Updated AM QIP Tracker Rev 24.10.15

CEAT Limited
AM TRACKER FOR THE MONTH OF: SEPTEMBER'15

Sr.No
Machine
Objective
AM Step III Certified - Fy'14-15 Q2
B/D Hours
Operational Efficiency
1
TTB 02
Quality : held up/Rework
Safety: No of Incidents
B/D Hours
2
TTB 04
B/D Hours
3
Bead Fillering 12
B/D Hours
4
Bead Fillering 16
B/D Hours
5
BBM 12
B/D Hours
6
NTC 49
Quality : no. of tyres scrap/month
B/D Hours
7
NTB 01
B/D Hours
1
TTC press D0
Quality : Tyre Scrap Nos./Month
B/D Hours
2
Bead Flipper 18
B/D Hours
3
TTB 11
B/D Hours
4
TTBB 13
B/D Hours
1
TTC press C1
B/D Hours
2
TTC press C2
B/D Hours
3
Bead Covering 22
B/D Hours
4
3.5" Extruder
Quality : Scrap/month
B/D Hours
5
TTC press C0
B/D Hours
6
TTC press D2
B/D Hours
7
BBM 15
Quality : Fabric scrap/month
B/D Hours
8
Bead Covering 21
B/D Hours
9
Bead Flipper 07
B/D Hours
10
NTB 02
B/D Hours
1
TTB no. 21
TTB no. 21

B/D Hours
NTB no. 03
B/D Hours
Radial Filler no. 17
B/D Hours
Bead Flipper no 09
B/D Hours
NTC 35
B/D Hours
TTC C 9

1
B/D Hours
TTB no. 19
B/D Hours
Bead Filler 20
B/D Hours
Bale Cutter no 1
B/D Hours
Band building 16
B/D Hours
NTB no. 4
B/D Hours
NTB no. 13
B/D Hours
NTC 48A
Trac
10
11
12
B/D Hours
NTC 36
B/D Hours
TTC B8
B/D Hours
Rad. Building 3A
B/D Hours
1000 CFM
Compressor
B/D Hours
ODR2000,RHEOME Operational Efficiency
TER
NTC 48A
Unit
Hours
%
Kg/Day
Nos.
Hours
%
Kg/Day
Nos.
Hours
%
Kg/Day
Nos.
Hours
%
Kg/Day
Nos.
Hours
%
Kg/Day
Nos.
Hours
%
Nos
Nos.
Hours
%
Kg/Day
Nos.
Hours
%
Nos./Month
Nos.
Hours
%
Kg/Day
Nos.
Hours
%
Kg/Day
Nos.
Base Line Target Results

48.6
79.8
0
0
72.64
85.25
0
0
6
94
0
0
6
94
0
0
49.75
76
16.7
0
15.12
85.67
3.5
0
6.83
85.33
0
0
34.2
88.46
0
0
54
88.46
0
0
4.2
95
0
0
4.2
95
0
0
34.83
88.22
11.69
0
12
85
2
0
4
91.05
0
0
40.2
86
0
0
26.25
94
0
0
1.3
98
0
0
2
92
0
0
1.5
92
20
0
9
85.49
2
0
3
93.88
0
0
22.45
16.8
73.703333 86.4675
4
2.8
1.75
0
5.52
3.86
87.28
89.02
0
0
0
0
0.52
0.4
94
95
0
0
0
0
46.13
80.34
3
0
0
100
0
0
3
95.73
0
0
Oct-14
Nov-14
Dec-14
40.20
86.00
0.00
0.00
26.25
94.00
0.00
0.00
1.30
98.00
0.00
0.00
2.00
92.00
0.00
0.00
1.50
92.00
20.00
0.00
37.45
84.00
0.00
0.00
23.55
93.00
0.00
0.00
0.00
96.44
0.00
0.00
1.09
91.98
0.00
0.00
4.62
84.43
20.00
0.00
31.30
85.00
17.00
3.00
0.00
92.54
0.00
0.00
22.95
86.84
0.00
0.00
14.30
95.69
1.00
0.00
0.00
95.01
0.00
0.00
0.00
97.08
0.00
0.00
5.48
88.00
16.40
0.00
5.49
93.37
6.00
1.00
0.00
86.79
0.00
0.00
3.00
93.88
0.00
0.00
Hours
%
Kg/Day
Nos.
Hours
%
Nos./Month
Nos.
Hours
%
Nos./Month
Nos.
Hours
%
Kg/Day
Nos.
Hours
%
Kg
Nos.
Hours
%
Nos.
Nos.
Hours
%
Nos.
Nos.
Hours
%
Kg/Day
Nos.
Hours
%
Kg/Day
Nos.
Hours
%
Kg/Day
Nos.
Hours
%
Kg/Day
Nos.
Hours
%
49.75 34.825
76 88.219
16.7
11.69
0
0
0.73
93
16.2
0
25.34
19
21.09
73.703333 86.4675 86.4675
4
3
2
1.75
0
0
16.75
12.6
10.18
73.703333 86.4675 86.4675
3.75
3
3
1.75
0
0
6.52
5.22
0
86.91
88.64
92.6
0
0
0
0
0
0
22
15
6.5
89
93
93.89
0.13
0.09
0.1
0
0
0
19.08
14.3
11.40
73.1
79.8
82.3
2
2
4
1
0
0
19.25
14.4
32
73.781667 80.3363
74.2
4.33
3
3
1
0
0
4.3
2
2
94.2
95
94
17.1
15
16
0
0
0
6.52
4.57
0
86.91
90.5
92.6
0
0
0
0
0
0
9.16
6.82
2.03
90.7
92
95.75
0
0
0
0
0
0
7.83
5.4
3
86.75
89.75
94
0
0
0
0
0
1.51
84.41
1.4
86.97
Kg/Day
Nos.
Hours
%
Kg/Day
Nos.
Hours
%
Kg/Day
Nos.
Hours
%
Kg/Day
Nos.
Hours
%
Nos/Month
Nos.
Hours
%
Nos/Month
Nos.
0
2
0
0
6
92
0
0
4.2
94
0
0
5.3
95
0
0
0
35.01
24.51
78.11
83.58
19
13
0
0
14.07
9.849
84.7 88.525
4
2.8
0
0
Tracking will start October onwards.

