OEMS REPORT

FY 2011-2012(July)

MONTHLY DISPATCHES FROM OEMS

OEM

Product

Apr,11

May,11

Jun,11

Jul,11

Advantec

SAC

8301

9815

3043

800

5495

5604

8245

2955

Advantec WRAC
Advantec

WRAC
KIT

500

Lloyd(D)

SAC

26112

3046

2035

1777

Lloyd(P)

SAC

9793

2708

560

5275

Lloyd(K)

WRAC

1437

Amber

SAC

8826

5718

1186

1844

Amber

WRAC

5553

4965

5538

Amber-R WRAC

Aug,11

Sep,11

Oct,11

Nov,11

Dec,11

Jan,12

Feb,12

Mar,12

DISPATCH
TOTAL DEFECT
T-DEFECT %

1844
74
4.01%

PART DEFECT

51

PA-DEFECT %

2.81%

PROCESS DEFECT
P-DEFECT %

23
1.20%

DELIVERY PERFORMANCE OF
AMBER DEHRADUN

10000
8826

9000

8151

8000

7722

7000
5718

6000
5000

4974

4000
3000
1844

2000

1186

1000
0

Jan

Feb

March

April

May

June

July

PROCESS V/S VENDOR DEFECTS

AT AMBER
250

10

Production

Vendor Defect

200

Process Defect

150

6
5

100

4
3

50

2
1

30-Jul

29-Jul

28-Jul

27-Jul

26-Jul

25-Jul

24-Jul

23-Jul

22-Jul

21-Jul

20-Jul

19-Jul

18-Jul

17-Jul

16-Jul

15-Jul

14-Jul

13-Jul

12-Jul

11-Jul

10-Jul

9-Jul

8-Jul

7-Jul

6-Jul

5-Jul

Vendor
Defect
Process
Defect

4-Jul

Production

3-Jul

2-Jul

1-Jul

1-Jul

2- 310- 11- 12- 13- 14- 15- 16- 17- 18- 19- 20- 21- 22- 23- 24- 25- 26- 27- 28- 29- 304-Jul 5-Jul 6-Jul 7-Jul 8-Jul 9-Jul
Jul Jul
Jul Jul Jul Jul Jul Jul Jul Jul Jul Jul Jul Jul Jul Jul Jul Jul Jul Jul Jul Jul Jul

61 0

15

32

86 200 49

52 120 164 125 122

117

35 165 122

2 0

3 0

FIRST TIME RIGHT AND

TOTAL DEFECT TREND AT AMBER
99.50%

4.50%
98.93%

99.00%

98.94%

98.99%
4.01%

98.49%

98.50%

FTR%

4.00%

Total Defect %

3.50%

97.83%

98.00%

3.00%

3.01%

97.50%

2.50%

97.00%
96.50%

2.17%

96.99%

2.00%

95.99%
96.00%

1.51%

1.50%

95.50%

1.07%

1.06%

1.01%

1.00%

95.00%
0.50%

94.50%
94.00%

0.00%
Jan'11

Year

Feb'11

Mar'11

Apr'11

May'11

Jun'11

Jul'11

Aug'11

Sep'11

Oct'11

Jan11

Feb'11

Mar'11 Apr'11 May'11 Jun'11 Jul'11 Aug'11 Sep'11

Total Def % 3.01%

1.51%

1.07%

FTR %

1.06%

1.01%

2.17% 4.01%

96.99% 98.49% 98.93% 98.94% 98.99% 97.83% 95.99%

Nov'11

Dec'11

Oct'11 Nov11 Dec11

IMPROVEMENT
CHECK POINTS

DETAILS

Continuous Improvement

PRODUCT
1.5 T Hot n Cold Chassis

BEFORE

DT. OF IMPLEMENTATION
July, 2011
AFTER

Remote packed in
cardboard box, no
visibility

CONTENTS:

Breakage found in earlier Fan

CONTENTS:

Fan Material change as per Specs given by

UCPL R&D

FINDINGS/ADVANTAGES

Improvement against Problem found during Mass Production.

