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F-cost

4,000 10 Plan 3,500

Jun10

Comp
09. Result

10 Rslt.

3,400

3,000

2,658 2,543 2,700


2,500 2,223 2,000

1,700
1,495 1,407

1,843

1,804

1,835

1,838

1,849

1,495 1,189
1,129

1,500

1,400

1,000

500

0
JAN FEB MAR APR MAY JUN JUL AUG SEP OCT NOV DEC

I t em 09. Result 10 P l an

JAN 2,700 1,000 1,495 67%

FEB 3,400 1,000 2,223 45%

MAR 1,700 1,000 1,407 71%

APR 1,189 1,000 1,129 89%

MAY 1,495 1,000 1,843 54%

JUN 1,804 1,000

JUL 1,835 1,000

AUG 1,400 1,000

SEP 1,838 1,000

OCT 1,849 1,000

NOV 2,658 1,000

DEC 2,543 1,000

Profitable Growth B3X

2010

10 R sl t . A . R at e

E st i m at i on

Number one to the customer !

IF + EF Cost
3,500 3,000 2,500 2,000 1,500 1,000 500 0
JAN FEB MAR APR MAY

Jun10
3,300

Comp
10 Plan 10 Rslt. 09. Result

IF- Cost

2,600 2,296 1,500 2,035 1,407


1,652

2,440

1,541

1,686 1,361

1,647

1,627

1,472

1,165

1,273

1,112

JUN

JUL

AUG

SEP

OCT

NOV

DEC

I t em 09. Result 10 P l an

JAN 2,600 900 1,472 61%

FEB 3,300 900 2,035 44%

MAR 1,500 900 1,407 64%

APR 1,165 900 1,112 81%

MAY 1,273 900 1,652 54%

JUN 1,541 900

JUL 1,686 900

AUG 1,361 900

SEP 1,647 900

OCT 1,627 900

NOV 2,296 900

DEC 2,440 900

Profitable Growth B3X

2010

10 R sl t . A . R at e

E st i m at i on
400 350 300 250 200 150 100 50 0 1 I t em 09. Result 10 P l an JAN 137 100 23 435% 2 FEB 24 100 188 53% 3 MAR 169 100 121 83% 4 APR 24 100 16 625% 5 MAY 222 100 192 52% 6 JUN 263 100 7 JUL 149 100 8 AUG 39 100 9 SEP 191 100 10 OCT 222 100 11 NOV 362 100 12 DEC 104 100 23 188

EF- Cost
263 222 169
121 192

10 Plan

10 Rslt.

362 09. Result

222 191 149 104 39

137

24

24

16

2010

10 R sl t . A . R at e

E st i m at i on

Number one to the customer !

IF-Cost Items

Jun10

Comp

Issue
Repairing Process 1% M/C shop WMS 3%

Counter Actions
Transformer Overheating Problem Gas Mixture Ration Problem One point lesson to be display at Stage

Resp
Prod/PE

Status
Done

Comp Scrap at Co2 Stage

L-Shell 225 K Assy Stator Assy


High Noise 109 K

Prod

Done Done 10th Jun

Operator to be identified & Fixed Visual display to be done for model change

Prod
Prod

U Shell 72 K Comp 64 K Assy C-Silencer 21 K

Paint Shop (WMS) 55%

Final Asm. (WMS) 39%

100% Continuity check at Teahwa Stator Assy. before dispatch (HV Fail, Main over) HV testing to be done in Sound proof chamber at Taehwa C-Block Bore/Boss Dent

QA

Done 20th Jun

QA

Reloading redn. thru Servo


Press MC Parameter Setting PE

Done

ITEM

Jan-10

Feb-10

Mar-10

Apr-10

May-10

Jun-10

Jul-10

Aug-10

Sep-10

Oct-10

Nov-10

Dec-10

Stand still Operation Repairing process IF-Cost Discarding Materials (wms) (K Rs.) Machine Shop Final Asm. Paint Shop Total IF Cost Sale Turn over
Internal Failure Cost % Target %

0 10 631 61 351 219 641 435428


0.15% 0.09%

0 10 987 136 599 252 997 485042


0.21% 0.09%

0 10 788 37 312 440 798 567591


0.14% 0.09%

0 10 677 27 243 397 687 608849


0.11% 0.09%

0 10 1017 31 448 538 1027 615870


0.17% 0.09% 0.09% 0.09% 0.09% 0.09% 0.09% 0.09% 0.09%

Profitable Growth B3X

Number one to the customer !

EF-Cost Items
140

Jun10

Comp
Export

120 100
K Rs.

Buyer Transport Cost Overseas Corporations Overseas Trips Overseas Service

80 60 40 20 0
Jan'10 Feb'10 Mar'10 Apr'10 May'10 Jun'10 Jul'10 Aug'10

Export Claims Supporting Gratutious Services Discarding Materials (Comp Ret) Field Return Domestic

Sep'10

Oct'10

Nov'10

Dec'10

ITEM

Jan-10

Feb-10

Mar-10

Apr-10

May-10

Jun-10

Jul-10

Aug-10

Sep-10

Oct-10

Domestic Field Return Discarding Materials (Comp Ret) Gratutious Services Supporting EFExport Claims Cost Overseas Service Overseas Trips Overseas Corporations Buyer Transport Cost Export
Total EF Cost Sale Turn over External Failure Cost % Target %

0 0 10 0 0 0 0 0 0 0 0
10 435428 0.002% 0.01%

79 0 0 0 0 12 0 0 0 0 0
91 485042 0.019% 0.01%

0 0 0 0 0 0 0 0 0 0 0
0 567591 0.00% 0.01%

0 0 10 0 0 0 0 0 0 0 0
0 608849 0.00% 0.01%

0 118 0 0 0 0 0 0 0 0 0
118 615870 0.019% 0.01% #DIV/0! 0.01% #DIV/0! 0.01% #DIV/0! 0.01% #DIV/0! 0.01% #DIV/0! 0.01%

Profitable Growth B3X

Number one to the customer !