Hours
%
Kg/Day
Nos.
Hours
%
Kg/Day
Nos.
Hours
%
Kg/Day
Nos.
Hours
%
Kg/Day
Nos.
Hours
%
Kg/Day
Nos.
Hours
%
Kg/Day
Nos.
Hours
%
Nos/Month
Nos.
Hours
%
Nos/Month
Nos.
Hours
%
Nos/Month
Nos.
Hours
%
Kg/Day
Nos.
Hours
%
Kg/Day
Nos.
Hours
%
Kg/Day
Nos.
Jan-15
Feb-15
Mar-15
Apr-15
May-15
Jun-15
Jul-15
21.00
91.06
0.00
0.00
12.75
95.19
0.00
0.00
0.00
91.78
0.00
0.00
0.00
100.00
0.00
0.00
2.26
89.00
16.20
0.00
2.37
92.17
1.00
0.00
1.00
88.49
0.00
0.00
21.00
93.44
0.00
0.00
21.00
95.09
0.00
0.00
0.00
96.23
0.00
0.00
0.00
95.60
0.00
0.00
4.39
90.00
15.80
0.00
19.47
90.11
4.00
0.00
2.00
93.00
0.00
0.00
23.55
95.00
0.00
0.00
24.10
93.00
1.00
0.00
0.00
94.00
0.00
0.00
0.00
91.34
0.00
0.00
4.39
87.00
16.00
0.00
8.52
95.92
1.00
0.00
0.00
92.00
0.00
0.00
20.45
92.00
0.00
0.00
22.35
95.00
0.00
0.00
2.45
94.64
0.00
0.00
1.82
90.28
0.00
0.00
0.97
93.00
16.20
0.00
4.57
95.56
1.00
0.00
0.00
93.00
0.00
0.00
15.61
93.34
0.00
0.00
13.20
96.00
0.00
0.00
1.09
95.64
0.00
3.00
0.00
90.20
0.00
3.00
1.79
93.00
18.00
0.00
9.52
92.29
1.00
0.00
0.00
91.00
0.00
0.00
8.55
92.56
0.00
0.00
21.10
91.13
0.00
0.00
0.00
97.40
0.00
0.00
0.71
95.40
0.00
0.00
0.00
80.00
14.00
0.00
9.71
95.48
3.00
0.00
0.00
90.00
0.00
0.00
12.30
93.11
0.00
0.00
22.10
93.67
0.00
0.00
0.00
97.80
0.00
0.00
0.00
94.00
0.00
0.00
0.00
93.00
13.30
0.00
18.80
95.30
6.00
0.00
0.00
89.00
0.00
1.00
46.13
80.34
3.00
0.00
0.00
100.00
0.00
0.00
3.00
95.73
0.00
0.00
43.28
76.82
5.00
0.00
3.00
97.20
0.00
0.00
0.75
96.25
0.00
0.00
15.11
81.43
0.00
0.00
1.24
98.00
0.00
0.00
0.60
98.00
0.00
0.00
10.60
83.19
4.00
0.00
0.00
99.04
0.00
0.00
0.75
98.00
0.00
0.00
14.22
82.89
5.00
0.00
0.00
89.90
0.00
3.00
0.90
98.83
0.00
0.00
13.01
87.93
2.00
0.00
0.00
93.60
0.00
0.00
2.05
97.59
0.00
0.00
18.18
89.00
11.00
0.00
0.00
98.00
0.00
0.00
1.50
96.34
0.00
0.00
0.73
93.00
16.20
0.00
4.09
93.00
15.80
0.00
1.30
88.00
16.00
0.00
0.00
98.00
16.20
0.00
1.54
86.00
18.00
0.00
0.00
93.00
14.00
0.00
0.00
98.24
0.00
0.00
21.40
85.50
2.00
0.00
33.30
71.30
0.00
0.00
2.82
90.97
0.00
0.00
12.05
92.17
0.10
0.00
11.40
82.30
4.00
0.00
32.00
74.20
3.00
0.00
1.54
95.00
16.20
0.00
2.82
90.97
0.00
0.00
0.00
98.21
0.00
0.00
7.00
87.00
0.00
0.00
15.27
90.37
1.00
0.00
9.81
76.27
23.00
0.00
0.00
90.97
0.00
3.00
9.70
94.58
0.09
0.00
26.79
84.05
5.00
0.00
42.18
80.38
1.00
0.00
0.00
97.00
18.00
0.00
0.00
90.97
0.00
3.00
2.20
92.80
0.00
3.00
9.00
86.00
0.00
0.00
32.72
85.36
0.00
0.00
29.81
81.80
6.00
0.00
1.97
95.50
0.00
0.00
13.30
93.39
0.10
0.00
18.90
80.05
3.00
0.00
14.54
72.72
0.00
0.00
0.00
95.00
14.00
0.00
1.97
95.50
0.00
0.00
0.00
95.59
0.00
0.00
9.00
88.00
0.00
0.00
26.90
89.90
1.00
0.00
18.18
82.05
12.00
0.00
1.20
95.70
0.00
0.00
3.38
95.20
0.06
0.00
16.72
88.30
1.00
0.00
0.00
0.00
0.00
0.00
2.32
83.00
13.30
0.00
1.20
95.70
0.00
0.00
0.00
95.30
0.00
0.00
0.00
87.00
0.00
0.00
23.40
88.80
0.00
0.00
0.00
92.00
0.00
0.00
0.80
97.00
0.00
0.00
0.00
98.10
0.00
0.00
0.29
99.90
1.00
0.00
11.77
88.14
2.00
0.00
Aug-15
Sep-15
15.95
94.78
0.00
0.00
10.25
94.57
0.00
0.00
0.00
97.64
0.00
0.00
0.00
93.38
0.00
0.00
1.30
90.00
15.70
0.00
19.40
96.48
2.00
0.00
8.00
91.00
0.00
0.00
12.30
97.31
0.00
0.00
15.60
93.31
0.00
0.00
0.00
96.70
0.00
0.00
0.00
94.00
0.00
0.00
0.00
96.00
17.80
0.00
18.78
90.94
3.00
0.00
6.00
89.74
0.00
0.00
38.00
83.89
0.00
0.00
0.00
100.00
0.00
0.00
0.30
98.79
0.00
0.00
13.16
83.00
4.00
0.00
0.00
100.00
0.00
0.00
0.30
97.32
0.00
0.00
0.00
100.00
0.00
0.00
0.00
91.00
0.00
0.00
40.00
89.45
3.00
0.00
26.40
90.00
1.00
0.00
0.00
96.78
0.00
0.00
4.70
93.43
0.10
0.00
51.50
85.38
1.00
0.00
0.00
0.00
0.00
0.00
0.00
98.00
15.70
0.00
0.00
100.00
0.00
0.00
0.00
95.25
0.00
0.00
6.00
93.00
0.00
0.00
35.30
90.13
2.00
0.00
2.90
91.80
2.00
0.00
0.00
95.04
0.00
0.00
7.40
93.16
0.09
0.00
9.70
94.03
4.00
0.00
0.00
0.00
0.00
0.00
9.98
97.00
17.80
0.00
0.00
100.00
0.00
0.00
0.00
97.70
0.00
0.00
6.00
86.94
0.00
0.00
40.05
88.41
38.70
92.78
0.00
0.00
7.20
94.00
0.00
0.00
0.00
97.46
0.00
0.00
0.00
98.00
0.00
0.00
14.00
65.30
30.00
0.00
18.06
89.60
4.00
0.00
0.00
0.00
12.20
82.82
0.00
0.00
0.00
93.70
0.00
0.00
0.00
95.00
0.00
0.00
45.70
56.80
115.00
0.00
3.50
91.07
1.00
0.00
Guidelines for Colour Coding

SN
QIP : Specific Problem
High Laceration Accidents/Month (Knifeless)
High rush of people in HR for queries
High usage of knife for flash cutting operation

(developing specialized tool)
High usage of knife Batch-off unit of Ban.no.5 ( for

sample cutting operation )
High usage of hot knife for ply cutting in NTB
High flash cure in tractor tyres
Radial tyre scrap due to No PCI
Elimination of naptha based outer paint in all radial sizes
Manual cutting operation of Belt edge cushion of

7.00R15 Milaze at 2A radial first stage building machine.
10
The manual process takes long time and workflow plans

& documents are paper-intensive.
11
No tread weight data analysis in excel also

No report generated through SAP
12 High light side wall defect in 6.00-16 Ayushman size
13
High Radial tyre scrap due to bladder over bead (BOB)

defect
14 HIgh Mica defect in rear tractor tyres.
15 Tread rejection due to side crack at 8*10 Extruder
15 Tread rejection due to side crack at 8*10 Extruder
16 Deteriotion of fabric booking liners
17
% Improvement in export lot size warehousing
InProcess QIP Tracker alongwith T

