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Treading the path of

excellence …
… at CVBU
TATA MOTORS
Parthasarathi Banerjee
Asst General Manager
Tata Business Excellence Model
Commercial Vehicle Business Unit
Tata Motors Ltd
Jamshedpur

Software Productivity Conference


Bangalore 18 February 2006
TBEM Group, Jamshedpur 1
Tata Motors - A Flagship
Automotive Company of the Tata Group

Leading the Future


TBEM Group, Jamshedpur 2
Tata Group

• Serving India for 127 years

• 93 diversified companies

• A Total Turnover of US$ 17.8 billion (2.8% of India’s GDP)

• Largest Market Cap. - Trusted over by 2 million shareholders

• Account for 5 % of India’s exports

• Strong Brand Equity and Business Values

TBEM Group, Jamshedpur 3


The Tata Group - 7 business sectors

Engineering Materials Energy Chemicals

Automotive and Power Chemicals


Metals
Engineering Products Composites

Communications & IT Consumer Products Services

Hotels
Telecommunications Consumer goods Financial Services
Information Technology International operations
Other Services

TBEM Group, Jamshedpur 4


Tata Motors

• India’s Largest Automotive Company

• Total income of US$ 4.7 billion (2004-05)

• Over 3 million Tata Vehicles plying on Indian Roads

• India’s only full range manufacturer of Passenger Cars & Commercial


Vehicles

• Product portfolio covers passenger cars, trucks, buses, and defence


vehicles

• Currently has four vehicle manufacturing units at Jamshedpur, Pune,


Lucknow and Gunsan (S Korea)

Leading the future of the Indian Automobile Industry


TBEM Group, Jamshedpur 5
Additional Strengths that Tata Motors can leverage

‰ Tata Group synergy for world class offering

‰ Tata Cummins for state-of-the-art Engines

‰ TACO - Collaboration with world class auto component /system


manufacturers including Johnson controls, Yazaki, Knorr Bremse,
Ficosa, Owens Corning, Faurecia,Toyo, etc..

‰ Tata Steel for HR & CR sheets and other steel inputs

‰ Telcon - Earth moving plant and machinery - collaboration with


Hitachi, John Deere, Euclid

‰ Tata Advance Materials for special materials & composites

‰ TCS / Tata Technologies for a range of engineering, manufacturing


and business system solutions software development

‰ Fiat s.p.A. for Design, Manufacturing, Sourcing and Distribution of cars

‰ Hispano Carrocera SA for Innovation in Buses

TBEM Group, Jamshedpur 6


Tata Motors

• Among the top 6 Medium & Heavy Commercial Vehicle Manufacturers in the
world

• Over 130 models of Vehicles & Automotive Products which include


• Cars & Multi-utility vehicles
• 1 ton LCVs to 40 ton HCVs / Tractor Trailers
• Buses from 12 seats to 67 seats
• Tippers to Special Purpose vehicles
• Wide Range of Defence vehicles

• Driven in 70 countries

Leading the future of the Indian Automobile Industry


TBEM Group, Jamshedpur 7
Tata Motors – Product Range : Cars and MUVs
Cars MUVs

Indica Safari

Indigo Sumo
Victa

Indigo Marina Sumo


Spacio

TBEM Group, Jamshedpur 8


Tata Motors - Commercial Vehicles Product Range

LCVs Medium & Heavy CVs- Trucks


Tata Mobile
LPT 1615
207- Pick
Truck
up

SFC 407 SE 1613 TC


Cargo Truck Truck

LPT 407
LPO 1613
Cargo Truck
Car Carrier

LPT 709 E LPT 2515


Container Tanker
Truck

ACE
Mini-Truck LPT 2516
Mixers

TBEM Group, Jamshedpur 9


Tata Motors - Commercial Vehicles Product Range

Medium & Heavy CVs – Dumpers/ Tippers / Tractor Trailer

LPK 1615 LPS 3015


Tipper Tractor

LPK 2516 LPS 3516


Heavy duty Tractor -
Dumper Container

LPK 1615
Turbo LPS 3516
Heavy Duty Tanker
Dumper

TBEM Group, Jamshedpur 10


TATA integrated logistics solutions

TBEM Group, Jamshedpur 11


Tata Motors- Defence & Paramilitary Vehicles

Tata SD 1015
Tata 407 Soft
TC (4X4)
Top
Troop Carrier
Troop Carrier

Tata 407 hard LPT 1615 TC


top (4X4)
Troop Carrier Troop Carrier

Tata LPT A
713 TC Tata LPT A
(4X4) 1621 TC (6X6)
Ambulance High mobility
(Logistics)

