMR / PBS And Down the line Mngrs

Oct 2013

Sample SUB TEAM FOR MUKHTIAR TEAM

Review of Current status to finalizing the Base Level (From where to improve upon)Oct 2013DATA COLLECTION IS IN PROGRESS :

What is Manufacturing System Design ?Manufacturing system structure designManufacturing strategyDesigning and implementation of KPI Operating policyDesigning and developing various policies Partnerships (with customer)Initiatives towards building and developing relationship with customerOrganization structure detailsClear and visible job description of each individual in organization (Plant)Manufacturing system infrastructure designBuildings, location, capacityContinual improvement initiativesProcess auto Automation / plant modernization / Machine selection / Layout changesSystematic approach towards above all

Element 1We are hereWay forward .. Future plan Draft

DraftDraftDesigned Target 2014-15 Followed for forthcoming Planned maintenance DraftFollowed for forthcoming Planned maintenance

We discuss these tools separatelyKeep in mind that these two are connected. I had to force myself to separate the two items as such. There is no manufacturing system design without a infrastructure design. As you will see most of the tools will imply that. Especially the framework we have come up with

First draft of policy :

Arial View: PTP 2

AchieveExcellence in operations at PTP 1 and 2

Thanks

LakshyaProductivity improvement at PTP (II) i.e. from 5000 kg to 8000 kg (60 % improvement).

LakshyaSystem introduction and addressing primary issues in thrashing plants.

LakshyaCustomer Satisfaction and aiming for Customer Delight.

LakshyaProcess facility PTP (I) and PTP (II) at par with each other and should have skill & system equilibrium.

LakshyaMore focus towards quality consistency and improvement at both plants

Excellence in operations at PTP 1 and 2

Consolidated MK

NameObjective Improved Productivity Customer Focus Reduction in Overhead cost Quality improvementSystem improvementInnovation at WorkPrasad 1 Phase one 10% improvement in throughputa2Designing process Audit format and executing first audit. (Reference- karedu plant audit by customer)a3Process Yield improvement.a4Optimum utilization of Production work strength. No extra manpowera5Spillage control and improvement at production halla6Operation diary introduction to each key process eqpt.a7Introduction of SOP / Dos and donts at shop floora8Re dryer automation in-house or through vendora9Introduction of 5 min 5's at production halla

Mukhtar Ahmd.1 Reduction in non-conformity product at shop floor.a2 As a part of consistency in quality - Designing and developing Quality control manual / judgment standard manual and imparting the training to all concern.a3Effective utilization of resources - consumables used for boiler and RO planta4Effective Engg. Manpower utilization by more in-house work execution avoiding vendor cost.a5 More QA focus - Daily QA report preparation and circulating to concern.a6Weekly quality report meeting and monthly Report system to bring Quality awareness in lime light.a7 Root Cause analysis of breakdowna8Introduction of online offline check sheet (Implementation of Karedu plant check sheet with little modification)a9Establishing communication system at plant.a10Ph Boosted drinking water for plant people.a

Reddy1Introducing first in first out (FIFO) at all ware houses for better Productivity a2Better ware house management/ control for addressing Customer compliant.a3Reduction in Damage at warehouse due to improper handlinga4Infestation monitoring and control at ware housesa5MIS / Barcode effective utilizationa6Better visual 5S at all ware housesa

Vijaya1Timely reporting of Production Highlight to HOa2PPC contact person for factorya3Monitoring Customer visit to factory through self-designed protocol and improvement a4All invoice and work order track record updating on daily basisa5Feasibility study and introduction of Time office for effective utilisation of manpowera6Display of Weekly performance chart of quality achievement to bring more quality awareness and further improvement in plant.a7Key writer role in Daily Factory meeting. Updating and circulatinga8Training need identification in consultation with concern and execution of samea9Head the safety related movement in plant.a

Consolidated BVS 1AreaObjectivesPrasadMukhtarReddyVijayaImproved productivity1 Phase one 10% improvement in throughputa2 Reduction in non-conformity product at shop floor.a3Introducing first in first out (FIFO) at all ware houses for better Productivity a4Timely reporting of Production Highlight to HOa5PPC contact person for factorya