% adherence to planned time lines
KPI
Accidents/month
Actual
Leader
Prasad Sarode
PLAN
Plan
Step I
Actual
Nos./month
Anand Rahatekar
Plan
Step I
Actual
Task Achievement
Rajiv Joshi
Plan
Step I
May W3
Actual
Task Achievement
Mahendra Sawardekar
Plan
Step I
Actual
Task Achievement
B J Choudhari
Plan
Step I
Actual
%age
Nandakishor Khade
Plan
Step I
May W4
Actual
Percentage scrap of No PCI in
all radial sizes of total
production
Task achievement
Vinayak pote
Plan
Step I
Actual
K Sudarshan
Plan
Step I
Actual
Task achievement
(Process reduction with
automation)
Adherence to timeline.
Vaibhav Gadgil
Plan
Step I
Actual
Sampayan Kar
Plan
Step I
Actual
Task Achievement
Vaibhav Shewale
Plan
Step I
July W2
Actual
% light side wall defect in 6.0016 Ayushman
Percentage scrap due BOB in all
radial sizes of total production
Mica defect in rear tractor
tyres.
Anil Pansare
Plan
Step I
Actual
Dinesh Gharate
Plan
Step I
June W1
Actual
Rajesh K. Pandulkar
Plan
Actual
Plan
Abhijeet Jadhav
Step I
July W2
Step I
Abhijeet Jadhav
Actual
Nos
Bhushan Joshi
Plan
Step I
June W4
Actual
%
Sanjay Kumar
Plan
Actual
Step I
Aug W4
er alongwith TIMELINE
Pending With Respect to the
Timeline
PLAN
DO
Step II
Step III
Step IV
Step II
Step III
Step IV
Step II
May W4
Step III
June W2
Step IV
June W3
Step II
Step III
Step IV
Step II
Step III
Step IV
Step II
June W1
Step III
June W3
Step IV
July W1
Step II
Step III
Step IV
Step II
Step III
Step IV
Step II
Step III
Step IV
Step II
Step III
Step IV
Step II
JulyW4
Step III
Aug W3
Step IV
Aug W4
Step II
Step III
Step IV
Step II
June W2
Step III
July W1
Step IV
July W4
Step II
July W3
Step III
Aug W1
Step IV
Aug W3
Step II
Step III
Step IV
Step II
July W1
Step III
July W3
Step IV
July W4
Step II
Step III
Step IV
Aug W4
Sept W3
Oct W3
CHECK
ACT
Step V
Step VI
Step VII
Step V
Step VI
Step VII
Step V
July W1
Step VI
July W4
Step VII
Aug W2
Step V
Step VI
Step VII
Step V
Step VI
Step VII
Step V
Aug W1
Step VI
Aug W2
Step VII
Aug W3
Step V
Step VI
Step VII
Step V
Step VI
Step VII
Step V
Step VI
Step VII
Step V
Step VI
Step VII
Step V
Sept W2
Step VI
Sept W3
Step VII
Sept W4
Step V
Step VI
Step VII
Step V
Monitoring
Step VI
for nxt
Step VII
3 months
Step V
Aug W4
Step VI
Aug W4
Step VII
Sept W1
Step V
Step VI
Step VII
Step V
Aug W1
Step VI
Aug W4
Step VII
Sept W3
Step V
Step VI
Step VII
Oct W4
Nov W2
Nov W3
CEAT
QIP TRACKER FOR THE

SN
List of downgraded QIPs of Fy'13-14
Reduction in premature failure of bladders due to degradation of
1
bladders
2
Reduction in bead scrap
3
Reducing the production loss in radial due to GT trolley shortage
List of downgraded QIPs of Fy'13-14

1
Reduction of accidents in bead
Completed QIP Quarter I FY 14-15 : Nasik
2
3
4
Asset identification in production areas - Curing Assets

Step off variation
Employee database updation in SAP
Completed QIP Quarter II FY 14-15 : Nasik

1
Reduction of Mica defect in Non Truck tyres
2
Reduction of tyre scrap due to split cord in radial tyres
3
Reduction of RMS delay in mixing
4
Reduction of flow crack in tractor
5
Reduction Of Tread shoulder seperation in Truck
Elimination of missing cord in CANYLO
Reduction of shoulder separation defect in 7.00R15 milaze lt
8
9
Reduction in employee complaints

OE Yield Improvement in LCV & Radial sizes
10
Reduction in Band Loss due to trolley shortage
Completed QIP Quarter III FY 14-15 : Nasik

1
Reduction of Soap Solution consumption
Tyre stiffness improvement in 7.50-16 double bead sizes for

indonesian market
Re-engineering of 195R15 LT Steelplus in Nashik due to tyre

claim
Squegee blister reduction in all radial sizes
Reduction in Mix Carbon Scrap
Uniformity yield improvement in 185R14 LT Milaze
Reduction of squeegee blister in 195R15 Steelplus
Reduce utility power consumption
Reduction of customer complaint tread joint open in size 80018Aayusmaan
Elimination of Toe Flash in 59 J (While excess Sidewall stitching)

10
Completed QIP Quarter IV FY 14-15 : Nasik
1
Elimination of customer complaint No serial
Manufacturing Lead time reduction
scrap reduction in 8x6 Lt cold feed extruder
Reduction in FM defect in tractor sizes from 7.8% to 6.24%
Reduction of Premature by reducing turn up separation in 100020H CL HL sizes
Reduction of Customer complaint of groove crack in size 120024HT SUPER
To reduce the bead failure in premature & claim tires in 1020

Mile XL /HCL /HL
Productivity improvement in Non truck sizes.
Improve the Resolution of Bol Bindass Complaints

( Admin & Engineering related)
Asset identification
& tagging
in production
Completed
QIP Quarter
I FY 15-16
: Nasik. areas Band building, Extruder, Calendering/Bias cutter/Balancing
1
Machine,PCI units, Utility, Drums, Inspection m/c, vehicles &
machines
2 other
High set
up time in NTC
9
Improvement of cut tyre rating in all radial sizes to A & B rating

from C
High canteen cost
High trimming damage defect in eleveta sizes (NTC)
High Loss of production Due to unmix batch generation at Ban02
High premature claims due to breaker stretch
High Ply width variation on High table bias cutter at radial dept.
Low Productivity in banbury 02
Completed QIP Quarter II FY 15-16 : Nasik.