IMPROVEMENT
CHECK POINTS

DETAILS

Continuous Improvement

PRODUCT
1.5 T Hot n Cold Chassis

BEFORE

DT. OF IMPLEMENTATION
July, 2011
AFTER

Remote packed in
cardboard box, no
visibility

CONTENTS:

Improper Fitment of Partition Plate with

Condenser End plate.

CONTENTS:

Manual Bending of Partition plate started on

line for proper fitment.

FINDINGS/ADVANTAGES

Improvement against Problem found during Mass Production.

DISPATCH

PRODUCTION
TOTAL DEFECT
T-DEFECT %
PART DEFECT
PA-DEFECT %

PROCESS DEFECT
P-DEFECT %

5275
2367
65
2.75 %
56
2.37 %
9
0.38 %

FIRST TIME RIGHT AND

TOTAL DEFECT TREND AT LLOYD
100.00%

5.00%

100.00%
FTR %

Total Def %

4.54%

4.50%

99.00%
4.08%

98.29%

3.75%

98.00%

3.46%

98.20%

4.00%

3.86%

3.59%

3.50%
97.25%

97.00%

3.00%
96.54%
96.25%

2.75%

96.41%

96.00%

2.50%

96.14%

95.92%

2.00%

95.46%

1.80%

1.71%

1.50%

95.00%

1.00%
94.00%

0.50%
93.00%

0.00%

0.00%

Oct'10

Nov'10

Dec'10

Jan'11

Feb'11

March'11

April'11

May'11

June 11'

July'11

Year

Oct'10

Nov'10

Dec'10

Jan'11

Feb'11

March'11

April'11

May'11

June'11

July'11

Total Def %

3.46%

3.75%

3.59%

4.54%

1.71%

4.08%

1.80%

3.86%

0.00%

2.75%

FTR %

96.54%

96.25%

96.41%

95.46%

98.29%

95.92%

98.20%

96.14%

100.00%

97.25%

PROCESS V/S VENDOR DEFECTS

AT LLOYD
8

350
Production

300

Vendor

Defect

Process Defect

250

6
5

200

4
150

3
100

50

0
31-Jul

30-Jul

29-Jul

28-Jul

27-Jul

26-Jul

25-Jul

24-Jul

23-Jul

22-Jul

21-Jul

20-Jul

19-Jul

18-Jul

17-Jul

16-Jul

15-Jul

14-Jul

13-Jul

Production 0
Vendor
0
Defect
Process
0
Defect

12-Jul

11-Jul

10-Jul

9-Jul

8-Jul

7-Jul

6-Jul

5-Jul

4-Jul

3-Jul

2-Jul

1-Jul

1-Jul 2-Jul 3-Jul 4-Jul 5-Jul 6-Jul 7-Jul 8-Jul 9-Jul

10- 11- 12- 13- 14- 15- 16- 17- 18- 19- 20- 21- 22- 23- 24- 25- 26- 27- 28- 29- 30- 31Jul Jul Jul Jul Jul Jul Jul Jul Jul Jul Jul Jul Jul Jul Jul Jul Jul Jul Jul Jul Jul Jul