Customer focus1Designing process Audit format and executing first audit. (Reference- karedu plant audit by customer)a2 As a part of consistency in quality - Designing and developing Quality control manual / judgment standard manual and imparting the training to all concern.a3Better ware house management/ control for addressing Customer compliant.a4Monitoring Customer visit to factory through self-designed protocol and improvement a

Reduction in over all cost1Process Yield improvement.a2Optimum utilization of Production work strength. No extra manpowera3Effective utilization of resources - consumables used for boiler and RO planta4Effective Engg. Manpower utilization by more in-house work execution avoiding vendor cost.a5Reduction in Damage at warehouse due to improper handlinga6All invoice and work order track record updating on daily basisa7Feasibility study and introduction of Time office for effective utilisation of manpowera

Quality improvement1Spillage control and improvement at production halla2 More QA focus - Daily QA report preparation and circulating to concern.a3Weekly quality report meeting and monthly Report system to bring Quality awareness in lime light.a4Infestation monitoring and control at ware housesa5Display of Weekly performance chart of quality achievement to bring more quality awareness and further improvement in plant.a

System imporovement1Operation diary introduction to each key process eqpt.a2Introduction of SOP / Dos and donts at shop floora3 Root Cause analysis of breakdowna4Introduction of online offline check sheet (Implementation of Karedu plant check sheet with little modification)a5MIS / Barcode effective utilizationa6Key writer role in Daily Factory meeting. Updating and circulatinga

Innovation at work1Re dryer automation in-house or through vendora2Introduction of 5 min 5's at production halla3Establishing communication system at plant.a4Ph Boosted drinking water for plant people.a5Better visual 5S at all ware housesa6Training need identification in consultation with concern and execution of samea7Head the safety related movement in plant.a

Consolidated MK

NameObjective Improved Productivity Customer Focus Reduction in Overhead cost Quality improvementSystem improvementInnovation at WorkPrasad 1 Phase one 10% improvement in throughputa2Designing process Audit format and executing first audit. (Reference- karedu plant audit by customer)a3Process Yield improvement.a4Optimum utilization of Production work strength. No extra manpowera5Spillage control and improvement at production halla6Operation diary introduction to each key process eqpt.a7Introduction of SOP / Dos and donts at shop floora8Re dryer automation in-house or through vendora9Introduction of 5 min 5's at production halla

Mukhtar Ahmd.1 Reduction in non-conformity product at shop floor.a2 As a part of consistency in quality - Designing and developing Quality control manual / judgment standard manual and imparting the training to all concern.a3Effective utilization of resources - consumables used for boiler and RO planta4Effective Engg. Manpower utilization by more in-house work execution avoiding vendor cost.a5 More QA focus - Daily QA report preparation and circulating to concern.a6Weekly quality report meeting and monthly Report system to bring Quality awareness in lime light.a7 Root Cause analysis of breakdowna8Introduction of online offline check sheet (Implementation of Karedu plant check sheet with little modification)a9Establishing communication system at plant.a10Ph Boosted drinking water for plant people.a

Reddy1Introducing first in first out (FIFO) at all ware houses for better Productivity a2Better ware house management/ control for addressing Customer compliant.a3Reduction in Damage at warehouse due to improper handlinga4Infestation monitoring and control at ware housesa5MIS / Barcode effective utilizationa6Better visual 5S at all ware housesa

Vijaya1Timely reporting of Production Highlight to HOa2PPC contact person for factorya3Monitoring Customer visit to factory through self-designed protocol and improvement a4All invoice and work order track record updating on daily basisa5Feasibility study and introduction of Time office for effective utilisation of manpowera6Display of Weekly performance chart of quality achievement to bring more quality awareness and further improvement in plant.a7Key writer role in Daily Factory meeting. Updating and circulatinga8Training need identification in consultation with concern and execution of samea9Head the safety related movement in plant.a