Tata LPT 709


E Hard Tata A 1615
Troop Carrier TC 4X2
LOC Carrier

TBEM Group, Jamshedpur 12


Tata Motors - Commercial Vehicles Product Range

Buses

SFC 407 LPO 1510


Mini bus CNG bus

LP/LPO
LP 709E 1510
Staff Bus Euro I
City Bus

LPO 1615 LPO 1616


TC TC
Luxury bus Luxury Bus

TBEM Group, Jamshedpur 13


Tata Daewoo Commercial Vehicle joins the Tata Family

• First major Overseas acquisition in March ‘04

• Significant addition to Product Range and manufacturing capabilities

• Access to South Korean Market for MCVs and ICVs

• A step towards International presence

TBEM Group, Jamshedpur 14


Tata Daewoo Commercial Vehicle joins the Tata Family

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

Acquisition of DWCW expected to


help
• Tata Motors in its efforts to make the 'truck of the
future',
• Enter Southeast Asian markets like South Korea,
Thailand and Malaysia as well as China, to truly boost
its presence in foreign markets

TBEM Group, Jamshedpur 16


Tie-up with Hispano Carrocera SA yields Starbus and Globus

Starbus
Seating capacities from 16 to 67 seats

Designed for optimum functionality and


comfort
Offer unparalleled economy to the operators
Starbus range includes Standard, Deluxe, Low
Floor and Skool bus options - each with a
customised set of features

Globus
Tata Globus Coach designed to transport
long-distance traveller in the very lap of luxury

Ergonomically designed seats


Spacious leg room
Special baggage space
Personalised climate control vents to quieter
engines
Air-suspension and superior braking systems

TBEM Group, Jamshedpur 17


The Business Model

• Malcom Baldrige National Quality Award for Business


Excellence
• European Foundation Quality Model
• … many others

TBEM Group, Jamshedpur 18


The Tata Group

• 1991 – the time India was beginning to get


liberalised. Mr. Ratan N Tata takes over as
Chairman, Tata Sons
• 1993 – Chairman for over 50 years Mr. JRD
Tata passes away
• 1994 – JRD QV Award for Business Excellence
instituted within the Group – in line with MBNQA
• 2000 – JRD QV BE Model renamed Tata
Business Excellence Model (TBEM)

TBEM Group, Jamshedpur 19


The Goals of TBEM

•Delivery of ever-improving value to customers,


resulting in marketplace success
Ever growing top line

• Improvement of overall organizational effectiveness


and capabilities
Ever improving efficiencies
and reducing costs

• Organisational & Personal Learning

TBEM Group, Jamshedpur 20


TBEM Core Values and Concepts

Visionary Leadership

Organizational & Customer- Driven


Personal Learning Excellence

Agility Focus on the Future

Social Responsibility
Management By Fact
& Citizenship

Valuing Employees &


Managing for Innovation
Partners

Focus on Results &


Systems Perspective
Creating Value

TBEM Group, Jamshedpur 21


TBEM Framework: A Systems Perspective
TBEM

85 85

450
125

85 85

90

TBEM Group, Jamshedpur 22


THE TBEM FRAMEWORK

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

TBEM Group, Jamshedpur 23


Business Excellence Awards to CVBU
JRD QV Award for Business Excellence 2005
Earlier winners
• TCS (2004)
• Tata Steel (2000)

