Subros: An Update

National Workshop on “Enabling MSME
to be Competitive through Quality Tools”
Subros : An Update
Established in 1985, Subros is the Largest AC company in India. A Joint

Venture company between Suri group, Suzuki and Denso.
Subros : An Update R&D Center Noida Plant

 No. of Employees (Regular) : 1600 nos.
Tool Room
 Investment : 5 B Rs
 Installed Capacity : 1.2 million kits/ annum.
 (Expansion to 2 million kits/annum by 2012)
 Turnover - FY 2010-11 : 12.0 B Rs
 Quality Certifications : ISO 14001 , TS 16949
Manesar Plant OHSAS 18001 Pune Plant
Future Plants
Sanand Plant (2012) Chennai (Oragadam) Plant (2012)

© Subros Limited. All rights reserved © Subros Limited. All rights reserved
Facilities Product Range

Existing Products Range Future Products Range
Engine Cooling Commercial

Car Aircon Systems
Existing New Total Systems Vehicle ACs
Plants Noida Noida Tool Room Chennai
Manesar Pune Sanand
R&D Compr / HX
Land 212,348
(Sq Mtr.) 11,840 38,688 8,940 39,940 55,940 16,000 40,000
Building (Sq 71,910

7,000 23,566 4,500 22,517 11,196 3,0318,0 100
Mtr.)
47,500* 22,500* 00* 20,000* 133,066*
Engineering & Development Centres :

Denso Subros Engineering Services Centre ( Design JV ) - Noida
Bus A/C
Central R&D – Noida
Product Engg Centres – Pune, Chennai Compressors HVACs & Evaporator
Cooling module
Plant wise Product Profile :
Noida – Compressors, RS Evaporators, PDC, Precision Press Shop, Tool room Rail A/C
Manesar – Car ACs
Pune – Car / CV ACs, ECM products
Chennai – Car / CV ACs, ECM products, Off Road ECM / ACs, Bus AC, Truck Refrigeration
Hose & Tubes Condenser Oil Coolers, CAC Truck A/c
Subros customers Manufacturing Infrastructure
Compressor
Endurance Compressor blocks machining line Squeeze & Vacuum Die Casting Machine
Testing Machine
No clok Brazing Furnace

Injection Molding Machine Robotic Vision Inspection for Condenser
Condenser Core
Assembly Line
Chip less Cutting Machine Vacuum Brazing

CNC Tube Bender Furnace for Evaporators
For Aluminum Tubes
1
Product Development Infrastructure:

Technology & Business Solution at Subros
R&D / Tool Room
Calorimeter Wire EDM

Environment Test Chamber
Vibration Testing
CAE
CNC Machines
Our People, Our Strength Achievements
Chairman & Senior Management Team

Top
Scorer
MACE
Audit
2011~12
Skill workshop with support from DNJP Skill workshop in progress Training Session on Shop fl
oor
Capacity Plan to Meet Future Customer Demand
2500 Sales Volume HVAC Basis(no. in K) Projected 25000

22422
Capacity ‐ 3 Shift Basis (no. in K)
Indian Market Share - 40% 2000
N e t Sale s V alu e ( Rs. M illio n )
2000 Net Sales Value (Rs. Million) 20000

14204
N o . o f U n it (,0 0 0 )
1500
Tier 2 Up - gradation
1500 10891 1336 15000
1200
9055 1025
1000 1000 895
1000 6627 750 6947 10000
6474 750 747
Subros Journey in
5890
5649 619
500 500 467 506
500 367 393 5000
0
2004‐05 2005‐06 2006‐07 2007‐08 2008‐09 2009‐10 2010‐11 2011‐12 2014‐15
0 ‘Pursuit of Perfection'
Year 2004‐05 2005‐06 2006‐07 2007‐08 2008‐09 2009‐10 2010‐11 2011‐12 2014‐15
Sales Volume HVAC Basis(no. in K) 367 393 467 506 619 747 895 1025 1336
Capacity ‐ 3 Shift Basis (no. in K) 500 500 750 750 1000 1000 1200 1500 2000
Net Sales Value (Rs. Million) 5890 5649 6474 6627 6947 9055 10891 14204 22422
2
Subros Defects Trend at MUL Line In House PPM Trend
Major
Concer
Major
n
Concer
n
Background Trend of Customer Complaints
 Between 2004-2011 Subros has made