1
Reduction of breakdown hours due to drop door rubber jamming

phenomina
Elimination of Frequent side wall jam up in Separating conveyor

at 8x6 Booking area
3
4
5
Elimination of 7.5 MVA Transformer

Improvement of Fumes Extraction System at Banbury
Reduction of 4.00-8 tyre scrap due to Arm Damage
CEAT Limited
QIP TRACKER FOR THE MONTH OF: SEPTEMBER'15
KPI
Name of leader
Base Line
Tyres/Bladder
Parameshwaran
130.00
%age Scrap
No. of tyre loss due to trolley
shortage/month
Sanjeev Sharma
0.075
Shyam sunder
434.00
No. of Accidents
Sanjeev Sharma
2.23
Task Achievement
Non-compliance in %
Task Achievement
Uday Kansara
Shrikant Ghadge
Sampayan Kar
Task
36.67
Task
%age
%age scrap in total scrap
%age Loss
Customer Complaints PPM
Premature Claims PPM
Pratap Patil
Sonal Nerkar
Sharad Khairnar
NE Khade
Parameshwaran
1.5800
16.40%
0.24
207
1084
Kalaivendhan
78
Sudarshan
Anand Rahatekar
Sunil Malagi
2.34
60
67.12
Jeevan Tambat
6.59
Pratap Patil
0.0011
Kiran Shankar
44
Kg
%age
No. per Month
%age
%age
Kg/Kg
Tyre defection (mm)
Task Achievement (ND PPM)

%age defect
%age Scrap
%age yield
%age Scrap
KWH
Customer Complaints for tread
joint open
%
No serial Customer complaint
Sudarshan
0.15
Sudarshan
0.32
Nitin Kolhe
0.112
Sudarshan
70
Sudarshan
9.6
Avinash Pradhan
34000
NE Khade
N Parameshwaran
70
NE Khade
R Kedia
11.91
Dablu Kumar
10.77
Shifts.
%age Tread rejection for Light
Truck Sizes
% Defect in tractor sizes
Anil Pansare
Premature claims due to Turn up

separation in 1000-20H CL HL
sizes (PPM)
N Khade
8.1
886
Customer complaint (nos.)

PPM
%age Productivity
N E Khade
Shrikant Ghadge
224
Kiran Sankar
Resolution %age
Anand Rahatekar
Task Achievement
Uday Mekhe
Task
Pravin Patil
244
Ankit Rana
77
Mins/Changeover
Monthly Cut tyre rating (%)
90
Rs. (Lacs)
Anand Rahatekar
%age trimming damage defect
Avg Min/month
Anil Pansare
3.40%
T Kalaivendhan
152
%age Non Compliance
Shrikant Ghadge
Process capability, Cp of bias

cutter
K Sudarshan
%age
Brk down Hrs/Month

Brk down Occurences
Cost in Lakhs
Muri Reduction
Tyre scrap in No's
60.35%
0.28
T Kalaivendhan
Pradeep Subedarpage
37
Prashant Kage
14
Sanjay Pagare
24
Pradeep Subedarpage
Vinayak Pote
23
Res/Tgt
150.00
0.049
94.00
0.00
Achieved
10.00
Achieved
1.4000
12%
0.12
154
867
Jul-15
Aug-15
Sep-15
143.00
0.063
146.00
0.060
153.00
0.055
30.00
23.00
168.00
1.00
0.00
0.00
0.90
8.87%
0.06
0.00
749.00
1.04
12.60%
0.09
0.00
234.00
One Time
One Time
1.17
3.04%
0.07
0.00
1489.00
QIP tracking completed

for 12 months
39
38.00
38.00
1.5
20
88.07
0.22
6.00
89.50
0.41
6.00
91.81
0.76
6.00
91.00
1.48
2.72
0.91
0.00098
0.00100
0.00097
4.41
0.0009
42
Size not Run in the Size not Run in the

Month of July'15
Month of Aug'15
Size not Run in the

Month of Sept'15
0.07
0.07
0.07
0.06
0.16
0.01
0.04
0.02
0.03
0.0015
0.0010
0.0000
77.00
87.00
90.00
0.47
0.90
0.43
30219
30904
30139
10
18
15
9.90
9.96
9.45
7.32%
6.3
9.07
5.20
4.35
5.00
882.00
364.00
0.00
15%
15%
15%
74
89
119.86
One Time
One Time
One Time
209
232
211
200.19
100
100.00
100.00
83.33
80
1.92
30000
0
56
9.92
8
6.48
708
0
124
10%
95
Achieved
Till Aug '15 Saving

one more month
is 1.5
Till Sept '15 saving is
for assesment lakhs/month(Appro Approx 3 Lakhs/month.
ximate )
0.50%
0.00
0.00
0.00
45.00
72.00
0.00
36.21
15%
11.96%
21.57
1.33
1.33
2.55
3.00
5.59% (Task
Achievement)
5.59% (Task
Achievement)
5.59% (Task
Achievement)
5.40
5.30
76
14
0
0
2
0
Tracking will start

Oct'15 onwards
Tracking done for 12 months.
CEAT Limited
AM TRACKER FOR THE MONTH OF: SEPTEMBER'15
Sr.No
Machine
Objective
B/D Hours
1
PTBM 23
B/D Hours
2
TTB 59J 06
B/D Hours
3
TTB 59J 23
B/D Hours
4
BBM 11
Fabric Scrap
B/D Hours
5
Bead Fillering 02
B/D Hours
6
Bead Fillering 08
B/D Hours
7
Bead Winding 02
B/D Hours per month
8
Radial Curing 50
B/D Hours per month
9
NTC 46
B/D Hours per month
10
Radial Building 2B
B/D Hours / month
11
NTBC 02
11
NTBC 02
12
TTC A5
13
TTC C3
Quality : held up/Rework (fabric scrap kg/day)

B/D Hours per month
B/D Hours per month
B/D Hours
BBM 4
B/D Hours
BBM 10
B/D Hours
BBM 14
B/D Hours
Bead Fillering 5
B/D Hours
Bead Fillering 10
B/D Hours
Bead Winding 03
B/D Hours / month
Ban 05
Quality : Comp Scrap
B/D Hours
PTBM 28
B/D Hours
TTB 15
B/D Hours
10
TTB 25
B/D Hours
11
TTB 17
B/D Hours per month
12
NTC 28A
B/D Hours per month
13
NTC 39
9
TTB 15
Bead Flipper 01
Bead Flipper 04
PTBM 05
TTB 13
BBM 02
NTC 48
S22 Strip Out
B/D Hours
B/D Hours
B/D Hours
B/D Hours
B/D Hours
B/D Hours per month
B/D Hours
S22 Strip Out
B/D Hours per month
1
Rad 52
B/D Hours
1
TTC press D0
B/D Hours
2
Bead Flipper 18
B/D Hours
3
TTB 11
B/D Hours
4
TTBB 13
B/D Hours
1
TTC press C1
B/D Hours
2
TTC press C2
B/D Hours
3
Bead Covering 22
B/D Hours
4
3.5" Extruder
B/D Hours
5
TTC press C0
B/D Hours
6
TTC press D2
B/D Hours
7
BBM 15
B/D Hours
8
Bead Covering 21
B/D Hours
9
Bead Flipper 07
B/D Hours
10
NTB 02
B/D Hours
B/D Hours
1
TTB no. 21
B/D Hours
2
NTB no. 03
B/D Hours
3
Radial Filler no. 17
B/D Hours
4
Bead Flipper no 09
B/D Hours
5
NTC 35
B/D Hours
6
TTC C 9
B/D Hours
7
B/D Hours

1
10
11
B/D Hours
TTB no. 19
B/D Hours
Bead Filler 20
B/D Hours
Bale Cutter no 1
B/D Hours
Band building 16
B/D Hours
NTB no. 4
B/D Hours
NTB no. 13
B/D Hours
NTC 48A
B/D Hours
NTC 36
B/D Hours
TTC B8
B/D Hours
Rad. Building 3A
B/D Hours
1000 CFM
Compressor
Trac
11
12
1000 CFM
Compressor