Consolidated BVS 1AreaObjectivesPrasadMukhtarReddyVijayaImproved productivity1 Phase one 10% improvement in throughputa2 Reduction in non-conformity product at shop floor.a3Introducing first in first out (FIFO) at all ware houses for better Productivity a4Timely reporting of Production Highlight to HOa5PPC contact person for factorya

Customer focus1Designing process Audit format and executing first audit. (Reference- karedu plant audit by customer)a2 As a part of consistency in quality - Designing and developing Quality control manual / judgment standard manual and imparting the training to all concern.a3Better ware house management/ control for addressing Customer compliant.a4Monitoring Customer visit to factory through self-designed protocol and improvement a

Reduction in over all cost1Process Yield improvement.a2Optimum utilization of Production work strength. No extra manpowera3Effective utilization of resources - consumables used for boiler and RO planta4Effective Engg. Manpower utilization by more in-house work execution avoiding vendor cost.a5Reduction in Damage at warehouse due to improper handlinga6All invoice and work order track record updating on daily basisa7Feasibility study and introduction of Time office for effective utilisation of manpowera

Quality improvement1Spillage control and improvement at production halla2 More QA focus - Daily QA report preparation and circulating to concern.a3Weekly quality report meeting and monthly Report system to bring Quality awareness in lime light.a4Infestation monitoring and control at ware housesa5Display of Weekly performance chart of quality achievement to bring more quality awareness and further improvement in plant.a

System imporovement1Operation diary introduction to each key process eqpt.a2Introduction of SOP / Dos and donts at shop floora3 Root Cause analysis of breakdowna4Introduction of online offline check sheet (Implementation of Karedu plant check sheet with little modification)a5MIS / Barcode effective utilizationa6Key writer role in Daily Factory meeting. Updating and circulatinga

Innovation at work1Re dryer automation in-house or through vendora2Introduction of 5 min 5's at production halla3Establishing communication system at plant.a4Ph Boosted drinking water for plant people.a5Better visual 5S at all ware housesa6Training need identification in consultation with concern and execution of samea7Head the safety related movement in plant.a

Sheet1AreaObjectivesPrasadMukhtarReddyVijayaCustomer focus1Designing process Audit format and executing first audit. (Reference- karedu plant audit by customer)a2 As a part of consistency in quality - Designing and developing Quality control manual / judgment standard manual and imparting the training to all concern.a3Better ware house management/ control for addressing Customer compliant.a4Monitoring Customer visit to factory through self-designed protocol and improvement a

Reduction in over all cost1Process Yield improvement.a2Optimum utilization of Production work strength. No extra manpowera3Effective utilization of resources - consumables used for boiler and RO planta4Effective Engg. Manpower utilization by more in-house work execution avoiding vendor cost.a5Reduction in Damage at warehouse due to improper handlinga6All invoice and work order track record updating on daily basisa7Feasibility study and introduction of Time office for effective utilisation of manpowera

Quality improvement1Spillage control and improvement at production halla2 More QA focus - Daily QA report preparation and circulating to concern.a3Weekly quality report meeting and monthly Report system to bring Quality awareness in lime light.a4Infestation monitoring and control at ware housesa5Display of Weekly performance chart of quality achievement to bring more quality awareness and further improvement in plant.a

System imporovement1Operation diary introduction to each key process eqpt.a2Introduction of SOP / Dos and donts at shop floora3 Root Cause analysis of breakdowna4Introduction of online offline check sheet (Implementation of Karedu plant check sheet with little modification)a5MIS / Barcode effective utilizationa6Key writer role in Daily Factory meeting. Updating and circulatinga

Innovation at work1Re dryer automation in-house or through vendora2Introduction of 5 min 5's at production halla3Establishing communication system at plant.a4Ph Boosted drinking water for plant people.a5Better visual 5S at all ware housesa6Training need identification in consultation with concern and execution of samea7Head the safety related movement in plant.a

