Sie sind auf Seite 1von 20

MAI Location Chakan Fact - Files Production 2010-2011

SS/ 08.Feb. 2011

Fact - File SBC Production in Chakan plant

1H1 2H10 Total Jan- Feb- Mar- 2Q11 2H11 Total 0 10 11 11 11 11 PRODUCTION ( Mio Pieces)
0.4 12.2 12.6 13.1 2.4 1.4 2.46 3 2.72 3 3.05 7.9 8.84 16.8 17.95 33.1 35 0.56 12.55 -

Budget ( Mio Pieces) Production ( Mio Pieces) Forecast ( Mio Pieces)

MANPOWER
4 Staff Budget 3.5 Staff Actual Operatives Budget 2 1 Operatives Actual 6 5 6 6 0.5 0.2 6 5 6 6 0.5 0.29 6 5 10 6 0.5 6 10 0.5 6 10 0.5 6 12 0.5 6 12 0.5 6 12 0.5 -

SCRAP RATIO ( %)
Scrap Ratio Target ( %) Scrap Ratio Actual ( %) PPM Target
0.5 0.38

EXTERNAL PPM Capacity coating system SBC: > 50 Mio pieces/year 2 0 2 0 2 0 10 10 -

PPM Actual

10 -

10 -

10 -

10 -

SBC PRODUCTION 2010/11

06/22/11

SS/Operations

SBC OPERATIVE MANPOWER


Operative Manpower Details

Only Operative Team Common Staff Like Maintenance / Logistic / Quality function are divided in equal proportions. Mubea + Contactor employees considered

06/22/11

SS/Operations

SBC STAFF MANPOWER


Staff manpower Details

Only White collar Common Staff Like Maintenance / Logistic / Quality function are divided in equal proportions.

06/22/11

SS/Operations

SBC SCRAP %

Action Proper Cleaning of Upper Tank to avoid paint lump

06/22/11

SS/Operations

SBC PPM

06/22/11

SS/Operations

Fact - File VS Production in Chakan plant

1H1 2H10 Total Jan- Feb- Mar- 2Q11 2H11 Total 0 10 11 11 11 11 PRODUCTION ( Mio Pieces)
1.9 2.22 4.25 4.39 6.15 6.6 0.8 0.6 0.6 1.3 1.3 1.5 1.4 4.4 4.1 8 9 16 16

Budget ( Mio Pieces) Production ( Mio Pieces) Forecast ( Mio Pieces)

MANPOWER
7 Staff Budget 6.5 Staff Actual Operatives Budget 3 3 Operatives Actual 8 7.5 7 7 6% 8 7.5 7 7 6% 8 7.5 7 7 2% 8 10 2% 8 10 2% 8 10 2% 8 10 2% 8 10 2% -

SCRAP RATIO ( %)
Scrap Ratio Target ( %) Scrap Ratio Actual ( %)
6% 1.49 1.34% 1.41% 1.2% %

EXTERNAL PPM PPM Target VS line: 1piece 2 Sec; 2 2 2 2 2 2 2 2 Capacity / GEFF 75 %; 21 WD;16.5 Mio pieces/year PPM Actual 0 0 0 0 -

VS Production 2010/11

06/22/11

SS/Operations

VS STAFF MANPOWER
Staff manpower Details

Only White collar Common Staff Like Maintenance / Logistic / Quality function are divided in equal proportions.

06/22/11

SS/Operations

10

VS OPERATIVE MANPOWER
Operative Manpower Details

Only Operative Team Common Staff Like Maintenance / Logistic / Quality function are divided in equal proportions. Mubea + Contactor employees considered

06/22/11

SS/Operations

11

VS SCRAP %

Action UPS Back up provided

06/22/11

SS/Operations

12

VS PPM

06/22/11

SS/Operations

13

Continuous improvment and Trainee Programm s Chakan Plant

Trainee program for coling process. 2 Trainees to Bedano from week 7 to week 15 2 Trainees Under Hot presetting machine ( Under Mr Prasad)

Continuous improvment results (last 8 weeks) : reduction HPS setting time from 1.5 hour to 0.5hour due to standard setting sytem better pipe system to avoid stopage of line. Achieved Zero rejection of Fall down spring ( Before After -

Forcast Stock of SBC


All values in millions Revised forecast date 02.02.2011

SBC INVENTORY ANALYSIS 1Forecast Sales 2ORDER / TANSIST 3Total Stock ( Chakan +
Slow Moving Moving

Feb Mar Apr May 2.86 3.10 3.25 2.59


0.44 2.42 0.55 2.55

1.9 0.56
Slow Moving Moving 5.68 7.87 5.24 7.35

0.48 2.77 0.2

0.56 2.03

CGN)

13.55 12.59 10.05


4.69 5.36

7.00
4.21 2.78

4Closing Stock

12.59 10.05

7.00

4.40

Slow Moving 5.24 4.69 4.21 3.65 Moving 7.35 5.36 2.78 0.75 Actions For Inventory Reduction Weekly Order strategy Implemented Slowing inventory to be sold other required Mubea locations- Under progress Clear DSI implementation

Investigation DSI Target s for VS


DSI total (sales base 4.Q11)= 33 DSI Actual DSI: 34 Lead time in total; wire ordering to shipping FG VS to EU: 114 days (5,7 month) Detailed steps of suplier- chain days Average time order and processing VS-W Suncall/Japan 80%; Suzuki-Garphytan/China 20% Transit /Shipping Japan/China India Customs/Clearance & Transit Mumbai pune Stock raw material Chakan Production Stock FG Chakan (incl. monthly Container fill up) 50 20 9 20 5 10 DSI related NO NO YES YES YES YES DSI transit = 6 DSI DSI inhouse = 27 DSI

Investigation DSI Target s for SBC


DSI total (sales base 4.Q11)= 60 Actual DSI : 74 days
Lead time in total; order uncoated SBC to domestic indian customer (north): 94 days Detailed steps of supplier chain Average time order and processing SBC uncoated MUB-Taican60%; MUB Attendorn 40% Average Transit /Shipping from China/Germany - India Customs/Clearance Transit Mumbai-Pune Stock raw material Chakan Production Stock FG Chakan (35% Volumes) Transit FG Dehli (65% Volumes) Stock FG Delhi (65% Volumes) days 26 24 5 2 20 2 10 5 10 (target) DSI related NO YES YES YES YES YES YES YES YES

DSI transit = 27

DSI inhouse = 33

Project Plan Stab Bar

06/22/11

SS/Operations

18

Layout for Stab Bar project (project plan see extra chart )

Stab bar production end heating (Oven LPG) end punching (Press) bending ( Pulzer ) correction (Correction Work Station) process flow from backside to front

THANK YOU