B/D Hours
ODR2000,RHEOME Operational Efficiency
TER
Unit
Hours
%
Kg/Day
Nos.
Hours
%
Kg/Day
Nos.
Hours
%
Kg/Day
Nos.
Hours
%
Kg/Day
Nos.
Hours
%
Kg/Day
Nos.
Hours
%
Kg/Day
Nos.
Hours
%
Kg/Day
Nos.
Hours
%
Nos
Nos.
Hours
%
Nos
Nos.
Hours
%
%
Nos.
Hours
Base Line Target Results

4.66
78.75
0.00
0.00
70.80
85.25
0.00
0.00
51.00
78.75
0.00
0.00
20.00
87.00
22.00
0.00
5.50
93.00
0.00
0.00
6.00
95.00
0.00
0.00
34.50
93.94
38.90
0.00
38.80
75.93
24.40
0.00
54.00
87.13
9.50
0.00
19.01
79.00
0.02
0.83
31.11
3.26
91.05
0.00
0.00
49.56
88.46
0.00
0.00
35.70
88.46
0.00
0.00
14.00
88.22
15.40
0.00
3.85
95.00
0.00
0.00
4.20
95.00
0.00
0.00
24.15
95.00
27.23
0.00
27.16
80.29
17.08
0.00
37.80
87.26
6.65
0.00
13.31
83.73
0.02
0.00
21.78
1.00
86.00
0.00
0.00
33.60
81.75
0.00
0.00
22.50
87.66
0.00
0.00
17.40
92.00
17.50
0.00
4.00
94.00
0.00
0.00
0.00
96.00
0.00
0.00
8.00
94.00
22.00
0.00
25.07
80.19
18.00
2.00
22.67
90.84
8.00
2.00
11.40
80.00
0.01
1.00
24.17
Jan-15
Feb-15
Mar-15
40.21
70.93
45.00
0.00
21.74
88.79
61.00
0.00
29.90
76.55
50.00
0.00
80.29
88.86
81.01
Kg/Day
67.54
47.28
43.22
Nos.
Hours
%
Nos
Nos.
Hours
%
Nos
Nos.
0.00
31.36
84.89
2.75
2.00
31.36
84.89
3.00
2.00
0.00
21.95
86.47
2
0.00
21.95
86.47
1.00
0.00
0.00
14.20
87.80
2.00
2.00
21.80
81.60
3.00
2.00
Hours
30
21
84
88.22
16.7
11.69
0
0
58.75
41.13
82
88.22
16.7
11.69
0
0
49.75
34.83
76
85
16.7
11.69
0
0
6.5
4.55
92.25
95
0
0
1
0
5
3.5
94
95
0
0
1
0
35.5
24.85
91.33
95
35.88 25.116
0
0
45
31.5
84.95
90.59
149.6 104.72
1
0
5.42
3.79
89.55
91.05
0
0
0
0
68.1
47.67
7.5
90
16.5
0
15
92
16.5
0
21
92
16.5
0
0
100
0
0
1
99
0
0
4
97
15
0
24
90.8
97
0
0
97
0
0
30
%
Kg/Day
Nos.
Hours
%
Kg/Day
Nos.
Hours
%
Kg/Day
Nos.
Hours
%
Kg/Day
Nos.
Hours
%
Kg/Day
Nos.
Hours
%
Kg/Day
Nos.
Hours
%
Kg/Day
Nos.
Hours
%
Kg/Day
Nos.
Hours
1.30
4.74
4.25
96.00
16.20
0.00
0.00
93.00
16.20
0.00
6.59
89.00
16.20
0.00
1.37
88.78
0.00
0.00
0.00
100.00
0.00
0.00
17.31
90.49
14.65
0.00
32.60
93.54
47.00
0.00
0.00
98.87
0.00
0.00
0.00
97.00
15.80
0.00
6.11
93.00
15.80
0.00
4.14
94.00
15.80
0.00
0.00
97.49
0.00
0.00
0.00
100.00
0.00
0.00
17.00
91.03
18.14
0.00
31.70
91.99
42.00
0.00
0.00
97.00
0.00
0.00
92.00
16.00
0.00
1.42
90.00
16.00
0.00
0.00
93.00
16.00
0.00
2.62
95.05
0.00
0.00
0.00
100.00
0.00
0.00
15.01
93.90
21.80
0.00
22.50
91.97
100.00
1.00
0.00
97.00
0.00
0.00
0.00
%
Kg/Day
Nos.
Hours
%
Kg/Day
Nos.
Hours
%
Kg/Day
Nos.
Hours
%
Nos
Nos.
Hours
%
Nos
Nos.
87.3
0
0
90.6
84
0
0
89.4
84
0
0
28.84
81.88
11.00
1.00
19.45
83.88
7.00
1.00
88.46
0
0
63.42
88.46
0
0
62.58
88.46
0
0
20.19
87.26
7.70
0.00
13.62
87.26
4.90
0.00
93
0
0
48
93
0
0
29
100
0
0
16.00
83.00
9.00
0.00
16.78
85.00
6.00
0.00
93.42
0.00
0.00
5.55
93.35
0.00
0.00
1.80
96.62
0.00
0.00
6.18
89.90
8.00
0.00
9.70
86.46
0.00
0.00
1.95
100.00
0.00
0.00
1.05
97.04
0.00
0.00
20.63
90.45
7.00
0.00
22.35
95.19
3.00
0.00
95.00
0.00
0.00
0.00
100.00
0.00
0.00
0.00
99.00
0.00
0.00
14.31
90.03
9.00
0.00
23.35
93.26
1.00
0.00
Hours
%
Kg/Day
Nos.
Hours
%
Kg/Day
Nos.
Hours
%
Kg/Day
Nos.
Hours
%
Kg/Day
Nos.
Hours
%
Kg/Day
Nos.
Hours
%
Nos
Nos.
Hours
%
Kg/Day
7.7
5.39
92.48
95
0
0
0
0
7.57
5.3
94.15
95
0
0
0
0
5
3.5
85.33
91.05
0
0
1
0
43.2
30.24
95.43
88.46
0
0
0
0
3.24
2.27
91.22 88.219
10
7
1
0
18
12.6
80.33
87.26
3
2.1
1
0
3.57
2.5
76.15
81.32
0.13
0.09
0
95.48
0
0
1.77
96.83
0
0
7
91.98
0
0
0
100
0
0
2.99
88
17
0
13.23
90
2
0
1.5
81.5
0.053
1.18
96.09
0.00
0.00
2.70
95.63
0.00
0.00
6.00
89.79
0.00
0.00
0.00
98.30
0.00
0.00
0.00
96.00
16.20
0.00
17.58
93.07
4.00
0.00
0.00
87.36
0.06
2.00
96.12
0.00
0.00
0.00
97.23
0.00
0.00
1.00
93.00
0.00
0.00
2.70
92.59
0.00
0.00
0.00
97.00
15.80
0.00
9.33
94.44
1.00
0.00
10.00
85.00
0.06
0.00
97.00
0.00
0.00
1.06
96.50
0.00
0.00
0.00
93.00
0.00
0.00
1.65
98.00
0.00
0.00
5.38
92.00
16.00
0.00
21.04
90.52
4.00
0.00
2.00
82.70
0.10
Nos.
28.91
80.9
24
1
20.24
80.29
16.8
0
Hours
%
Nos./Month
Nos.
Hours
%
Kg/Day
Nos.
Hours
%
Kg/Day
Nos.
Hours
%
Kg/Day
Nos.
22.45
16.8
73.703333 86.4675
4
2.8
1.75
0
5.52
3.86
87.28
89.02
0
0
0
0
0.52
0.4
94
95
0
0
0
0
49.75 34.825
76 88.219
16.7
11.69
0
0
Hours
%
Nos./Month
Nos.
Hours
%
Nos./Month
Nos.
Hours
%
Kg/Day
Nos.
Hours
%
Kg
Nos.
Hours
%
Nos.
Nos.
Hours
%
Nos.
Nos.
25.34
19
21.09
73.703333 86.4675 86.4675
4
3
2
1.75
0
0
16.75
12.6
10.18
73.703333 86.4675 86.4675
3.75
3
3
1.75
0
0
6.52
5.22
0
86.91
88.64
92.6
0
0
0
0
0
0
22
15
6.5
89
93
93.89
0.13
0.09
0.1
0
0
0
19.08
14.3
11.40
73.1
79.8
82.3
2
2
4
1
0
0
19.25
14.4
32
73.781667 80.3363
74.2
4.33
3
3
1
0
0
Hours
%
Nos
Nos.
0.00
0.00
0.00
19.32
83.9
19
0
11.63
92.11
6.00
0.00
18.73
91.33
22.00
0.00
14.54
92.70
26.00
0.00
46.13
80.34
3
0
0
100
0
0
3
95.73
0
0
0.73
93
16.2
0
46.13
80.34
3.00
0.00
0.00
100.00
0.00
0.00
3.00
95.73
0.00
0.00
0.73
93.00
16.20
0.00
43.28
76.82
5.00
0.00
3.00
97.20
0.00
0.00
0.75
96.25
0.00
0.00
4.09
93.00
15.80
0.00
15.11
81.43
0.00
0.00
1.24
98.00
0.00
0.00
0.60
98.00
0.00
0.00
1.30
88.00
16.00
0.00
Hours
%
Kg/Day
Nos.
Hours
%
Kg/Day
Nos.
Hours
%
Kg/Day
Nos.
Hours
%
Kg/Day
Nos.
Hours
%
Kg/Day
Nos.
4.3
94.2
17.1
0
6.52
86.91
0
0
9.16
90.7
0
0
7.83
86.75
0
0
2
95
15
0
4.57
90.5
0
0
6.82
92
0
0
5.4
89.75
0
2
94
16
0
0
92.6
0
0
2.03
95.75
0
0
3
94
0
0
Hours
%
Kg/Day
Nos.
Hours
%
Kg/Day
Nos.
Hours
%
Kg/Day
Nos.
Hours
%
Kg/Day
Nos.
Hours
%
Nos/Month
Nos.
Hours
%
Nos/Month
Nos.
Hours
%
Kg/Day
1.51
84.41
0
2
1.4
86.97
0
0
0
0
6
92
0
0
4.2
94
0
0
5.3
95
0
35.01
24.51
78.11
83.58
19
13
0
0
14.07
9.849
84.7 88.525
4
2.8
0
0
Nos.
Hours
%
Kg/Day
Nos.
Tracking will start October onwards.