Consolidated MK

NameObjective Improved Productivity Customer Focus Reduction in Overhead cost Quality improvementSystem improvementInnovation at WorkPrasad 1 Phase one 10% improvement in throughputa2Designing process Audit format and executing first audit. (Reference- karedu plant audit by customer)a3Process Yield improvement.a4Optimum utilization of Production work strength. No extra manpowera5Spillage control and improvement at production halla6Operation diary introduction to each key process eqpt.a7Introduction of SOP / Dos and donts at shop floora8Re dryer automation in-house or through vendora9Introduction of 5 min 5's at production halla

Mukhtar Ahmd.1 Reduction in non-conformity product at shop floor.a2 As a part of consistency in quality - Designing and developing Quality control manual / judgment standard manual and imparting the training to all concern.a3Effective utilization of resources - consumables used for boiler and RO planta4Effective Engg. Manpower utilization by more in-house work execution avoiding vendor cost.a5 More QA focus - Daily QA report preparation and circulating to concern.a6Weekly quality report meeting and monthly Report system to bring Quality awareness in lime light.a7 Root Cause analysis of breakdowna8Introduction of online offline check sheet (Implementation of Karedu plant check sheet with little modification)a9Establishing communication system at plant.a10Ph Boosted drinking water for plant people.a

Reddy1Introducing first in first out (FIFO) at all ware houses for better Productivity a2Better ware house management/ control for addressing Customer compliant.a3Reduction in Damage at warehouse due to improper handlinga4Infestation monitoring and control at ware housesa5MIS / Barcode effective utilizationa6Better visual 5S at all ware housesa

Vijaya1Timely reporting of Production Highlight to HOa2PPC contact person for factorya3Monitoring Customer visit to factory through self-designed protocol and improvement a4All invoice and work order track record updating on daily basisa5Feasibility study and introduction of Time office for effective utilisation of manpowera6Display of Weekly performance chart of quality achievement to bring more quality awareness and further improvement in plant.a7Key writer role in Daily Factory meeting. Updating and circulatinga8Training need identification in consultation with concern and execution of samea9Head the safety related movement in plant.a

Consolidated BVS 1AreaObjectivesPrasadMukhtarReddyVijayaImproved productivity1 Phase one 10% improvement in throughputa2 Reduction in non-conformity product at shop floor.a3Introducing first in first out (FIFO) at all ware houses for better Productivity a4Timely reporting of Production Highlight to HOa5PPC contact person for factorya

Customer focus1Designing process Audit format and executing first audit. (Reference- karedu plant audit by customer)a2 As a part of consistency in quality - Designing and developing Quality control manual / judgment standard manual and imparting the training to all concern.a3Better ware house management/ control for addressing Customer compliant.a4Monitoring Customer visit to factory through self-designed protocol and improvement a

Reduction in over all cost1Process Yield improvement.a2Optimum utilization of Production work strength. No extra manpowera3Effective utilization of resources - consumables used for boiler and RO planta4Effective Engg. Manpower utilization by more in-house work execution avoiding vendor cost.a5Reduction in Damage at warehouse due to improper handlinga6All invoice and work order track record updating on daily basisa7Feasibility study and introduction of Time office for effective utilisation of manpowera

Quality improvement1Spillage control and improvement at production halla2 More QA focus - Daily QA report preparation and circulating to concern.a3Weekly quality report meeting and monthly Report system to bring Quality awareness in lime light.a4Infestation monitoring and control at ware housesa5Display of Weekly performance chart of quality achievement to bring more quality awareness and further improvement in plant.a

System imporovement1Operation diary introduction to each key process eqpt.a2Introduction of SOP / Dos and donts at shop floora3 Root Cause analysis of breakdowna4Introduction of online offline check sheet (Implementation of Karedu plant check sheet with little modification)a5MIS / Barcode effective utilizationa6Key writer role in Daily Factory meeting. Updating and circulatinga

Innovation at work1Re dryer automation in-house or through vendora2Introduction of 5 min 5's at production halla3Establishing communication system at plant.a4Ph Boosted drinking water for plant people.a5Better visual 5S at all ware housesa6Training need identification in consultation with concern and execution of samea7Head the safety related movement in plant.a