CII-Exim Bank Award for Business Excellence 2005


Earlier winners
• Infosys (2002)
• Tata Steel (2000)
• Maruti Udyog (1998)
• Hewlett Packard (1997)
TBEM Group, Jamshedpur 24
Journey in the Award Process, so far…
Wins …
• JRD QV Award for Business Excellence
• CII-Exim Bank Award for Business Excellence
700
620
578
600 551
503
500 410 437
400
400

300

200

100

0
1998 1999 2000 2001 2002 2003 2004 2005
TBEM Group, Jamshedpur 25
Business Excellence Model … key elements

Strategic Execution Organizational


Leadership Excellence Learning

… to …

Lead the Manage the Improve the


organization organization organization

TBEM Group, Jamshedpur 26


We work through …

Strategic Execution Organizational


Leadership Excellence Learning

… to …

Lead the Manage the Improve the


organization organization organization

TBEM Group, Jamshedpur 27


Strategic Leadership

• Leadership System
• Strategic Planning
• Focus on Customer

TBEM Group, Jamshedpur 28


Strategic Leadership

• Leadership System
• Strategic Planning
• Focus on Customer

TBEM Group, Jamshedpur 29


Leadership Role

• Set direction
• Organise and allocate resources
• Review to achieve plans
• Develop Employees
• Innovate and improve

TBEM Group, Jamshedpur 30


Aspire for … Vision – Mission - Values

Core Values Vision


To be a world class corporate constantly furthering the interests of all
its stakeholders
Integrity
Mission
Customer Focus
Shareholders :To consistently create shareholder value by
Corporate Citizenship Purpose generating returns in excess of WACC during the upturn and at least
equal to WACC during the downturn of the business cycle
Passion for To create
economic Customers :To strengthen the Tata brand and create lasting
Engineering
assets for road relationships with customers by working closely with business
transportation for partners to provide superior value for money over the life cycle
the bulk movement of goods Vendors and Channel Partners: To foster a long term relationship
and people and participate in so as to introduce a broad range of innovative products and services,
managing these over the life that would benefit our customers and other stakeholders
of assets in order to create Employees:To create a seamless organisation that incubates and
and capture economic promotes innovation, excellence and the Tata core values
value Community: To proactively participate in reshaping the country’s
economic growth and to take a holistic approach towards
environmental protection

Strengthen and leverage the Low Cost base and Offer a


world class Product Range at the most competitive price
– A Unique Value Proposition from Tata

TBEM Group, Jamshedpur 31


Leadership System
Co
mm
l
ode Set Direction and Plan un
ica
M Co
le t
R o mm e an
a i tm dB
Be en uil
Understand Vision, t d
Stakeholder Needs,
Higher Level
Objectives
Innovate, Share
and Learn
Customers
Adapt to New Challenges

Employees Partners Organise, Align, and


and Raise the Bar

Mission Allocate Resources

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

Passion for Engineering Customer Focus Integrity Corporate Citizenship

Tata Code of Conduct 32


TBEM Group, Jamshedpur
Leadership System - Deployment

Levels of Leadership
• Innocence
• Awareness
• Commitment
• World-class
TBEM Group, Jamshedpur 33
Self – Evaluation Matrix

TBEM Group, Jamshedpur 34


Social Responsibility & Organisational Governance

• CVBU complies with Global


Reporting Initiative (GRI)
Guidelines – Triple Bottomline
approach
• Tata Code of Conduct
• Communication
• Tracking adherence
• Effectiveness Measurement

TBEM Group, Jamshedpur 35


Strategic Leadership

• Leadership System
• Strategic Planning
• Focus on Customer

TBEM Group, Jamshedpur 36


Strategic Leadership

• Leadership System
• Strategic Planning
• Focus on Customer

TBEM Group, Jamshedpur 37


Strategic Planning

through
• Balanced Scorecard -
Development and Deployment

TBEM Group, Jamshedpur 38


I believe that lack of Strategic Planning has a
profound influence on the position of a Business
Organization in the marketplace and most of the
problems of the Organization can usually be traced
to lack of Planning

Ratan N. Tata 1996

TBEM Group, Jamshedpur 39


Strategic Planning

TBEM Group, Jamshedpur 40


Strategic Planning
• Think
• Environment Scanning
• Visioning
• Strategic Challenges
• Setting Strategic Direction

• 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

"TO SATISFY OUR SHAREHOLDERS,


WHAT FINANCIAL OBJECTIVES MUST
WE ACCOMPLISH?”