Hours
%
Kg/Day
Nos.
Hours
%
Kg/Day
Nos.
Hours
%
Kg/Day
Nos.
Hours
%
Kg/Day
Nos.
Hours
%
Kg/Day
Nos.
Hours
%
Kg/Day
Nos.
Hours
%
Nos/Month
Nos.
Hours
%
Nos/Month
Nos.
Hours
%
Nos/Month
Nos.
Hours
%
Kg/Day
Nos.
Hours
%
Kg/Day
Nos.
Hours
%
Kg/Day
Nos.
Apr-15
May-15
Jun-15
Jul-15
Aug-15
Sep-15
66.60
81.10
46.00
0.00
24.23
92.09
28.00
0.00
30.18
89.89
23.00
0.00
16.11
87.66
30.00
0.00
17.60
93.60
33.00
0.00
25.00
88.80
19.00
0.00
18.25
94.49
18.50
0.00
7.67
95.00
20.00
3.00
6.30
96.30
23.40
0.00
6.40
97.00
24.00
0.00
3.79
96.00
22.00
0.00
11.20
96.60
23.24
0.00
3.00
95.08
0.00
0.00
2.25
96.24
0.00
0.00
0.00
0.00
0.00
0.00
0.00
99.11
0.00
0.00
22.90
58.90
101.00
0.00
17.20
88.40
6.00
0.00
0.00
94.95
0.00
0.00
0.00
98.34
0.00
0.00
2.00
92.00
0.00
0.00
0.00
96.00
0.00
0.00
7.17
95.00
16.20
0.00
5.81
89.01
1.00
0.00
1.00
87.25
0.10
0.00
99.00
0.00
3.00
0.00
98.00
0.00
3.00
0.00
94.00
0.00
0.00
0.60
97.50
0.00
0.00
0.00
93.00
18.00
0.00
4.90
94.50
4.00
0.00
1.00
88.12
0.08
0.00
98.30
0.00
0.00
0.00
98.19
0.00
0.00
0.00
91.00
0.00
0.00
0.00
98.03
0.00
0.00
0.00
96.00
14.00
0.00
16.15
94.00
3.00
0.00
1.00
87.25
0.10
0
99
0
0
0
98
0
0
2
87.02
0
0
0
100
0
0
3.52
96
17.8
1
20.57
88.35
5
0
0.00
89.57
0.08
0.00
0.00
0.00
0.00
10.24
87.70
27.00
0.00
18.96
88.85
33.00
0.00
36.78
89.48
34.00
0.00
17.18
88.23
14.00
0.00
42.78
86.20
30.00
0.00
10.60
83.19
4.00
0.00
0.00
99.04
0.00
0.00
0.75
98.00
0.00
0.00
0.00
98.00
16.20
0.00
14.22
82.89
5.00
0.00
0.00
89.90
0.00
3.00
0.90
98.83
0.00
0.00
1.54
86.00
18.00
0.00
13.01
87.93
2.00
0.00
0.00
93.60
0.00
0.00
2.05
97.59
0.00
0.00
0.00
93.00
14.00
0.00
18.18
89.00
11.00
0.00
0.00
98.00
0.00
0.00
1.50
96.34
0.00
0.00
0.00
98.24
0.00
0.00
38.00
83.89
0.00
0.00
0.00
100.00
0.00
0.00
0.30
98.79
0.00
0.00
0.00
100.00
0.00
0.00
13.16
83.00
4.00
0.00
0.00
100.00
0.00
0.00
0.30
97.32
0.00
0.00
0.00
91.00
0.00
0.00
21.40
85.50
2.00
0.00
33.30
71.30
0.00
0.00
2.82
90.97
0.00
0.00
12.05
92.17
0.10
0.00
11.40
82.30
4.00
0.00
32.00
74.20
3.00
0.00
15.27
90.37
1.00
0.00
9.81
76.27
23.00
0.00
0.00
90.97
0.00
3.00
9.70
94.58
0.09
0.00
26.79
84.05
5.00
0.00
42.18
80.38
1.00
0.00
32.72
85.36
0.00
0.00
29.81
81.80
6.00
0.00
1.97
95.50
0.00
0.00
13.30
93.39
0.10
0.00
18.90
80.05
3.00
0.00
14.54
72.72
0.00
0.00
26.90
89.90
1.00
0.00
18.18
82.05
12.00
0.00
1.20
95.70
0.00
0.00
3.38
95.20
0.06
0.00
16.72
88.30
1.00
0.00
0.00
0.00
0.00
0.00
40.00
89.45
3.00
0.00
26.40
90.00
1.00
0.00
0.00
96.78
0.00
0.00
4.70
93.43
0.10
0.00
51.50
85.38
1.00
0.00
0.00
0.00
0.00
0.00
35.30
90.13
2.00
0.00
2.90
91.80
2.00
0.00
0.00
95.04
0.00
0.00
7.40
93.16
0.09
0.00
9.70
94.03
4.00
0.00
0.00
0.00
0.00
0.00
1.54
95.00
16.20
0.00
2.82
90.97
0.00
0.00
0.00
98.21
0.00
0.00
7.00
87.00
0.00
0.00
0.00
97.00
18.00
0.00
0.00
90.97
0.00
3.00
2.20
92.80
0.00
3.00
9.00
86.00
0.00
0.00
0.00
95.00
14.00
0.00
1.97
95.50
0.00
0.00
0.00
95.59
0.00
0.00
9.00
88.00
0.00
0.00
2.32
83.00
13.30
0.00
1.20
95.70
0.00
0.00
0.00
95.30
0.00
0.00
0.00
87.00
0.00
0.00
0.00
98.00
15.70
0.00
0.00
100.00
0.00
0.00
0.00
95.25
0.00
0.00
6.00
93.00
0.00
0.00
9.98
97.00
17.80
0.00
0.00
100.00
0.00
0.00
0.00
97.70
0.00
0.00
6.00
86.94
0.00
0.00
23.40
88.80
0.00
0.00
0.00
92.00
0.00
0.00
0.80
97.00
0.00
0.00
0.00
98.10
0.00
0.00
0.29
99.90
1.00
0.00
11.77
88.14
2.00
0.00
40.05
88.41
0.00
0.00
7.20
94.00
0.00
0.00
0.00
97.46
0.00
0.00
0.00
98.00
0.00
0.00
14.00
65.30
30.00
0.00
18.06
89.60
4.00
0.00
38.70
92.78
0.00
0.00
12.20
82.82
0.00
0.00
0.00
93.70
0.00
0.00
0.00
95.00
0.00
0.00
45.70
56.80
115.00
0.00
3.50
91.07
1.00
0.00
m/c off shedule
SN
Completed QIP Quarter II FY 14-15 : Nasik