Sheet1AreaObjectivesPrasadMukhtarReddyVijayaReduction in over all cost1Process Yield improvement.a2Optimum utilization of Production work strength. No extra manpowera3Effective utilization of resources - consumables used for boiler and RO plant and Powera4Effective Engg. Manpower utilization by more in-house work execution avoiding vendor cost.a5Reduction in Damage at warehouse due to improper handlinga6All invoice and work order track record updating on daily basisa7Feasibility study and introduction of Time office for effective utilisation of manpowera

Quality improvement1Spillage control and improvement at production halla2 More QA focus - Daily QA report preparation and circulating to concern.a3Weekly quality report meeting and monthly Report system to bring Quality awareness in lime light.a4Infestation monitoring and control at ware housesa5Display of Weekly performance chart of quality achievement to bring more quality awareness and further improvement in plant.a

System imporovement1Operation diary introduction to each key process eqpt.a2Introduction of SOP / Dos and donts at shop floora3 Root Cause analysis of breakdowna4Introduction of online offline check sheet (Implementation of Karedu plant check sheet with little modification)a5MIS / Barcode effective utilizationa6Key writer role in Daily Factory meeting. Updating and circulatinga

Innovation at work1Re dryer automation in-house or through vendora2Introduction of 5 min 5's at production halla3Establishing communication system at plant.a4Ph Boosted drinking water for plant people.a5Better visual 5S at all ware housesa6Training need identification in consultation with concern and execution of samea7Head the safety related movement in plant.a

Consolidated MK

NameObjective Improved Productivity Customer Focus Reduction in Overhead cost Quality improvementSystem improvementInnovation at WorkPrasad 1 Phase one 10% improvement in throughputa2Designing process Audit format and executing first audit. (Reference- karedu plant audit by customer)a3Process Yield improvement.a4Optimum utilization of Production work strength. No extra manpowera5Spillage control and improvement at production halla6Operation diary introduction to each key process eqpt.a7Introduction of SOP / Dos and donts at shop floora8Re dryer automation in-house or through vendora9Introduction of 5 min 5's at production halla

Mukhtar Ahmd.1 Reduction in non-conformity product at shop floor.a2 As a part of consistency in quality - Designing and developing Quality control manual / judgment standard manual and imparting the training to all concern.a3Effective utilization of resources - consumables used for boiler and RO planta4Effective Engg. Manpower utilization by more in-house work execution avoiding vendor cost.a5 More QA focus - Daily QA report preparation and circulating to concern.a6Weekly quality report meeting and monthly Report system to bring Quality awareness in lime light.a7 Root Cause analysis of breakdowna8Introduction of online offline check sheet (Implementation of Karedu plant check sheet with little modification)a9Establishing communication system at plant.a10Ph Boosted drinking water for plant people.a

Reddy1Introducing first in first out (FIFO) at all ware houses for better Productivity a2Better ware house management/ control for addressing Customer compliant.a3Reduction in Damage at warehouse due to improper handlinga4Infestation monitoring and control at ware housesa5MIS / Barcode effective utilizationa6Better visual 5S at all ware housesa

Vijaya1Timely reporting of Production Highlight to HOa2PPC contact person for factorya3Monitoring Customer visit to factory through self-designed protocol and improvement a4All invoice and work order track record updating on daily basisa5Feasibility study and introduction of Time office for effective utilisation of manpowera6Display of Weekly performance chart of quality achievement to bring more quality awareness and further improvement in plant.a7Key writer role in Daily Factory meeting. Updating and circulatinga8Training need identification in consultation with concern and execution of samea9Head the safety related movement in plant.a

Consolidated BVS 1AreaObjectivesPrasadMukhtarReddyVijayaImproved productivity1 Phase one 10% improvement in throughputa2 Reduction in non-conformity product at shop floor.a3Introducing first in first out (FIFO) at all ware houses for better Productivity a4Timely reporting of Production Highlight to HOa5PPC contact person for factorya