60
tremendous effort to improve Quality.
GOOD
Number of Defects / Year
50
48
40
30
20 17 16
15 14 14
10 7 6 6
0
03~04 04~05 05~06 06~07 07~08 08~09 09~10 10~11 11~12
(till
date)
YEAR
In-house PPM Trend Background
45000
41951
40000
 Between 2004-2011 Subros has made

GOOD
35000
30000 tremendous effort to improve Quality.

25000
 Analysis shows - 50~60% problem is

PPM
20000
15000
15613
from sub-vendors.
10281
10000
9507
5000
0
PPM 03~04 PPM 09~10 PPM 10~11 PPM 11~12 (Upto
Dec' 11)
YEAR
3
Defects Distribution Background
Year  Between 2004-2011 Subros has made tremendous

effort to improve Quality.
02~04
In-house
43%
 Analysis shows - 50~60% problem is from sub-
vendors.
 Sustenance of Quality Improvement not feasible

without improving the complete supply chain.
Vendor
Parts
57%
Subros Vision 2015 for TIER 2 Improvement Targets - Tier 2 Development
Demand Chain Management

 Strong supplier capability with self sustained quality
systems and overall excellence.
Efficiency Responsiveness
SCM
 Replicate the OEM experience of Tier-1 vendor up- ZERO DEFECT

gradation to Tier-2.
L C
 Entire Supplier Base move towards ‘Manufacturing Optimum I O
G
O
M
F Dedicated
Inventory N Q A
Excellence’ along with Subros through Systems Up V IS U M C
Facilities
gradation. E TI A U I
N C N L
L
T S I I
I
 Vendor end PPM at Subros end = Max 50 PPM. O
T
C
A
T
R I Faster &
Efficient Y TI
Y E Effective
transportation O
 All vendors to be TS-16949 Certified. N
S
Communicatio
n
Subros Limited
Approach History – Vendor Parts PPM Trend
Focused Improvement High Vendor

Activities
Receipt PPM
Act at Subros
30000 72468 end. 67132
24000
Review Cluster
Plan
Rej. (PPM)
Check
 Assess situation 18000

Meetings
with Suppliers
Improvement  Set Targets
Activity 12000
6000
Do 0
(Cumm. Apr'02-Mar'03) (Cumm. Apr'03-Mar'04)
Teach & Impart Subros learning in quality
Journey to extended partners
4
History – Vendor Parts Defect Trend History – Vendor Parts Delivery Trend
Abnormally High Production Downtime /

Frequent Line
Vendor Defects at
Stoppages at Subros
110 Subros end. 96 120 end due to High nos. of
100
87 110 99 Delivery Issues.
No. of delivery failures

90 100
80 90
No. of defects
70 80 67
70
60
60
50
50
40 40
30 30
20 20
10 10
0 0
(Cumm. defects, Apr'02- (Cumm. defects, Apr'03- (Cumm. delivery failure, (Cumm. delivery failure,
Mar'03) Mar'04) Apr'02-Mar'03) Apr'03-Mar'04)
Vendor parts defect stratification Vendor Parts Defects Distribution
Work Sporadic
Inspection Instruction
Control Plan Issues
Not Followed Gauge NA Not followed
16%
11% 6% 22%
Vendor
Inspection Improper
process NG Handling
11% 6%
Non-
Process fool adherence
proofing NA to Existing System
6% Tool Condition Systems Gaps
Set up pc.
Mixup
NG 26% 58%
6%
32%
Approach Vendor Targets
Focused Improvement
Activities
Act
GOOD
Review
Cluster
Plan
Check
Meetings Improvement  Assess situation

with Suppliers  Set Targets
Activity
Do 2007-11
2007-11 2011~12
2004-07
5
Vendor Targets Vendor Targets
GOOD
GOOD
500
2004~07 2007-11 2007-11

