ANNEXURE VI - QUALITY OBJECTIVES

MEASUREMENT CRITERIA
PLANT MEASURABLES
Capability Utilisation % Planned Productivity % Downtime Hours a b c d e R/M Problem Tool Loading & Unloading Tool Problem M/c Breakdown Process Problem Trial Hours No. of Loadings No. of Repeat Loadings Average Change over Time ( in hours) JCA qty. / Scheduled qty. % Production Value (in lacs) % compliance to Preventive maintenance plan MTTR & MTTB Power Consumption (CPP) No. of Units Consumed ( in thousands) Cost of Power Consumed (in lacs) Cost of Power/ Prod. Cost % Safety No. of Accidents (Human) No. of Accidents (Tools / Machines) Date of last Accident Days since Last Accident Scrap Value R/M Thermoset Rej. % (Cum) R/M Thermoplast Rej. % (Cum) PPM Internal Raw Material Consumption (U-1 only) R/M Consumption / Prod. Value % Finishing Cost Bill % w.r.t. JCA value - TS Bill % w.r.t. JCA value - TP % Extra Work w.r.t. Sale value Packing Cost
Packing Material Cost Consumption (in lacs)

TYPE
S C C

A 1 2 3

4 5 6 7 8 9 10 11

S S S S S S S S

11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 B 1 2 3 4 5 6 7 8

S S C C C S S C C C S S S S S S S S S S S S C C C C C

% of Packing mat. Cost / JCA Value Value of rejection due to packing On-line Packing No. of components under On-line Packing No. of components under On-line Finishing

QUALITY & SYSTEM MEASURABLES

Audits Scheduled / Held Total no. of NCs No. of NCs Open No. of CAPA Raised No. of CAPA open till month Average Days of CAPA closure No. of Days since last Customer concern PPM External

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ANNEXURE VI - QUALITY OBJECTIVES

9 10 11 12 13 C 1 2 3 4 5 6 7 8 a b 9 10 11 12 D 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 E 1 2 3 4 F 1 3 4 5 6 G 1 2 3 Customer Scorecard-Ford & Visteon Avg. GRN clearance time (feeding + printing) No. of complaints from Production (related to material quality) % Compliance to Calibration plan No. of Poke Yokes identified and implemented C S S S S S C C C C S S S S S S S C S C S C C C S S S C S S C S S S S S S C S S S S S C S S

LOGISTICS MEASURABLES
Total Inventory Moulding( in lacs) Inventory Turn-over ratio( Mldg. ) Value of Non-moving R/M Stock(in lacs) Hours lost due to R/M non-availability Cum. Cost reduction achd. (in lacs) Expenses Telephone,Courier/Fax Expenses(in lacs) Travelling Cost (in lacs) Transportation Cost (in lacs) Freight Inward (in lacs) Freight Outward (in lacs) Miscellaneous Purchases (in lacs) Expenses / Sale Value % Premium Freight (Incoming) Supplier Performance Rating (% suppliers below 80%)- Quarterly

DELIVERY/ SALES MEASURABLES

Delivery Performance Rating % Sales Measurables Capacity Booked % Total Sale/ Employee for IPK (in lacs) Total Sale of Moulding(U-1 & 2) in lacs
Sale / Employee for Moulding (U-1 & 2) in lacs

Value of Finished Part Stock ( in lacs) Value of Non-moving Stock (in lacs ) (more than 3 months) Total Value of Sale Return ( in lacs) Premium Freight ( in lacs ) Outgoing Payment Collection Performance % Payment due for more than 90 days(in lacs) Payment Outstanding Factor Value of outstanding C forms (in lacs) Response time to Enquiry Response time to quotation subnmission

STORAGE
Pre-QC GRN lead time Value of R/M stock / cu.ft. Average issuance time (for raw materials) No. of customer complaints (related to qty. & packing)

HRD MEASURABLES
Overtime (in lacs) No. of Trainings (Operators) No. of Trainings (Staff) % Av.Monthly Performance Rating (Deptt.) % Absenteeism

PDC / TOOL ROOM MEASURABLES

PDC Performance No. of Tools for modification Modification Performance %(within 2 trials) Average Lead time ( in days ) for :

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ANNEXURE VI - QUALITY OBJECTIVES

4 5 6 7 H 1 2 3 4 I 1 2 3 4 5 6 C= S= Tool Modification Tool Development In-house Tool Development In-India Tool Development Abroad S S S S