Customer focus1Designing process Audit format and executing first audit. (Reference- karedu plant audit by customer)a2 As a part of consistency in quality - Designing and developing Quality control manual / judgment standard manual and imparting the training to all concern.a3Better ware house management/ control for addressing Customer compliant.a4Monitoring Customer visit to factory through self-designed protocol and improvement a

Reduction in over all cost1Process Yield improvement.a2Optimum utilization of Production work strength. No extra manpowera3Effective utilization of resources - consumables used for boiler and RO planta4Effective Engg. Manpower utilization by more in-house work execution avoiding vendor cost.a5Reduction in Damage at warehouse due to improper handlinga6All invoice and work order track record updating on daily basisa7Feasibility study and introduction of Time office for effective utilisation of manpowera

Quality improvement1Spillage control and improvement at production halla2 More QA focus - Daily QA report preparation and circulating to concern.a3Weekly quality report meeting and monthly Report system to bring Quality awareness in lime light.a4Infestation monitoring and control at ware housesa5Display of Weekly performance chart of quality achievement to bring more quality awareness and further improvement in plant.a

System imporovement1Operation diary introduction to each key process eqpt.a2Introduction of SOP / Dos and donts at shop floora3 Root Cause analysis of breakdowna4Introduction of online offline check sheet (Implementation of Karedu plant check sheet with little modification)a5MIS / Barcode effective utilizationa6Key writer role in Daily Factory meeting. Updating and circulatinga

Innovation at work1Re dryer automation in-house or through vendora2Introduction of 5 min 5's at production halla3Establishing communication system at plant.a4Ph Boosted drinking water for plant people.a5Better visual 5S at all ware housesa6Training need identification in consultation with concern and execution of samea7Head the safety related movement in plant.a

Sheet1AreaObjectivesPrasadMukhtarReddyVijayaQuality improvement1Spillage control and improvement at production halla2 More QA focus - Daily QA report preparation and circulating to concern.a3Weekly quality report meeting and monthly Report system to bring Quality awareness in lime light.a4Infestation monitoring and control at ware housesa5Display of Weekly performance chart of quality achievement to bring more quality awareness and further improvement in plant.a

System imporovement1Operation diary introduction to each key process eqpt.a2Introduction of SOP / Dos and donts at shop floora3 Root Cause analysis of breakdowna4Introduction of online offline check sheet (Implementation of Karedu plant check sheet with little modification)a5MIS / Barcode effective utilizationa6Key writer role in Daily Factory meeting. Updating and circulatinga

Innovation at work1Re dryer automation in-house or through vendora2Introduction of 5 min 5's at production halla3Establishing communication system at plant.a4Ph Boosted drinking water for plant people.a5Better visual 5S at all ware housesa6Training need identification in consultation with concern and execution of samea7Head the safety related movement in plant.a

Consolidated MK

NameObjective Improved Productivity Customer Focus Reduction in Overhead cost Quality improvementSystem improvementInnovation at WorkPrasad 1 Phase one 10% improvement in throughputa2Designing process Audit format and executing first audit. (Reference- karedu plant audit by customer)a3Process Yield improvement.a4Optimum utilization of Production work strength. No extra manpowera5Spillage control and improvement at production halla6Operation diary introduction to each key process eqpt.a7Introduction of SOP / Dos and donts at shop floora8Re dryer automation in-house or through vendora9Introduction of 5 min 5's at production halla

Mukhtar Ahmd.1 Reduction in non-conformity product at shop floor.a2 As a part of consistency in quality - Designing and developing Quality control manual / judgment standard manual and imparting the training to all concern.a3Effective utilization of resources - consumables used for boiler and RO planta4Effective Engg. Manpower utilization by more in-house work execution avoiding vendor cost.a5 More QA focus - Daily QA report preparation and circulating to concern.a6Weekly quality report meeting and monthly Report system to bring Quality awareness in lime light.a7 Root Cause analysis of breakdowna8Introduction of online offline check sheet (Implementation of Karedu plant check sheet with little modification)a9Establishing communication system at plant.a10Ph Boosted drinking water for plant people.a