2004~07 2007-11
Vendor Targets Approach

Focused Improvement
Activities
Act
GOOD
Review Cluster
Plan
Check
 Assess situation
Meetings
with Suppliers
Improvement  Set Targets
Activity
2004~07 2007-11
Do
Focus of Improvement Activities Back Bone of Cluster Activity
 Implement effective Change Control

Management.
 Operators skill review at critical stations.
 System to eliminate set up piece mix up.
 Poka Yoke for fitment parameters of OEM’s.
 Tool Maintenance.
6
Quality Improvement Activities List of Cluster-1 Vendors Total : 8 Vendors
Initiative
• Design Specification Joint
Criticality
Review with Tier 2. of Parts
• Tool Design Review. S.NO. VENDOR LOCATION
• Joint Tool Maintenance Supplied
1 SUMATI ENGG. P. LTD. FARIDABAD
Initiative
2 PYN PRECISION COMPONENTS FARIDABAD
SSIG Activity Launched

3 SWASTIKA AUTOMATICS FARIDABAD
2009~10
4 SPECIAL TOOLS P. LTD. SAHIBABAD
5 ALLENA AUTO P. LTD. MOHALI

2007~08 Initiative
6 SUNVISOR INDIA P. LTD GURGAON
System Up gradation to
Initiative
ISO/TS 16949
• MACE Cluster-1 7 INTERFACE MICROSYSTEMS GURGAON
• MACE Cluster-2 Launched
Launched 2005~07
Quality
8 NRB BEARINGS LTD.
Busines
JALNA / THANE
Initiative Performanc s
Trainings & Execution of
2004~05 Projects at Vendor e at Subros Volume
Cluster Members
Quality Improvement Activities Activity Plan
Phase-1 (2005-06) Phase-2 (2006~07) Phase-3 (2007~09)
1. Customer 1. Complete 5 S
Phase 1 Fundamentals & Trainings Satisfaction Report 1. Cluster – 2 Launched
implementation
2. Training of Cluster 2. Lean Manufacturing 2. Lean Manufacturing
Members
3. Gemba Kaizen Horizontal Deployment
3. Red Bin Analysis (In
Execution of Projects 4. Deep Analysis
Phase 2 house rejection
analysis) 5. Energy Cost
3. Tool Maintenance
4. Implementation of Monitoring
4. External Participation in
1S and 2S 6. Cost of Poor Quality
Cluster Competitions.
5. Single piece flow –
Bench Marking
Phase 3 Model Line.
6. Quality circle
activity
7. Poka Yoke
Customer Satisfaction Report Monthly Quality Feedback – Tier 2

M/s NRB Bearings Ltd.
S Control 2009-10 Apr-09 May- Jun-09 Jul- Aug- Sep- Oct- Nov- Dec- Jan- Feb-
10
Mar- 2009-10
TARGET
# Parameter (Cumm) 09 09 09 09 09 09 09 10 10
1 Rejection at PPM 7132 0 0 0 0 0 500

Subros
2 Defect noted at Nos 3 1 1 0 1 0 0 0 2

Subros
3 Supplier Quality 0-100

Scale
37 50 50 60 0 40 10 40 >=90
Rating
4 Delivery not as No of
times
0 0 0 0 0 0 0 0 0
per schedule
5 Any other 0 0 0 0 0 0 0 0 0
concern of
customer
6 Subros 0-10
Scale
>=9
Satisfaction
Index
7
Activity Plan Training Program Conducted for Cluster vendors

1) Suggestion and Quality Circle
1. Customer
Satisfaction Report
1. Complete 5 S
1. Cluster – 2 Launched 2) Lean Manufacturing System
implementation
2. Training of Cluster 2. Lean Manufacturing
3) 5–S
2. Lean Manufacturing
Members
4) 7 QC Tools
3. Red Bin Analysis (In
house rejection 4. Deep Analysis 5) 5 Why analysis sheet
analysis) 3. Tool Maintenance
5. Energy Cost 6) Process FMEA
4. External Participation in 7) Energy Management
5. Single piece flow – 8) Level up Training
Model Line.
9) Tier-2 up gradation
6. Quality circle
activity
7. Poka Yoke
Cluster Member Training – Problem Solving Cluster Member Training – 5S
Cluster Member Training – Lean Manufacturing Trainings impact

