MT PRESENTATION

MY VIEWS ON KSB ORIENTATION PLAN WITH EMPHASIS ON GOVERNING PROCESSES / MODUS OPERANDI OF ALL SECTIONS / DEPARTMENTS

Supplier Customer Relationship

Complaint

Service
Repair, Maintenance, Spares

Customer
PO Pump AO

Sales/ Marketing (P&A, PM) Machines, Utilities, Facilities In right condition Maintenance Machines, Utilities, Facilities In right condition

Foundry

PO

Sales Order/ AO Planning/ Stores PR Machining. assembly, painting, testing

Pump Engineering BOM/Drawings Raw Material Materials

WR

Raw Casting Raw Casting, Prod Ord, Painting Plan Production

I MT Presentation I Muhammad Ali I 2012

Admin & IR
Admin & IR

Company Perspective
Business Units Submersible Single Stage Multi Stage Automation Valves

Manpower

Legal

Industrial Relations

The Factories Act, 1934

Duties and Obligations Polices Rules and Regulations Code of Conduct

Business Segments Water and Waste water Building Services Industry and Energy Turnkey Projects

Union

I MT Presentation I Muhammad Ali I 2012

Projects & Application

Business Type BT1 Stock BT2 Standard BT3 Modified Standard BT4 & 5 New Design P & A is back sales office

Sales
6 sales office

KSB Partner Franchises

Dealership WWW I,E,B 500 - 600 Million PKR 600 - 700 Million PKR

Pump Selection

Export Sales

Service
Project

200
500

Million PKR
Million PKR Million PKR Imported Nominal Pressure Temperature

Foundry 200 KSB Easy Select MBK

Valves
Butterfly Valves Gate & Globe Valves

Sales Order

Tubular Casing Pumps/ B Pumps

Control Valves
Diaphragm Valves Ball Valves
4

Acceptance of Order

I MT Presentation I Muhammad Ali I 2012

Planning
Forecasting XP Make to order XD Make to stock XB Make to stock with reorder point

IT
SD

QM Sales Order Auto MRP (1 as default)

PP

SAP

Make In house E PlnOrd

Outsource F Auto PRs

CO/FI

MM

Convert to Production order

Release

Foundry 634 Release

Local 621
Release

Import 622
Release

SC/OS 623 Release

SAP, an ERP SAP Rollout as per plan in Nov,2011 To bring visibility, integration, speed and quality MDM

Auto PO to Foundry

To MM for Purchase order

I MT Presentation I Muhammad Ali I 2012

Foundry

Production

CNC Machines

Group technology Cellular Manufacturing (8

Cells) Lean Manufacturing Reduce lead time On time delivery Enhance manpower productivity Reduce WIP

Pump Parts Automotive Parts

OEE Routes KPIs

Capacity Utilization
Productivity % Rejection Turner/ Machinist Efficiency
I MT Presentation I Muhammad Ali I 2012

Assembly Shop
Sub-Assemblies assembled by fasteners

Test Bed
To ensure trouble free pump operation and verification

Concept of super market for small parts

Lean Manufacturing Separate assembly stations for large and small pumps

Two open loop test fields

Max DN 1000, Pressure 60 bar, Q 6000 m3/h, Power 500 KW Instruments: Pressure Gauges, Flow meters,

Painting Plan

Tachometers, Test motors, Power meter, Vibrometer

Calibration DIN, ISO, API standards Performance curves: Q vs H, Q vs , Q vs Power input

Blasting, Coating, Painting

Controlling the parameters Relative Humidity, Temperature, Adhesion

Total head is the difference of total energy at discharge

flange and suction flange. Total energy is the sum of pressure head, velocity head and datum head. Affinity or Model Laws Witness testing
7 I MT Presentation I Muhammad Ali I 2012

Materials
PR Release Purch Grp

Maintenance
Pump Division Foundry Division

Maintenance

Imports

Local

SC/ OS
Breakdown Maintenance Facility Management Industrial Engineering

RFQ

If price list vendor then purchase order is given if not then at least 3 Quotations are taken

Work Request

Utilities

Expansion/ Civil Works

3 Quotations Vendor Payment Inspection Report Purchase Order

Quality Price Lead Time

Work Order SMED KANBAN

Follow up

Electrical
Vendor Development Multiple Sourcing
8

Mechanical

I MT Presentation I Muhammad Ali I 2012

Product Management
External Product Management Market Information/Needs Business Strategy Product Behavior (Life Cycle) Competitiveness In-House Capability Sourcing Profitability Product Need/Feasibility Streamlined Operations Effective Resource Utilisation 9

Service
Internal
7 service office, 3 Repair center

Northern, Central, Southern Region

EPCC Repair, Maintenance, Over hauling Energy Audit

Deliver Value!

Customer Complaint Handling

Pumps on Rental Spares Service on site

Controlling Product Life Cycle Cost Optimization

Trouble Shooting

Pricing/Profitability
Product Competitiveness

I MT Presentation I Muhammad Ali I 2012

QHSE
Integrated Management System Quality management principles TQM = QC + QA + Total Quality

Engineering
Bill of Material
Standard Non standard

Order Processing Drawings

ISO 9001, ISO 14001, Mbk Certification

Self quality inspection Quality inspection at Incoming and Outgoing Quality Notifications

10

I MT Presentation I Muhammad Ali I 2012

THANK YOU
11 I MT Presentation I Muhammad Ali I 2012