CUSTOMER PERSPECTIVE

"TO ACHIEVE OUR FINANCIAL


OBJECTIVES, WHAT CUSTOMER
NEEDS MUST WE SERVE?”

INTERNAL PERSPECTIVE

"TO SATISFY OUR CUSTOMERS, AND


SHAREHOLDERS, IN WHICH INTERNAL
BUSINESS PROCESSES MUST WE
EXCEL?”

LEARNING PERSPECTIVE
"TO ACHIEVE OUR GOALS, HOW
MUST OUR ORGANIZATION
LEARN AND INNOVATE?”

TBEM Group, Jamshedpur 42


CVBU – BSC Implementation Structure

STEERING COMMITTEE
CVBU - BSC

PLANT / FUNCTIONAL STEERING


COMMITTEE - BSC

DIVISIONAL/ CX STEERING COMMITTEE


BSC

DEPARTMENTAL STEERING COMMITTEE


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

BSC Assessment - Level Definitions


AREA 1 2 3 4 5
The Beginning Early Development Effective Deployment Towards Maturity A Way Of Life
Customer Clear identification of customers Key customers' requirements SLAs on critical Q and D targets; SLAs on all critical targets; reviews SLAs on all important parameters;
Orientation and their requirements are collected through systematic reviews take place as scheduled take place as scheduled reviews take place as scheduled
process
Data Data on all KPMs - past data, Performance data available for Projections of targets available for Projections of targets available for Projections of targets available for
Sufficiency targets, and accountability in all KPMs 50% of KPMs 75% of KPMs all the KPMs
standard format; Performance
data available for 60% of KPMs
Alignment Links to BSC is understood and Links to BSC is understood and Links to BSC is understood and Links to BSC is understood and All possible BSC KPMs are
with Plant noted in the SQDCM Format for noted in the SQDCM Format for noted in the SQDCM Format for noted in the SQDCM Format for all addressed through Divisional
BSC 25% of possible KPMs 50% of possible KPMs 75% of possible KPMs possible measures SQDCM
Comparative Intra-plant comparative data Inter-plant comparative data External comparative data Benchmark data available on critical Benchmarking processes based on
Comparison available on all KPMs and used available on all KPMs and used available for all critical KPMs and KPMs identified benchmarks is in progress
and for setting targets on at least 50% for setting targets on at least used for setting targets for these
Benchmarking of KPMs 50% of KPMs KPMs
Quality of Regular and timely reviews AOP and CA are available for AOP and CA are available for 50% AOP and CA are available for 75% AOP and CA are available for all the
Review and 25% of KPMs; Corrective action of KPMs; Corrective action planned of KPMs; Corrective action planned KPMs; Corrective action planned
Analysis planned are actionable with PDC are actionable with PDC and are actionable with PDC and are actionable with PDC and
and accountabilities available accountabilities available accountabilities available accountabilities available
Degree of Standard SQDCM Board Divisional heads and TBEM Parameters and targets displayed Most employees are aware and All employees are aware and
Involvement available at pre-determined place coordinators are involved in the in all areas; Accountable Managers involved in SQDCM involved in SQDCM
SQDCM process own their KPMs
Learning and Learning is documented. Learning and sharing with a few Learning and Sharing with all Learning and Sharing with all Learning and Sharing - Inter-plant
Sharing departments departments divisions
Quality of Trend of Performance and Overall Trend of Performance and Trend of Performance and Overall Trend of Performance and Overall Trend of Performance and Overall
Performance good performance on target for a Overall good performance on good performance on target for good performance on target for 75% good performance on target for all
few of KPMs (<25%) target for 25% of KPMs 50% of KPMs of KPMs the KPMs
The Beginning Early Development Effective Deployment Towards Maturity A Way Of Life
AOP: Analysis of Performance; CA: Corrective Action; PDC: Probable Date of Completion; BSC:
Balanced ScoreCard; KPM: Key Performance Measure

