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excellence …
… at CVBU
TATA MOTORS
Parthasarathi Banerjee
Asst General Manager
Tata Business Excellence Model
Commercial Vehicle Business Unit
Tata Motors Ltd
Jamshedpur
• 93 diversified companies
Hotels
Telecommunications Consumer goods Financial Services
Information Technology International operations
Other Services
• Among the top 6 Medium & Heavy Commercial Vehicle Manufacturers in the
world
• Driven in 70 countries
Indica Safari
Indigo Sumo
Victa
LPT 407
LPO 1613
Cargo Truck
Car Carrier
ACE
Mini-Truck LPT 2516
Mixers
LPK 1615
Turbo LPS 3516
Heavy Duty Tanker
Dumper
Tata SD 1015
Tata 407 Soft
TC (4X4)
Top
Troop Carrier
Troop Carrier
Tata LPT A
713 TC Tata LPT A
(4X4) 1621 TC (6X6)
Ambulance High mobility
(Logistics)
Buses
LP/LPO
LP 709E 1510
Staff Bus Euro I
City Bus
Erstwhile DWCV
• Second largest CV maker in South Korea with a
market share of around 26 per cent.
• Produced 200-400 horse power range of heavy duty
trucks
• Has over 93 models of cargo trucks, dumpers, mixer
vehicles and also the capacity to make light
commercial vehicles.
• Also makes tractors and utility vehicles and has an
annual production capacity of 20,000 vehicles.
• DWCV makes commercial vehicles in 200-400 BHP
range, while Tata Motors makes trucks up to a
maximum capacity of 200 BHP.
TBEM Group, Jamshedpur 15
Tata Daewoo Commercial Vehicle joins the Tata Family
Starbus
Seating capacities from 16 to 67 seats
Globus
Tata Globus Coach designed to transport
long-distance traveller in the very lap of luxury
Visionary Leadership
Social Responsibility
Management By Fact
& Citizenship
85 85
450
125
85 85
90
Leadership 125
Strategic Planning 85
Customer & Market Focus 85
Measurement, Analysis& KM 90
Human Resource Focus 85
Process Management 80
Business Results 450
TOTAL 1000
300
200
100
0
1998 1999 2000 2001 2002 2003 2004 2005
TBEM Group, Jamshedpur 25
Business Excellence Model … key elements
… to …
… to …
• Leadership System
• Strategic Planning
• Focus on Customer
• Leadership System
• Strategic Planning
• Focus on Customer
• Set direction
• Organise and allocate resources
• Review to achieve plans
• Develop Employees
• Innovate and improve
Shareholders Community
w er
Communicate and Involve po d
m
E rate
,
te le
it va cce
Create a Culture of Review and Adjust to , Mo or A nge
u ild m f Cha
Develop, Reward and High Performance Achieve Plan B ea
T
Recognise Employees
Levels of Leadership
• Innocence
• Awareness
• Commitment
• World-class
TBEM Group, Jamshedpur 33
Self – Evaluation Matrix
• Leadership System
• Strategic Planning
• Focus on Customer
• Leadership System
• Strategic Planning
• Focus on Customer
through
• Balanced Scorecard -
Development and Deployment
• Develop
• Strategic Analysis
• Strategic Focus/ Objectives
• Target Setting/ Resource Allocation
• Deploy
• Balanced Scorecard Deployment
• Review
• Review
• Evaluation & Improvement
TBEM Group, Jamshedpur 41
BSC – Four Perspectives
FINANCIAL PERSPECTIVE
CUSTOMER PERSPECTIVE
INTERNAL PERSPECTIVE
LEARNING PERSPECTIVE
"TO ACHIEVE OUR GOALS, HOW
MUST OUR ORGANIZATION
LEARN AND INNOVATE?”
STEERING COMMITTEE
CVBU - BSC
INDIVIDUAL MPAs
TBEM Group, Jamshedpur 43
BSC Assessment
ATTRIBUTES
QUALITY OF GOALS
•Customer Orientation
•Data Sufficiency
• Alignment with next higher level BSC
•Comparative Comparison and/ or Benchmarking
QUALITY OF PROCESS
• Quality of Review and Analysis
• Degree of Involvement
•Learning and Sharing
QUALITY OF PERFORMANCE
• Trend of and Overall Performance
TBEM Group, Jamshedpur 44
BSC Assessment Chart
LEVELS OF PERFORMANCE
Level 1: THE BEGINNING
Level 2: EARLY DEVELOPMENT
Level 3: EFFECTIVE DEPLOYMENT
Level 4: TOWARDS MATURITY
• Leadership System
• Strategic Planning
• Focus on Customer
• Leadership System
• Strategic Planning
• Focus on Customer
Product/ Business
Market Network
Service Planning &
Planning Planning
Planning Development
… to …
… to …
• Customer Relations
• HR Focus
• Manage Processes
• Operational Improvements
• Assess and Improve
• Customer Relations
• HR Focus
• Manage Processes
• Operational Improvements
• Assess and Improve
Relationship Management
Customers/ Channel Members Determine contact requirements
Inputs through L&L on - New CRM approaches/ modify
• Accessibility existing CRM approaches
•Recognition for loyalty
•Guidance & Assistance CVBU/ LOB SC
Analysis of inputs, Review of
current approaches
Benchmarking Information
Customer Database Deployment of CRM approaches
• QFD Information throughout network
• Dealership Network study Review of impact on Business
• Best practices in Auto Industry Results
C3 – Customer C2 – Customer
Vehicle Delivered LOI/Token Payment
(TATA Customer) Received
• Customer Relations
• HR Focus
• Manage Processes
• Operational Improvements
• Assess and Improve
• Customer Relations
• HR Focus
• Manage Processes
• Operational Improvements
• Assess and Improve
Cross-Functional Teams
Self-Directed Teams
Development Centres
• Customer Relations
• HR Focus
• Manage Processes
• Operational Improvements
• Assess and Improve
• Customer Relations
• HR Focus
• Manage Processes
• Operational Improvements
• Assess and Improve
(Employees,Investors,Govt, Society)
Market Development Sales Planning
Channel Partner Management Vehicle Financing
MANAGEMENT PROCESSES
and
Processes
Internal & External Communication
SUPPORT PROCESSES
Manufacturing
EPM Process No: CVBU-EL-11
CVBU-EL-11-04 Analyis Of Customer Complaints Heads (QA, CQ, Customer Support) - Pune, JSR, LKO
Inputs
• B/O materials, aggregates and Key Steps in - Produce Outputs
components Vehicles/Aggregates/Components • Vehicle, aggregate,
• In-house materials, aggregates 1.Prepare production schedule component as per quality
2.Allocate manpower norms and S&OP
and components
3.Ensure availability of material, tooling,
• Production schedule
equipment
• Estimate sheets/routings 4.Production of parts, aggregates and
• Support from other functions vehicles
• Quality plan/work 5.Monitoring of quality, productivity, safety
instructions/Control Plans and cost
• Resources manpower, direct
material, Indirect material/tools,
Performance Measure Unit
machines, equipments and
Efficiency
vehicles. • Eq. Unit./ Man/ Year Ratio
• Variable Conversion Cost / Unit Rs./ Unit
• Respective factory/shop co-ordinates with concerned agencies to ensure • Safety index (SR & FR)
%
on time availability of material, tools, machines etc.