Red Bin Analysis
Kaizens
+ Poka Yoke
7 QC
1S+2S Tools
+RedTag Quality
Circles
Small
5S Group
Activity
Cluster
Training’s
Problem
Solving Suggestion
Tools Scheme
Kaizens
Rejection/Rework
+ PPM
MPS + Continuous
Improvement
Projects
Single piece flow

+ Model Line
8
LEARNING FROM CLUSTER Activity Plan

TRAINING TO
TOP
MANAGEMENT Phase-1 (2005-06) Phase-2 (2006~07) Phase-3 (2007~09)
Satisfaction Report 1. Cluster – 2 Launched
implementation
PASSED ON TO 2. Training of Cluster 2. Lean Manufacturing 2. Lean Manufacturing
GRASS ROOT Members
LEVEL 3. Red Bin Analysis
(In house rejection 4. Deep Analysis
analysis) 3. Tool Maintenance
5. Energy Cost
4. External Participation in
Model Line.
6. Quality circle
activity
7. Poka Yoke
Red Bin Analysis – M/s STPL ( Tier 2 ) Activity Plan
1. Cluster – 2 Launched
Satisfaction Report implementation
Members
3. Red Bin Analysis
4. Deep Analysis
(In house rejection
3. Tool Maintenance
Monitoring
4. Implementation of 4. External Participation in
Model Line.
6. Quality circle
activity
7. Poka Yoke
1S /2S in Press Shop – M/s NRB 1S /2S in Molding Shop – M/s Sanatan
9
Tool Room 1S / 2S Activity – M/s NRB Activity Plan
Members
3. Red Bin Analysis
4. Deep Analysis
(In house rejection
3. Tool Maintenance
Monitoring
Model Line.
6. Quality circle
activity
7. Poka Yoke
Single Piece Flow Line M/s Allena Single Piece Flow Line M/s PSPL
PRODUCTION SHOP
BEFORE AFTER
COMMENTS: COMMENTS:
1. ZIG ZAG PROCESS FLOW 1. SINGLE PIECE FLOW.
Activity Plan
Quality Circles Learning from Cluster
BRAIN STOARMING SESSION ON SHOP FLOOR – Tier 2

Members
3. Red Bin Analysis
4. Deep Analysis
(In house rejection
3. Tool Maintenance
Monitoring
Model Line.
6. Quality circle
activity
7. Poka Yoke
10
DEFECT CAUSE ANALYSIS ACTIONS INITIATED BASED ON QC FINDINGS

PIE ANALYSIS – DIMENSIONAL VARIATION PIE ANALYSIS – BURRS
RESULTS
INSPECTION
METHOD
DEFECTS CAUSE ACTION PLAN
TOOL DESIGN
41% 22%
METHOD OF
INSPECTION
PROCESS
44%
PARAMETERS
Tool Design
 Reduced
4%
PREVENTIVE review with
MAINTENANCE Dimensional Inadequate Subros started Defects at
43% variation Tool Design jointly. Customer
end.
SKILL OF
PREVENTIVE
MAINTENANCE
TOOL DESIGN
13%
 Reduced
OPERATOR 26% Inadequate PPM Level
7%
Method of Method of at
PIE ANALYSIS – DENT PIE ANALYSIS – OFFSET IN COMPONENTS Inspection inspection Customer
not in line aligned with End.
TOOL DESIGN
Offset in parts, with SL Subros
Chips
TOOL DESIGN
8%
20%
 Tool
getting SPARE FEEDER
Burrs Breakdow
stuck up Inadequate Adherence of
n time
7%
54% Tool Preventive

reduced.
Preventive maintenance of
Maintenance Tools started.  Tool life
PREVENTIVE SKILL OF OPERATOR PREVENTIVE MAINTENANCE
increased.
MAINTENANCE 8%
38% 57%
Inadequate
Process Kaizen
Dents Design Implemented
PROCESS PARAMETERS
© Subros Limited. All rights reserved 8% © Subros Limited. All rights reserved
Quality Circle Competition – Tier 2 ACHIEVEMENT : SUBROS CLUSTER
Over All Winner - 1st Position MPS Competition