Reddy1Introducing first in first out (FIFO) at all ware houses for better Productivity a2Better ware house management/ control for addressing Customer compliant.a3Reduction in Damage at warehouse due to improper handlinga4Infestation monitoring and control at ware housesa5MIS / Barcode effective utilizationa6Better visual 5S at all ware housesa

Vijaya1Timely reporting of Production Highlight to HOa2PPC contact person for factorya3Monitoring Customer visit to factory through self-designed protocol and improvement a4All invoice and work order track record updating on daily basisa5Feasibility study and introduction of Time office for effective utilisation of manpowera6Display of Weekly performance chart of quality achievement to bring more quality awareness and further improvement in plant.a7Key writer role in Daily Factory meeting. Updating and circulatinga8Training need identification in consultation with concern and execution of samea9Head the safety related movement in plant.a

Consolidated BVS 1AreaObjectivesPrasadMukhtarReddyVijayaImproved productivity1 Phase one 10% improvement in throughputa2 Reduction in non-conformity product at shop floor.a3Introducing first in first out (FIFO) at all ware houses for better Productivity a4Timely reporting of Production Highlight to HOa5PPC contact person for factorya

Customer focus1Designing process Audit format and executing first audit. (Reference- karedu plant audit by customer)a2 As a part of consistency in quality - Designing and developing Quality control manual / judgment standard manual and imparting the training to all concern.a3Better ware house management/ control for addressing Customer compliant.a4Monitoring Customer visit to factory through self-designed protocol and improvement a

Reduction in over all cost1Process Yield improvement.a2Optimum utilization of Production work strength. No extra manpowera3Effective utilization of resources - consumables used for boiler and RO planta4Effective Engg. Manpower utilization by more in-house work execution avoiding vendor cost.a5Reduction in Damage at warehouse due to improper handlinga6All invoice and work order track record updating on daily basisa7Feasibility study and introduction of Time office for effective utilisation of manpowera

Quality improvement1Spillage control and improvement at production halla2 More QA focus - Daily QA report preparation and circulating to concern.a3Weekly quality report meeting and monthly Report system to bring Quality awareness in lime light.a4Infestation monitoring and control at ware housesa5Display of Weekly performance chart of quality achievement to bring more quality awareness and further improvement in plant.a

System imporovement1Operation diary introduction to each key process eqpt.a2Introduction of SOP / Dos and donts at shop floora3 Root Cause analysis of breakdowna4Introduction of online offline check sheet (Implementation of Karedu plant check sheet with little modification)a5MIS / Barcode effective utilizationa6Key writer role in Daily Factory meeting. Updating and circulatinga

Innovation at work1Re dryer automation in-house or through vendora2Introduction of 5 min 5's at production halla3Establishing communication system at plant.a4Ph Boosted drinking water for plant people.a5Better visual 5S at all ware housesa6Training need identification in consultation with concern and execution of samea7Head the safety related movement in plant.a

Sheet1AreaObjectivesPrasadMukhtarReddyVijayaSystem imporovement1Operation diary introduction to each key process eqpt.a2Introduction of SOP / Dos and donts at shop floora3 Root Cause analysis of breakdowna4Introduction of online offline check sheet (Implementation of Karedu plant check sheet with little modification)a5MIS / Barcode effective utilizationa6Key writer role in Daily Factory meeting. Updating and circulatinga

Innovation at work1Re dryer automation in-house or through vendora2Introduction of 5 min 5's at production halla3Establishing communication system at plant.a4Ph Boosted drinking water for plant people.a5Better visual 5S at all ware housesa6Training need identification in consultation with concern and execution of samea7Head the safety related movement in plant.a

Consolidated MK

NameObjective Improved Productivity Customer Focus Reduction in Overhead cost Quality improvementSystem improvementInnovation at WorkPrasad 1 Phase one 10% improvement in throughputa2Designing process Audit format and executing first audit. (Reference- karedu plant audit by customer)a3Process Yield improvement.a4Optimum utilization of Production work strength. No extra manpowera5Spillage control and improvement at production halla6Operation diary introduction to each key process eqpt.a7Introduction of SOP / Dos and donts at shop floora8Re dryer automation in-house or through vendora9Introduction of 5 min 5's at production halla