TBEM Group, Jamshedpur 45


BSC ASSESSMENT - CONCLUSION

LEVELS OF PERFORMANCE
Level 1: THE BEGINNING
Level 2: EARLY DEVELOPMENT
Level 3: EFFECTIVE DEPLOYMENT
Level 4: TOWARDS MATURITY

Level 5: A WAY OF LIFE

TBEM Group, Jamshedpur 46


BSC JOURNEY

• CVBU BSC evolved first in September 2000

• Concept cascaded to Plants and Functions by 2001

• Assessments to develop maturity initiated in 2003

• Most divisions have matured BSC processes in 2005

TBEM Group, Jamshedpur 47


… and …
A Recognition WE, at CVBU, are
proud of …

TBEM Group, Jamshedpur 48


CVBU Tata Motors, the first and the only
Indian Company, awarded with the BSC
Hall of Fame in 2003 by Balanced
Scorecard Collaborative from the creators
of Balanced Scorecards - Drs. Kaplan and
Norton

Also, we are in the company of only 29


other companies in the world who have
won this award

TBEM Group, Jamshedpur 49


… warning!!

The Balanced Scorecard is not


a substitute for good
management
- it is only a tool.

It requires good management!!

TBEM Group, Jamshedpur 50


Strategic Leadership

• Leadership System
• Strategic Planning
• Focus on Customer

TBEM Group, Jamshedpur 51


Strategic Leadership

• Leadership System
• Strategic Planning
• Focus on Customer

TBEM Group, Jamshedpur 52


Focus on Customer

Market Development Process


Preparation of
Derive Marketing Listening &
Annual Business
Direction Learning
Plans

Implementation & Preparation of


Reivew Marketing Plan

Customer Touch Points


• One every 900 sq. km.

TBEM Group, Jamshedpur 53


Focus on Customer

Listen and learn

Customer Listening Capture customer & market


& Learning informationas per predetermined
Approaches frequency

Analyses of data by NPI and LOBs


Competitive
information from Priritisation of key customer
FIBRES requirements & their relative
Benchmarking importance in purchasing decisions
based on inputs from customers
through surveys

Product/ Business
Market Network
Service Planning &
Planning Planning
Planning Development

Development of the Plans by LOBs/ NPI/ Sales/ Services

Monthly Review of the impact on Business results, in SC


Meetings

TBEM Group, Jamshedpur 54


We work through …

Strategic Execution Organizational


Leadership Excellence Learning

… to …

Lead the Manage the Improve the


organization organization organization

TBEM Group, Jamshedpur 55


We work through …

Strategic Execution Organizational


Leadership Excellence Learning

… to …

Lead the Manage the Improve the


organization organization organization

TBEM Group, Jamshedpur 56


Execution Excellence

• Customer Relations
• HR Focus
• Manage Processes
• Operational Improvements
• Assess and Improve

TBEM Group, Jamshedpur 57


Execution Excellence

• Customer Relations
• HR Focus
• Manage Processes
• Operational Improvements
• Assess and Improve

TBEM Group, Jamshedpur 58


Customer Relationships

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

Sales Process Improvement


C0 – Customer C1 – Customer
(Prospects) (Performa Issued)

C3 – Customer C2 – Customer
Vehicle Delivered LOI/Token Payment
(TATA Customer) Received

TBEM Group, Jamshedpur 59


Customer Relationships
Customer Satisfaction Improvement Process
Qualitative Discovery phase to clarify all issues impacting
customer satisfaction

Questionnaire development (positively worded statements,


covering above aspects)

Customer interviews (recent buyers of CVBU and Competition)

Analysis of data using Regression analysis, Factor analysis

Relative importance of each Satisfaction & Dissatisfaction


Factor in customer satisfaction levels of CVBU & Competitors
and dissatisfaction on each factor

Relative rating of CVBU Vs Competition for prioritization


for improvement

Action plan development and deployment

Inputs from Annual review of Changes in


partners The process segments

TBEM Group, Jamshedpur 60


Execution Excellence

• Customer Relations
• HR Focus
• Manage Processes
• Operational Improvements
• Assess and Improve