1
Reduction of Mica defect in Non Truck tyres
2
Reduction of tyre scrap due to split cord in radial tyres
3
Reduction of RMS delay in mixing
4
Reduction of flow crack in tractor
5
Reduction Of Tread shoulder seperation in Truck
Elimination of missing cord in CANYLO
Reduction of shoulder separation defect in 7.00R15 milaze lt
8
9
Reduction in employee complaints

OE Yield Improvement in LCV & Radial sizes
10
Reduction in Band Loss due to trolley shortage
Completed QIP Quarter III FY 14-15 : Nasik

1
Reduction of Soap Solution consumption
Tyre stiffness improvement in 7.50-16 double bead sizes for

indonesian market
Re-engineering of 195R15 LT Steelplus in Nashik due to tyre

claim
Squegee blister reduction in all radial sizes
Reduction in Mix Carbon Scrap
Uniformity yield improvement in 185R14 LT Milaze
Reduction of squeegee blister in 195R15 Steelplus
Reduce utility power consumption
Reduction of customer complaint tread joint open in size 80018Aayusmaan
10
Elimination of Toe Flash in 59 J (While excess Sidewall stitching)
Completed QIP Quarter IV FY 14-15 : Nasik

1 Elimination of customer complaint No serial
2
Manufacturing Lead time reduction
scrap reduction in 8x6 Lt cold feed extruder
Reduction in FM defect in tractor sizes from 7.8% to 6.24%
Reduction of Premature by reducing turn up separation in 100020H CL HL sizes
Reduction of Customer complaint of groove crack in size 120024HT SUPER
To reduce the bead failure in premature & claim tires in 1020

Mile XL /HCL /HL
Productivity improvement in Non truck sizes.
Improve the Resolution of Bol Bindass Complaints

( Admin & Engineering related)
Asset identification
& tagging
in production
Completed
QIP Quarter
I FY 15-16
: Nasik. areas Band building, Extruder, Calendering/Bias cutter/Balancing
1
Machine,PCI units, Utility, Drums, Inspection m/c, vehicles &
machines
2 other
High set
up time in NTC
9
Improvement of cut tyre rating in all radial sizes to A & B rating

from C
High canteen cost
High trimming damage defect in eleveta sizes (NTC)
High Loss of production Due to unmix batch generation at Ban02
High premature claims due to breaker stretch
High Ply width variation on High table bias cutter at radial dept.
Low Productivity in banbury 02
Completed QIP Quarter II FY 15-16 : Nasik.

1
TRACKING WILL START OCT'15 ONWARDS
Reduction of breakdown hours due to drop door rubber jamming

phenomina
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Elimination of Frequent side wall jam up in Separating conveyor

at 8x6 Booking area
Elimination of 7.5 MVA Transformer
Improvement of Fumes Extraction System at Banbury #1&2
Reduction of 4.00-8 tyre scrap due to Arm Damage
Radial tread Recutting
High time consumption during cut tyre analysis &

rating
Wrong die usage at 8*10 Extruder
Knifeless operation at banbury dump mill
Sq. Gauge variation at Truck 3 Roll calender
Deteriotion of fabric booking liners
High Water consumption
Over-size of tyres in Radial sizes
High Grease consumption in A Div
High oil consumption due to leakages
CEAT
QIP TRACKER FOR THE

KPI
%age
%age scrap in total scrap
%age Loss
Customer Complaints PPM
Premature Claims PPM
Name of leader
Base Line
Pratap Patil
Sonal Nerkar
Sharad Khairnar
NE Khade
Parameshwaran
1.5800
16.40%
0.24
207
1084
Kalaivendhan
78
Sudarshan
Anand Rahatekar
Sunil Malagi
2.34
60
67.12
Jeevan Tambat
6.59
Pratap Patil
0.0011
Kiran Shankar
44
Sudarshan
0.15
Sudarshan
0.32
Nitin Kolhe
0.112
Sudarshan
70
Sudarshan
9.6
Avinash Pradhan
34000
Kg
%age
No. per Month
%age
%age
Kg/Kg
Tyre defection (mm)
Task Achievement (ND PPM)
%age defect
%age Scrap
%age yield
%age Scrap
KWH
Customer Complaints for tread joint open NE Khade

%
N Parameshwaran
5
70
No serial Customer complaint
NE Khade
R Kedia
11.91
Dablu Kumar
10.77
Shifts.
%age Tread rejection for Light Truck Sizes
% Defect in tractor sizes
Premature claims due to Turn up
separation in 1000-20H CL HL sizes
(PPM)
Anil Pansare
8.1
N Khade
886
N E Khade
Shrikant Ghadge
224
Customer complaint (nos.)