4. Production of parts and aggregates Index
• Production activities are carried out as per estimate sheets / routings.
• Operatives carry out in process inspections/checks as per quality plan/
work instructions. Central QA performs audit checks to ensure that laid
down system is being followed. Sub process : Produce Vehicles/Aggregates/Components
5. Monitoring of quality, productivity, safety and cost Sub Process Ref : CVBU-EL-11-02 (version 1.1)
• Factory/Plant management reviews production, productivity, quality and Process Owner : Pune -JSR -LKO
cost on daily/monthly basis and takes corrective action as required. EPM Linkage– CVBU-EL-11 ( Manufacturing )
Preparation Date : 31/03/04 (updated 05/02/05)
• Customer Relations
• HR Focus
• Manage Processes
• Operational Improvements
• Assess and Improve
• Customer Relations
• HR Focus
• Manage Processes
• Operational Improvements
• Assess and Improve
Achieved through …
• 5 -S
• TPM
• Poka Yoke
• Kaizen
• Customer Relations
• HR Focus
• Manage Processes
• Operational Improvements
• Assess and Improve
• Customer Relations
• HR Focus
• Manage Processes
• Operational Improvements
• Assess and Improve
Process
• Application Writing
• Evaluation by certified assessors
• Guided by senior executives as mentors
… a Tool for
Assessment
and
Improvement
• Interactive Workshops
• Inter-divisional competition on overall
Performance Excellence, 5S, Kaizen, TPM
• Interact with various stakeholders to
seek their expectations afresh
Robust
Powerfully Built, Marked by Richness and Fullness
Deployment
Application of an organisation’s approaches.
Deployment is evaluated on the basis of the breadth and
depth of application of the approach to relevant
processes and work units throughout the organisation
Processes
Linked activities with the purpose of producing a product
or service for a customer within or outside the
organisation. It involves combinations of people,
machines, tools, techniques, and materials in a
systematic series of steps or actions
In areas of …
• Business Excellence
• TPM, Kaizen, 5S
• Safety & Health
• Human Values
• Quality in Education
• Operational Quality and the Customer
• Supplier Quality
• Ethics & Governance
TBEM Group, Jamshedpur 85
We work through …
… to …
… to …
•Training to excel
•Knowledge Management
• … and, Consequent Results
•Training to excel
•Knowledge Management
• … and, Consequent Results
TBEM coordinators
in divisions
Change Agents to 26
32
drive BSC, External
Benchmarking, KM Internal 20
and other business
excellence
initiatives 180 195
19
120
7
They are also the 5
26 39
TBEM Internal
Assessors
2000 2001 2002 2003 2004 2005
Assessors Base 2nd
only to Tata Steel –
a leading steel
manufacturer
•Training to excel
•Knowledge Management
• … and, Consequent Results
•Training to excel
•Knowledge Management
• … and, Consequent Results
1 2 3
Understand Encourage Exchange and
Knowledge Knowledge Use
Requirements Sharing Knowledge
5 4
Build
Improve the
Knowledge
Process
Repositories
Channel Partners
• Review meetings
Employees
•Use KM
Customers
• Experts
•Provide KM
Vendors
• CFT, CLT
EPM • Knowledge •Identify process
Processes Workbook Best Practices
(Knowledge given / •Linkage to BSC
gained, BP)
• Mentoring, Training
Best Practices
Benchmarks
•Training to excel
•Knowledge Management
• … and, Consequent Results
•Training to excel
•Knowledge Management
• … and, Consequent Results
ESI
VA/ Employee
COQ
CSI-MHCV Trucks
Revenue
EBIDTA/ TO
MS-MHCV
TBEM
551-650
Effective, systematic approaches to overall item
requirements and to key organisational needs
Fact-based, systematic evaluation and improvement
process resulting in overall organisational learning.
No major gaps in deployment.
Improvement trends and/ or good performance are
reported for most areas of importance.
Results address most key customer/ stakeholder,
market and process requirements and demonstrate
area of strength.
Business – HR alignment
Institutionalised EPM