TBEM Group, Jamshedpur 61


Execution Excellence

• Customer Relations
• HR Focus
• Manage Processes
• Operational Improvements
• Assess and Improve

TBEM Group, Jamshedpur 62


HR Focus

• Attract the GOOD


• Advance the BETTER
• Retain the BEST

TBEM Group, Jamshedpur 63


HR Vision and Mission

Enhance and maintain Human Capital, which


will make the Organisation a world class player
and further the interests of all stakeholders

‰ Source, develop and maintain Human Capital,


which will drive the culture of customer focus, high
performance and seamlessness.
‰ Create, learn and implement best in class HR
practices and processes in pursuit of excellence.
‰ Retain and attract the talent by improving the
brand through employee delight and loyalty.
‰ Improve Community friendliness.

TBEM Group, Jamshedpur 64 64


Work Structures

‰ Concept of Factories and Centres of


Excellence (CX)

‰ Cross-Functional Teams

‰ Self-Directed Teams

TBEM Group, Jamshedpur 65 65


Employee Development
‰ Focused Leadership Development through

‰ Fast track schemes

‰ Development Centres

‰ Technical Specialist Scheme

‰ Talent Management Scheme

‰ Focused Employee Training aligned with Business


Needs

‰ Evaluation of Training Effectiveness

TBEM Group, Jamshedpur 66 66


Employee Welfare

‰ Policy on Safety, Health, Security &


Ergonomics

‰ Business Risk Management

‰ Employee Welfare Services

‰ Employee Satisfaction Surveys

TBEM Group, Jamshedpur 67 67


Execution Excellence

• Customer Relations
• HR Focus
• Manage Processes
• Operational Improvements
• Assess and Improve

TBEM Group, Jamshedpur 68


Execution Excellence

• Customer Relations
• HR Focus
• Manage Processes
• Operational Improvements
• Assess and Improve

TBEM Group, Jamshedpur 69


Enterprise Process Model
Expectations, Statutory Requirements
ƒ Performance Improvement VALUE CREATION PROCESSES
& Change Management
Demand Creation Processes
ƒ Leadership & Corporate Citizenship ƒ Strategic Planning

(Employees,Investors,Govt, Society)
ƒ Market Development ƒ Sales Planning
ƒ Channel Partner Management ƒ Vehicle Financing
MANAGEMENT PROCESSES

Other Stake Holders


CUSTOMER
Demand Fulfillment Processes
Design Processes Production & Delivery Service Processes

and
Processes
ƒ Internal & External Communication

ƒ New Product ƒ Sales & Operations


Introduction Planning ƒ After Sales
ƒ Organisational Governance

ƒ Vendor Management Service


ƒ Services
Design ƒ Manufacturing

SUPPORT PROCESSES

ƒ Human Resource Management ƒ Finance & Budgeting


ƒ Facilities & Environment ƒ Information & Knowledge
Management Management

TBEM Group, Jamshedpur 70


EL11-Manufacturing …

Manufacturing
EPM Process No: CVBU-EL-11

Locational Process Chiefs: Locational Manufacturing Heads

Principal Process Owner: A P AryaMV


- Sr Raja
VP (JSR andVP
Rao, Lucknow
(Mfg)Works)
Sub_Proc No Sub Process Name Sub_Process Owner

CVBU-EL-11-01 Material Scheduling & Logistics Head Materials - Pune,JSR, LKO

CVBU-EL-11-02 Produce Vehicles/Aggregates/Components Factory/Divisional Heads - Pune, JSR,LKO

Heads Vehicle Despatch, Exports & CKD, Auto Services -


CVBU-EL-11-03 Vehicles & Spares despatch'
Pune, JSR, LKO

CVBU-EL-11-04 Analyis Of Customer Complaints Heads (QA, CQ, Customer Support) - Pune, JSR, LKO

CVBU-EL-11-05 Implementation of Design Modifications Head (TS/STDs I) - Pune, JSR, LKO