Mukhtar Ahmd.1 Reduction in non-conformity product at shop floor.a2 As a part of consistency in quality - Designing and developing Quality control manual / judgment standard manual and imparting the training to all concern.a3Effective utilization of resources - consumables used for boiler and RO planta4Effective Engg. Manpower utilization by more in-house work execution avoiding vendor cost.a5 More QA focus - Daily QA report preparation and circulating to concern.a6Weekly quality report meeting and monthly Report system to bring Quality awareness in lime light.a7 Root Cause analysis of breakdowna8Introduction of online offline check sheet (Implementation of Karedu plant check sheet with little modification)a9Establishing communication system at plant.a10Ph Boosted drinking water for plant people.a

Reddy1Introducing first in first out (FIFO) at all ware houses for better Productivity a2Better ware house management/ control for addressing Customer compliant.a3Reduction in Damage at warehouse due to improper handlinga4Infestation monitoring and control at ware housesa5MIS / Barcode effective utilizationa6Better visual 5S at all ware housesa

Vijaya1Timely reporting of Production Highlight to HOa2PPC contact person for factorya3Monitoring Customer visit to factory through self-designed protocol and improvement a4All invoice and work order track record updating on daily basisa5Feasibility study and introduction of Time office for effective utilisation of manpowera6Display of Weekly performance chart of quality achievement to bring more quality awareness and further improvement in plant.a7Key writer role in Daily Factory meeting. Updating and circulatinga8Training need identification in consultation with concern and execution of samea9Head the safety related movement in plant.a

Consolidated BVS 1AreaObjectivesPrasadMukhtarReddyVijayaImproved productivity1 Phase one 10% improvement in throughputa2 Reduction in non-conformity product at shop floor.a3Introducing first in first out (FIFO) at all ware houses for better Productivity a4Timely reporting of Production Highlight to HOa5PPC contact person for factorya

Customer focus1Designing process Audit format and executing first audit. (Reference- karedu plant audit by customer)a2 As a part of consistency in quality - Designing and developing Quality control manual / judgment standard manual and imparting the training to all concern.a3Better ware house management/ control for addressing Customer compliant.a4Monitoring Customer visit to factory through self-designed protocol and improvement a

Reduction in over all cost1Process Yield improvement.a2Optimum utilization of Production work strength. No extra manpowera3Effective utilization of resources - consumables used for boiler and RO planta4Effective Engg. Manpower utilization by more in-house work execution avoiding vendor cost.a5Reduction in Damage at warehouse due to improper handlinga6All invoice and work order track record updating on daily basisa7Feasibility study and introduction of Time office for effective utilisation of manpowera

Quality improvement1Spillage control and improvement at production halla2 More QA focus - Daily QA report preparation and circulating to concern.a3Weekly quality report meeting and monthly Report system to bring Quality awareness in lime light.a4Infestation monitoring and control at ware housesa5Display of Weekly performance chart of quality achievement to bring more quality awareness and further improvement in plant.a

System imporovement1Operation diary introduction to each key process eqpt.a2Introduction of SOP / Dos and donts at shop floora3 Root Cause analysis of breakdowna4Introduction of online offline check sheet (Implementation of Karedu plant check sheet with little modification)a5MIS / Barcode effective utilizationa6Key writer role in Daily Factory meeting. Updating and circulatinga

Innovation at work1Re dryer automation in-house or through vendora2Introduction of 5 min 5's at production halla3Establishing communication system at plant.a4Ph Boosted drinking water for plant people.a5Better visual 5S at all ware housesa6Training need identification in consultation with concern and execution of samea7Head the safety related movement in plant.a

Sheet1AreaObjectivesPrasadMukhtarReddyVijayaInnovation at work1Re dryer automation in-house or through vendora2Introduction of 5 min 5's at production halla3Establishing communication system at plant.a4Ph Boosted drinking water for plant people.a5Better visual 5S at all ware housesa6Training need identification in consultation with concern and execution of samea7Head the safety related movement in plant.a