PPM
%age Productivity
Kiran Sankar
Resolution %age
Anand Rahatekar
Task Achievement
Uday Mekhe
Task
Pravin Patil
244
Ankit Rana
77
Mins/Changeover
Monthly Cut tyre rating (%)
90
Rs. (Lacs)
Anand Rahatekar
%age trimming damage defect
Avg Min/month
Anil Pansare
3.40%
T Kalaivendhan
152
%age Non Compliance
Shrikant Ghadge
Process capability, Cp of bias cutter
K Sudarshan
%age
60.35%
0.28
T Kalaivendhan
G WILL START OCT'15 ONWARDS

Brk down Hrs/Month
Pradeep Subedarpage
37
Brk down Occurences

Cost in Lakhs
Muri Reduction
Tyre scrap in No's
Quality
Time in Mins/Section
Technology
No of accident
Gauge in MM
Nos
Kg/Kg
Customer Complaints in No's
Grease consumption (Kg)
Oil consumption in liters per month
Prashant Kage
14
Sanjay Pagare
24
Pradeep Subedarpage
Vinayak Pote
23
K Apparao
Shrikant Ghadge
Dablu Kumar
Raj Parvatikar
Abhijeet Dushing
Bhushan Joshi
Mukul Karande
Ankit Rana
Raj Parvatikar
Pradeep Subedarpage
Task Achievement
CEAT Limited
ACKER FOR THE MONTH OF: SEPTEMBER'15

Res/Tgt
1.4000
12%
0.12
154
867
39
1.5
20
88.07
4.41
0.0009
Sep-14
Oct-14
Nov-14
Dec-14
Jan-15
1.30
9.77%
0.00
686.00
1.40
7.10%
0.08
0.00
164.52
1.30
9.10%
0.06
0.00
434.05
1.20
21.00%
0.08
0.00
338.00
1.10
14.47%
0.04
0.00
295.00
29.00
34
35
30
36
1.48
21.00
86.00
1.31
20.00
86.00
1.10
15.00
87.77
0.83
14.00
86.46
3.53
0.86
0.89
0.85
0.0009
42
0.07
0.05
0.16
0.05
0.03
0.001
80
69.00
1.92
30000
0
56
0.52
30649
0
12.0
9.92
8
6.48
708
0
124
10%
95
Achieved
209
100
0.50%
76
36.21
1.33
14
0
0
2
0
Task Achievement
Feb-15
Mar-15
Apr-15
May-15
Jun-15
1.70
34.34%
0.11
0.00
796.00
1.10
19.18%
0.28
0.00
910.00
1.46
4.54%
0.11
0.00
940.00
1.10
4.50%
0.09
0.00
877.00
0.02
0.00
1994.00
1.17
3.04%
0.07
0.00
1489.00
65
38.00
16.00
38.00
10.00
38.00
0.49
15.00
87.45
0.20
5.00
82.77
0.39
13.00
90.50
0.35
3.00
89.72
0.86
6.00
89.25
0.22
6.00
89.50
0.77
1.65
1.83
3.23
2.80
1.48
0.0009
0.0009
0.0009
0.0009
0.0009
0.00098
0.80
Jul-15
Size not Run in the

Month of July'15
0.06
0.07
0.07
0.07
0.07
0.07
0.02
0.13
0.11
0.00
0.01
0.01
0.0010
0.0036
0.0040
0.0030
0.0020
0.0015
72.00
69.00
92.00
89.00
87.00
77.00
0.18
0.18
1.35
0.06
0.33
0.47
30122
28959
28527
28662
30196
30219
14.0
13.5
19
15
16
10
9.5
9.6
9.7
9.4
9.75
9.90
8.00
9.20
10.58
10.35
7.32%
5.71
4.71
616.00
285.00
546.00
882.00
15%
15%
15%
15%
95%
87%
115
74
One Time
One Time
One Time
One Time
5.20
232
100.00
one more month
for assesment
0.00
45.00
15%
1.33
5.59% (Task
Achievement)
Aug-15
Sep-15
0.90
8.87%
0.06
0.00
749.00
1.04
12.60%
0.09
0.00
234.00
QIP tracking completed
for 12 months
38.00
Tracking done for 12 months.
0.41
6.00
91.81
0.76
6.00
91.00
2.72
0.91
0.00100
0.00097
Size not Run in the

Month of Aug'15
Size not Run in the

Month of Sept'15
0.07
0.06
0.04
0.02
0.0010
0.0000
87.00
90.00
0.90
0.43
30904
30139
18
15
9.96
9.45
6.3
9.07
4.35
5.00
364.00
0.00
15%
15%
89
119.86
One Time
One Time
211
200.19
100.00
83.33
Till Aug '15 Saving

is 1.5
Till Sept '15 saving is
lakhs/month(Appro Approx 3 Lakhs/month.
ximate )
0.00
0.00
72.00
0.00
11.96%
21.57
2.55
3.00
5.59% (Task
Achievement)
5.59% (Task
Achievement)
5.40
5.30
Tracking will start

Oct'15 onwards

Updated AM QIP Tracker Rev 24.10.15

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Updated AM QIP Tracker Rev 24.10.15

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CEAT Limited

AM TRACKER FOR THE MONTH OF: SEPTEMBER'15

Quality : Fabric scrap/month

AM Step III Certified - Fy'15-16 Q2

Base Line Target Results

Tracking will start October onwards.

Guidelines for Colour Coding

QIP : Specific Problem

High Laceration Accidents/Month (Knifeless)

High rush of people in HR for queries

High usage of knife for flash cutting operation

High usage of knife Batch-off unit of Ban.no.5 ( for

High usage of hot knife for ply cutting in NTB

High flash cure in tractor tyres

Radial tyre scrap due to No PCI

Elimination of naptha based outer paint in all radial sizes

Manual cutting operation of Belt edge cushion of

The manual process takes long time and workflow plans

No tread weight data analysis in excel also

12 High light side wall defect in 6.00-16 Ayushman size

High Radial tyre scrap due to bladder over bead (BOB)

14 HIgh Mica defect in rear tractor tyres.

15 Tread rejection due to side crack at 8*10 Extruder

15 Tread rejection due to side crack at 8*10 Extruder

16 Deteriotion of fabric booking liners

% Improvement in export lot size warehousing

InProcess QIP Tracker alongwith T

QIP TRACKER FOR THE

Reducing the production loss in radial due to GT trolley shortage

List of downgraded QIPs of Fy'13-14

Asset identification in production areas - Curing Assets

Completed QIP Quarter II FY 14-15 : Nasik

Elimination of missing cord in CANYLO

Reduction of shoulder separation defect in 7.00R15 milaze lt

Reduction in employee complaints

Reduction in Band Loss due to trolley shortage

Completed QIP Quarter III FY 14-15 : Nasik

Reduction of Soap Solution consumption

Tyre stiffness improvement in 7.50-16 double bead sizes for

Re-engineering of 195R15 LT Steelplus in Nashik due to tyre

Squegee blister reduction in all radial sizes

Reduction in Mix Carbon Scrap

Uniformity yield improvement in 185R14 LT Milaze

Reduction of squeegee blister in 195R15 Steelplus

Reduce utility power consumption

Reduction of customer complaint tread joint open in size 80018Aayusmaan

Elimination of Toe Flash in 59 J (While excess Sidewall stitching)

Elimination of customer complaint No serial

Manufacturing Lead time reduction

scrap reduction in 8x6 Lt cold feed extruder

Reduction in FM defect in tractor sizes from 7.8% to 6.24%

Reduction of Premature by reducing turn up separation in 100020H CL HL sizes

Reduction of Customer complaint of groove crack in size 120024HT SUPER

To reduce the bead failure in premature & claim tires in 1020

Productivity improvement in Non truck sizes.

Improve the Resolution of Bol Bindass Complaints

Improvement of cut tyre rating in all radial sizes to A & B rating

High canteen cost

High trimming damage defect in eleveta sizes (NTC)

High Loss of production Due to unmix batch generation at Ban02

High premature claims due to breaker stretch

Low Productivity in banbury 02

Completed QIP Quarter II FY 15-16 : Nasik.

Reduction of breakdown hours due to drop door rubber jamming