Head (maintenance): Respective Maintenance Heads/ CX


CVBU-EL-11-06 Maintenance
Heads in Factory/division, CX, Department

TBEM Group, Jamshedpur 71


EL11-02 Produce Vehicles/ Aggregates/ Components

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

How, it operates (Methods/ Practices) Effectiveness


1. Prepare production schedule • S&OP Schedule Adherence CLIP Score
• Based on vehicle production/dispatch schedule and spare parts call up • Quality Index Index
each factory/shop works out Production Schedule. • First Shot OK (Aggregate/ Assy Line Level) %
2. Allocate manpower • COPQ Rs./ Unit
• Each factory/shop works out its manpower requirement on the basis of • Process Capability Improvement (Machining) Ppk > 1.67 for identified %
processes
production plan and productivity targets and redistribute manpower and
• Process Capability Improvement (Non-measurable) % Conformance > 99.73
communicate net shortage/excess to HR. %
3. Ensure availability of materials, tooling, equipment • Process Capability Improvement (Tightening) Ppk > 1.33

• 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)

TBEM Group, Jamshedpur 72


Execution Excellence

• Customer Relations
• HR Focus
• Manage Processes
• Operational Improvements
• Assess and Improve

TBEM Group, Jamshedpur 73


Execution Excellence

• Customer Relations
• HR Focus
• Manage Processes
• Operational Improvements
• Assess and Improve

TBEM Group, Jamshedpur 74


Operational Improvements

Achieved through …
• 5 -S
• TPM
• Poka Yoke
• Kaizen

TBEM Group, Jamshedpur 75


Execution Excellence

• Customer Relations
• HR Focus
• Manage Processes
• Operational Improvements
• Assess and Improve

TBEM Group, Jamshedpur 76


Execution Excellence

• Customer Relations
• HR Focus
• Manage Processes
• Operational Improvements
• Assess and Improve

TBEM Group, Jamshedpur 77


Assess and Improve

CVBU Internal Assessment Process


Purpose
• Divisions/ Functions as Profit/ Cost Centres
• Align the function for breakthrough performances
• Improving systems and processes
• Sharing/ adapting best practices

Process
• Application Writing
• Evaluation by certified assessors
• Guided by senior executives as mentors

TBEM Group, Jamshedpur 78


Excellence Plan
‰ Inputs
‰ TBEM Assessment Feedback Report
‰ CII-Exim Bank Award Assessment Feedback
Report
‰ Process
‰ Divisions allocated relevant OFIs for evolving
the Excellence Plan as also the implementation
plan
‰ Output
‰ Timeplan against each Excellence Plan steps
‰ Implementation of Excellence plans

TBEM Group, Jamshedpur 79


Quality Month …

… a Tool for
Assessment
and
Improvement

TBEM Group, Jamshedpur 80


Quality Month Objectives

‰ To revisit our approaches and practices


‰ To understand the level of their
deployment
‰ To develop an Improvement Road Map

TBEM Group, Jamshedpur 81


…through …

• Interactive Workshops
• Inter-divisional competition on overall
Performance Excellence, 5S, Kaizen, TPM
• Interact with various stakeholders to
seek their expectations afresh

TBEM Group, Jamshedpur 82


Theme … this year
Robust Deployment of Enterprise Processes

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

TBEM Group, Jamshedpur 83


Theme
Robust Deployment of Enterprise Processes
Enterprise
An undertaking of some scope, complication, and risk;
A purposeful or industrious undertaking - one that
requires effort or boldness

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

TBEM Group, Jamshedpur 84


Training Workshops and Seminars and Debates …

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 …

Strategic Execution Organizational


Leadership Excellence Learning

… to …

Lead the Manage the Improve the


organization organization organization

TBEM Group, Jamshedpur 86


We work through …

Strategic Execution Organizational


Leadership Excellence Learning

… to …

Lead the Manage the Improve the


organization organization organization

TBEM Group, Jamshedpur 87


Organisational Learning

•Training to excel
•Knowledge Management
• … and, Consequent Results

TBEM Group, Jamshedpur 88


Organisational Learning

•Training to excel
•Knowledge Management
• … and, Consequent Results

TBEM Group, Jamshedpur 89


TBEM Champions

TBEM Champions are CHANGE AGENTS


Three-tier Structure:
• Business Excellence Champions
• Business Excellence leaders
• Business Excellence Mentors
Experts in Business Excellence Concepts
Coordinate BE activities in their divisions/ work areas
Leaders/ Members of External Assessment teams