ENGG. / PROJECT MEASURABLES

No. of Projects in Hand No. of Projects due during month No. of Projects completed during month Savings achd. In the month (in thousands) ENGG. / MEMMINGER MEASURABLES Sale of Engineering (in lacs) Total Inventory Engineering( in lacs) Inventory turn over ratio (Engg.) Value of non-moving stock (in lacs) Payment collection performance% Value of outstanding C forms (in lacs) Core Measurables Support Mesurables S S S S S S S S S S

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ANNEXURE VI - QUALITY OBJECTIVES

MEASUREMENT CRITERIA
PLANT MEASURABLES
Capability Utilisation % Planned Productivity % Downtime Hours a b c d e f g R/M Problem ( MARKETING ) R/M Problem ( PURCHASE ) R/M Problem ( PRODUCTION ) Tool Loading & Unloading Tool Problem M/c Breakdown Process Problem Average Change over Time ( in hours) JCA qty. / Scheduled qty. % OEE % compliance to Preventive maintenance plan Power Consumption (CPP) No. of Units Consumed ( in lakhs) Cost of Power Consumed (in lakhs) Cost of Power/ Prod. Cost % Units / Lakh of production Scrap Value R/M Thermoplast Rej. % (Cum) PPM Internal Finishing Cost Bill % w.r.t. JCA value - TP % Extra Work w.r.t. Sale value Packing Cost
Packing Material Cost Consumption (in lakhs)

TYPE
S C C

A 1 2 3

4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 B 20 21 22 23 24 25 26 27 C 28 29 30 31 32 33 34

S S C S S S C C C C S S S S S S

% of Packing mat. Cost / JCA Value On-line Packing No. of components under On-line Packing % of onlline packaging

QUALITY & SYSTEM MEASURABLES

PPM External No of Customer Complaints 8D Status - No of 8Ds open 8D Status - No of 8Ds Closed No. of Deviations Customer Score Card ( Visteon ) Avg. GRN Clearance Time ( in days ) No of days since last Customer Concern Cost of Poor Quallity C C S S S C S C C

PURCHASE / LOGISTICS MEASURABLES

Total Inventory Moulding( in lakhs) Inventory Turn-over ratio Value of Non-moving R/M Stock(in lakhs) Hours lost due to R/M non-availability Frieght Inward ( in lakhs ) Freight Outward ( in Lakhs ) Premium Freight ( Incoming ) in Rs. S C C C S S C

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ANNEXURE VI - QUALITY OBJECTIVES

D 35 36 37 38 39 40 41 42 43 44 45 46 47 E 48 49 50 F 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 71 G 73 74 75 76 77 H 78 79 C=

DELIVERY/ SALES MEASURABLES

Delivery Performance Rating % Sales Measurables Capacity Booked % Total Sale/ Employee for IPC (in lakhs) Total Sale Value in lacs Value of Non-moving Stock (in lakhs ) Value of Finished Stock (in lakhs ) Value of Non-moving Stock (in lakhs ) Total Value of Sale Return ( in lakhs) Premium Freight ( in lakhs ) Outgoing Payment Collection Performance % Payment due for more than 90 days(in lakhs) Payment Outstanding Factor Value of outstanding C forms (in lakhs) C S C C C S S S C S S C S S S C

STORAGE
Pre-QC GRN lead time ( in days ) Average issuance time (for raw materials) No. of customer complaints (related to qty. & packing)

HRD MEASURABLES Safety

No. of Accidents ( Human ) Date of Last Accident Days since last accident No of Failure ( Tools / Machines ) Date of Last Failure Overtime (in lakhs) No. of Trainings (Operators) No. of Trainings (Staff) % of Absentism including Leave Cost of Transport ( in Lakhs ) Cost of Telephone ( in Lakhs ) contract Labour cost ( in Lakhs) Water cost ( in Lakhs) % Av.Monthly Performance Rating (Deptt.) % Absenteeism Cost of Transport ( in Lakhs ) Cost of Telephone ( in Lakhs ) contract Labour cost ( in Lakhs) Water cost ( in Lakhs) Security ( in Lakhs) Fax & Xerox ( in Lakhs ) % Avg monthly performance rating ( Deptt) C C S S S C C C S S S S S S S S S S S S S S

PDC / TOOL ROOM MEASURABLES

No of tools for modification Modification Performance %(within 2 trials) No of Tool complaints in a month No of tools modified for online packing No of PPAP missed S C C S S

ENGG. / PROJECT MEASURABLES

No. of Projects due during month Savings achd. In the month (in thousands) Core Measurables S = Support Measurables Page 5 of 5 C C