Mrm4 advanced cluster teemag_v1

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





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





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





Actions taken and status of points from previous MRMs

Click the link below to view in detail

Teemag_MOM





Part ‘A’

CEO’sCEO’s Presentation Presentation





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





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





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


Hrs

Breakdown(Hrs)/month Target

0102030405060708090

100


%

OEE (%) Target

0.0

20.0

40.0

60.0

80.0

100.0


%

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





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





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





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.





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.





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





Part ‘B’

Coordinator’s PresentationCoordinator’s Presentation

• Overview of all Cluster Initiatives

• Key Indicators and Plans for Improvement

15





Left view

Front view

Back view

Right view

Company Photos





Employee Suggestions

0.0

0.1

0.1

0.2

0.2

0.3

2010 2011 2012 YTD


No

s

Suggestions per Employee/month Target

Desired Trend ↑

Note : 1) YTD – Update cumulative value, up to the corresponding MRM





Kaizens – Overall

0

2

4

6

8

10

12

2010 2011 2012YTD


No

.

Kaizens Identified Kaizens Implemented Target

Desired Trend ↑

Note : 1) YTD – Update cumulative value, up to the MRM month





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





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.





Poka Yoke – Overall

0

0.5

1

1.5

2

2.5

3

3.5

4

4.5

2010 2011 2012YTD


No

.

Poke yoke Identified Poke yoke Implemented Target

Desired Trend ↑






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





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





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





5S Score % Desired Trend ↑

0

10

20

30

40

50

60

70

80

90

100

2010 2011 2012 YTD


%

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





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


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






27

Worst Point Photos

BEFORE

AFTER

Red Tag Area Inspection station

10.04.1210.04.12





Fixed Point Photos

STORE - OIL STORE - MATERIALS

CHIPS SCRAP AREA INSPECTION AREA





Safety Tag Campaign – Overall

0369

1215

2010 20112012 YTDJan Feb Mar Apr May

No

. of

Tag

s

Tags Identified Tags Removed





Safety Photos

BEFORE

AFTER





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↓






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.


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






Absenteeism Desired Trend↓

0.00

2.00

4.00

6.00

8.00

10.00


%

Absenteeism(%) Upper Limit





Actions for reducing Absenteeism


1 To minimize absenteeism

Plan to discuss with like minded CEO’s of the cluster member companies for a common strategy.

CEO






Customer Complaints (PPM)

0

2

4

6

8

10

12

14

2010 2011 2012YTD


PP

M

PPM Upper Limit

Desired Trend ↓






Actions for reducing Customer Complaints



No Customer Complaints





Internal Rejections PPM

0

5000

10000

15000

20000

25000

2010 2011 2012YTD


PP

M

Internal Rejections PPM Upper Limit

Desired Trend ↓






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





Actions for reducing Internal Rejections


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






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





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





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%





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





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 ↑






Actions for improving Delivery Performance



Already at 100 %





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





Machine Breakdown (Hrs)

0

100

200

300

400

500

2010 2011 2012YTD


Hrs

Breakdown(Hrs)/month Upper Limit

Desired Trend ↓

Note : 1) YTD – Update average value, up to the MRM month





Actions for reducing Machine Breakdown


1 Motor confirmed defective Spare motor procured Management Mar 12

2 General Machine conditionPreventive maintenance / Total refurbishing planned

Production deptContinuous / Dec ‘12






Inventory Turn Ratio - ITR

0

2

4

6

8

10

12

14

16

2010 2011 2012YTD


No.

ITR Target

Desired Trend ↑





Inventory Control – Red, Grey, Green Inventory Red Grey Green Inventory





Actions for improvement of ITR


1Excess stock due to high fluctuation in customer demand.

Customer should provide monthly requirement

CEO / Production Department /

BOSCHEnd June






VAPCO

0.00

2.00

4.00

6.00

8.00

10.00

2010 2011 2012YTD


No

.

VAPCO Target

Desired Trend ↑






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


un

its

in

KW

hr

KWhr consumption/month KWhr per lac of sales





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)





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





#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


Not Covered





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






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





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





ThanksThanks

to allto all

22nd June – 1st July 2012Palace Grounds

Bangalore Palace

Mrm4 advanced cluster teemag_v1

Business

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