TBEM Group, Jamshedpur 90


TBEM Champions

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

TBEM Group, Jamshedpur 91


Organisational Learning

•Training to excel
•Knowledge Management
• … and, Consequent Results

TBEM Group, Jamshedpur 92


Organisational Learning

•Training to excel
•Knowledge Management
• … and, Consequent Results

TBEM Group, Jamshedpur 93


Knowledge Management … as a process

1 2 3
Understand Encourage Exchange and
Knowledge Knowledge Use
Requirements Sharing Knowledge

5 4
Build
Improve the
Knowledge
Process
Repositories

TBEM Group, Jamshedpur 94


Knowledge Management… Structure

Transfer Mechanisms KM Focus Stakeholders

Measures : Efficiency and Effectiveness


• OC, SC Meetings
• Review Forums
• Role Model for KM
• Stakeholder Meets • Drive Best Practices
Strategic • Consultants • Breakthroughs

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

• Experts / CoPs •Mentor KM


• Suggestion Schemes •Enable the use of
Sub – • CX, SDT, Work Teams, Best Practices
Processes Improvement groups
•Improve Processes
• Mentoring, Training
•Measure Results

Supported by IT and non IT Knowledge Management tools

TBEM Group, Jamshedpur 95


KM for all - documentation
Knowledge Workbook Processes
Summary

Best Practices

Benchmarks

Knowledge Given and


KM Workbook Knowledge Gained
[ Best Practice Document
describing Benchmarks, Best
Performance against
Practices, Knowledge &
information Resources, Benchmarks
Knowledge Management,
Knowledge Sharing for each
EPM Process] Information & Knowledge
Resources

TBEM Group, Jamshedpur 96


Organisational Learning

•Training to excel
•Knowledge Management
• … and, Consequent Results

TBEM Group, Jamshedpur 97


Organisational Learning

•Training to excel
•Knowledge Management
• … and, Consequent Results

TBEM Group, Jamshedpur 98


Results

TBEM Group, Jamshedpur 99


Correlation of Results
Business Results 2000-01 2001-02 2002-03 2003-04 2004-05 GOOD
Trng Hrs/Empl

ESI

VA/ Employee

COQ

CSI-MHCV Trucks

Revenue

EBIDTA/ TO

MS-MHCV

TBEM

TBEM Group, Jamshedpur 100


Summarising …
Global
GlobalImage
Image
876 – 1000: World Class Leader

751 – 875: Benchmark Leader Excellent


Excellent
We are
here 651 – 750: Industry Leader

551 – 650: Emerging Industry Leader

451 – 550: Good Performance Average


Average

351 – 450: Early Improvements

251 – 350: Early Results


Beginning
Beginning
0 – 250: Early Development

TBEM Group, Jamshedpur 101


Band Descriptors

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.

TBEM Group, Jamshedpur 102


Band Descriptors
651-750
Refined approaches, including key measures
Good deployment in most Areas
Very good results in most Areas
Organisation alignment, learning, and sharing are key
management tools
Some outstanding activities and results address most
key customer/ stakeholder, market, process and
action plan requirements.
Industry* leader in most areas
Refers to other organisations performing substantially the same functions, thereby
facilitating direct comparisons

TBEM Group, Jamshedpur 103


Way Forward

‰ Leadership System Deployment

‰ Alignment and Integration of BSCs

‰ Customer – from SATISFACTION to DELIGHT

‰ Knowledge Management – as a Strategic Tool

‰ Business – HR alignment

‰ Institutionalised EPM

‰ Continuous Learning through Results


TBEM Group, Jamshedpur 104
THANK YOU

TBEM Group, Jamshedpur 105

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