0 80 200 0 87 0

0 40 190 60 0

0 230 310 63 250 0 280 270 127 130 50 0

7 6

4 4

1 0

0 3

1 0

0 0

DISPATCH

PRODUCTION
TOTAL DEFECT
T-DEFECT %
PART DEFECT
PA-DEFECT %

PROCESS DEFECT
P-DEFECT %

1777
2367
96
4.06 %
70
2.96 %
26
1.10 %

FIRST TIME RIGHT AND

TOTAL DEFECT TREND AT LLOYD
6.00%

100.00%
99.00%

FTR %

Total Def %

5.68%

5.57%

5.00%

5.22%

98.00%

97.65%

97.00%

4.00%

4.39%
3.75%

96.00%

3.46%

2.35%

3.59%

3.51%

96.41%

96.49%

4.06%
3.00%

95.00%
94.00%

96.54%

96.25%

93.00%

2.00%
95.61%

94.78%

94.32%

95.94%

94.43%

1.00%

92.00%

0.00%

91.00%

Oct'10

Nov'10

Dec'10

Jan'11

Feb'11

March'11

April'11

Year

Oct'10

Nov'10

Dec'10

Jan'11

Total Def %

3.46%

3.75%

3.59%

5.68%

3.51%

5.22%

FTR %

96.54%

96.25%

96.41%

94.32%

96.49%

94.78%

May'11

Feb'11 March'11 April'11

June'11

July'11

May'11

June'11

July'11

5.57%

4.39%

2.35%

4.06%

94.43%

95.61%

97.65%

95.94%

PROCESS V/S VENDOR DEFECTS

AT LLOYD
450

20

Production

400

Vendor

350

18

Defect

16

Process Defect

14

300

12

250

10
200

150

100

50

0
30-Jul

29-Jul

28-Jul

27-Jul

26-Jul

25-Jul

24-Jul

23-Jul

22-Jul

21-Jul

20-Jul

19-Jul

18-Jul

17-Jul

16-Jul

15-Jul

14-Jul

13-Jul

Vendor
Defect
Process
Defect

12-Jul

Production 0

11-Jul

10-Jul

9-Jul

8-Jul

7-Jul

6-Jul

5-Jul

4-Jul

3-Jul

2-Jul

1-Jul

1-Jul 2-Jul 3-Jul 4-Jul 5-Jul 6-Jul 7-Jul 8-Jul 9-Jul

10- 11- 12- 13- 14- 15- 16- 17- 18- 19- 20- 21- 22- 23- 24- 25- 26- 27- 28- 29- 30- 31Jul Jul Jul Jul Jul Jul Jul Jul Jul Jul Jul Jul Jul Jul Jul Jul Jul Jul Jul Jul Jul Jul

0 302 340 112 0 246 25 27 400 0

0 303 305 307 0

2 11 3

0 18 0

0 10 7 12 0

DISPATCH(ODU Kit)

800

TOTAL DEFECT

12

T-DEFECT %

1.50%

PART DEFECT

10

PA-DEFECT %

1.25%

PROCESS DEFECT
P-DEFECT %

2
0.25%

DISPATCH(WRAC)
TOTAL DEFECT
T-DEFECT %

2955
85
2.87%

PART DEFECT

39

PA-DEFECT %

1.32%

PROCESS DEFECT
P-DEFECT %

46
1.55%

PROCESS V/S VENDOR DEFECTS

AT LLOYD
500

Production

450

Vendor Defect

400

Process Defect
350

300

5
250
4
200
3

150

100
50

0
30-Jul

29-Jul

28-Jul

27-Jul

26-Jul

25-Jul

24-Jul

23-Jul

22-Jul

21-Jul

20-Jul

19-Jul

18-Jul

17-Jul

16-Jul

15-Jul

14-Jul

13-Jul

12-Jul

11-Jul

10-Jul

9-Jul

8-Jul

7-Jul

6-Jul

5-Jul

4-Jul

3-Jul

2-Jul

1-Jul

1-Jul 2-Jul 3-Jul 4-Jul 5-Jul 6-Jul 7-Jul 8-Jul 9-Jul

10- 11- 12- 13- 14- 15- 16- 17- 18- 19- 20- 21- 22- 23- 24- 25- 26- 27- 28- 29- 30- 31Jul Jul Jul Jul Jul Jul Jul Jul Jul Jul Jul Jul Jul Jul Jul Jul Jul Jul Jul Jul Jul Jul

Production 459 169 0 298 476 370 333 9 158 0 132 27 0 231 71 0
Vendor
Defect
6 2 0 3 6 5 3 0 2 0 1 0 0 3 2 0
Process
Defect
5 1 0 3 5 5 4 0 3 0 4 0 0 8 0 0

0 208 186 42 55 0