FCost Improvement Plan (May10)


Sl. Issue Cause
Transformer Overheating
1. Co2 Leakage Tip Cleaning not done -100 pcs. Gas Mixture ratio problem

Comp Action Plan


Fan provided in transformer Tip Cleaning verification by Sec. Leader Daily Machine TPM by operator (6-8pm) Praxair person visit & Training provide 100% DCon Tube Straightening in MC Shop

Resp.
Pravin Mauli Mauli Dahiya

Tgt. Dt.
Done

Cont.
Cont. Done Done Done Done Done

Saket

2.

High Noise

Body Gap checking not OK Wrong L/Shell or U/Shell

Bending Plate Alignment Corrected at Vendor One point lesson to be display at Stage Operator to be identified & Fixed Model Change sheet to be revised Air Gap checking person report to QA

Anil T
Mishra Mishra Mishra Rajeev A Arora A Arora Rajeev

Done
Done Done 20 June Done

3.

H V Fail

Loose wire Touch with Rotor Testing not proper at vendor

100% Continuity test at Taehwa before Dispatch HV testing to done in sound proof chamber at Taehwa Visual check : Check point to be made

Dismantling of Drop Assy. Due C-Block 4.


(Bore & Boss Dent)

10 Sample testing to be done in transportation Air Gap checking person report to QA Time Check : To be maintain by Micrometer Operator Awareness Level Up

Rajeev Rajeev Mauli

Imme. Done Done

- Bore & Boss Dent - Low Voltage - Air Gap NG

- Piston Jam

Profitable Growth B3X

Number one to the customer !

CO2 Leakage issue


Target :- CO2 Leakage reduction from 35000 PPM3000 PPM
Current Trend :Welding Leakage PPM 40000 35000 30000 25000 20000 15000 10000 5000 0
34811

03/06/2010
Strategy :- Fixture wise analysis
Pareto Chart of Fixture
1600 1400 1200 1000 80 60 40 20 0 100

13210 4772 20-May 24-May 28-May 4501 1-Jun 4933

800 600 400

Fixture no 3,4 major contributor

3-Jun

20-May PPM 34811

24-May 13210

28-May 4772 Date

1-Jun 4501

3-Jun 4933

200 0 Fixture Count Percent Cum % 4 334 22.1 22.1 3 329 21.8 43.8 6 280 18.5 62.4 2 229 15.1 77.5 5 207 13.7 91.2 1 133 8.8 100.0

FTA analysis (major Contributors):


Sr No 1 2
T.Date imm imm 10/6/2010 imm 23/6/10 imm 23/6/10 imm

Long term Activities


Activity Upper Shell pressing JIG design change RANDO OIL (50 L) application for cleaning and DOE Loader 1 and 2 no design change bench marking loader no 3 Late Welding optimum distacnce between Wire and Shell matching profile findout and program change if no fault in Panasonic transformer Fixture no 1,2,3,4 Digital display of volatage and current Creator voltage with linear scale calibration Res S Puranik Rajeev Sharma T.Date Atul Mishra 4-Jul 23-Aug

Short Term and Long term activities for 50003000 PPM


Sr No 1 2 3 4 5 6 7 8

Short term activities


Activity Vendor information for no mixing 10 days cross checking 100% for mixing Liner Mounting proper design Argon+CO2 partial pressure checking 3hrs Model changeover time reduction Limit switch cleaning/changing before frequency DOE's for Index plate different profiles Late Welding again discussion with Panasonic and further action plan. Res A.Tandon/Praveen Saket Goel,Atul Sharma S.Puranik,Manoj Mohan singh/Maharana Rajeev Sharma Pravin Sharma Pravin Sharma,S Puranik Atul Mishra

Atul Mishra 23-Aug Atul Mishra,Prav 23-Aug in Sharma Atul Mishra 4-Jul Atul Mishra 23-Aug

5 6

Profitable Growth B3X

Number one to the customer !

Percent

Count

PPM

Body Gap NG
Defect Detail
Noise Problem coming in LQC-2 129 Pcs. Scrap due to Noise WMS Amt 1.3 Lakhs

06.06.10

Action Taken
Activity
100% DCon Straightening in MC Shop after Pickling Process Body Gap Checking Person Fixed & Will Report to QA Tube Bending Plate Alignment Corrected at Taehwa Daily Checking & guidance given to MC Shop Operator Anil T Saket Done Cont. Krishan Done

Resp.
Saket

T. Date
Done

Cause
Body Assembly Position Shift & Touching with Upper Shell D-Con Pipe Bending NG ( 90 Degree ) Shifted Towards RHS.

100% DCon Straightening in MC Shop


DCon tube Bending NG Spec : 90 Obser : Bending Towards RHS Spec :< 2.5 mm Observation : 1.5mm

Body Gap Checking Person Report to QA

Result
129
Qty

8
May10 W1 Jun10

Noise

Profitable Growth B3X

Number one to the customer !

Thank You

Profitable Growth B3X

Number one to the customer !