( All MACE Cluster Members ) MSIL
M/s SANATAN AUTOPLAST
Change
MACE team along with cluster members - Q.C. competition at Subros
Poka Yoke Implementation At M/S Swastika

Activity Plan
Part Name :- Cap Receiver Bush
Collar 2.00 ± 0.1
Part no. :- 647831-3060
Phase-1 (2005-06) Phase-2 (2006~07) Phase-3 (2007~09) Problem Observed :- Milling cutter cut Collar thickness 2mm.
Effect :- Leakage Problem
1. Customer 1. Complete 5 S Milling Dimn 31-0.1
1. Cluster – 2 Launched Problem occur :- Subros
POKA YOKE :- Provided under cut in Adopter to control collar thickness
Members Before After
3. Red Bin Analysis
4. Deep Analysis
(In house rejection Under cut slot
3. Tool Maintenance
analysis) 5. Energy Cost 2mm Provided
Monitoring
Model Line.
6. Quality circle
activity
7. Poka Yoke Milling cutter can cut collar thickness Milling cutter can not cut collar
thickness.
11
Poka Yoke Implementation At M/s Swastika Poka Yoke Implementation At M/s Metal Former
Part Name :- Bush Receiver Part Name :- Cover Dust
Part no. :- 647831-3090 Part no. :- 047372-0830
Problem Observed :- without milling piece observed Problem Observed :- Bending Angle 200 +0/-10 & 650 +20/-00 Found NG
Effect :- Fitment Problem Effect :- Fitment Problem
Milling Dimn 28-0.1
Problem occur :- In-House. Problem occur :- In-House.
POKA YOKE :- Make a profile in Jig to control without milling operation. POKA YOKE :- Introduced 3 Locator to fool proof the bending in given tolerance angle
only one locater provided & open type tool

Before After three
locaters
provided
no
chances of
piece
shifting &
close type
Profile dimn 28 tool
Before no profile of dimn 28
Without milling piece can be Without milling piece can not drill Comments :- Locater on one side only Comments :- Locater provided on all the three
missed for bending operation so that piece was sides for bending operation so no chances of
shifting from its original position while bending being N.G as the piece cannot shift.
operating.
Poka Yoke Implementation At M/s Swastika Poka Yoke Implementation At M/s Global
Part Name :- Charging Port Part Name :- Tube connector
Part no. :- 646171-3780 Part no. :- 646172-3400
Problem Observed :- Chamfer operation miss Problem Observed :- CD 14.0 ±0.3 was observed under size / Over Size
Effect :- Fitment Problem Effect :- Fitment Problem
Problem occur :- In-House. Problem occur :- In-House.
POKA YOKE :- Introduced Chamfer in fixture to fool proof the chamfer in component POKA YOKE :- Introduced a Pin to fool proof CD CD 14.0 ±0.3
O.K PART WITH CHAMFER
Chamfer
provided
on the Provided
bottom of Locators
pin inside
the fixture for CD
Comments :- Chamfer missing can not Comments :- PIN provided in the CNC fixture & No control to detect CD 14.0±0.3 Error proofing to control CD 14.0±0.3
detected in the process. Method of chamfer provided at the bottom of pin which will
detection for chamfer missing is visual not allow any with out chamfer part to sit into the
inspection. CNC fixture
Poka Yoke Implementation At M/S Global Poka Yoke Implementation At M/S Swastika
Part Name :- Tube Connector Part Name :- Bracket

Part no. :- 647782-0830
Part no. :- 445012-4020
Problem Observed :- Without operation pc.mixing
26.0±0.2
Problem Observed :- Dia 16.0 +0.05-0.15 Over Size.

Reason :- operation missing
Reason :- Insert worn out. Effect :- Fitment Problem
Effect :- Fitment Problem Problem occur :- In-house Problem
Dia 16.00
Problem occur :- In-house Problem POKA YOKE :- Provided T stopper in drilling Jig to
POKA YOKE :- Inserting dia 16 in Jig while drilling to avoid mixing of avoid mixing of without milling operation
Over size pieces
Before After
Before After
Remarks:-Don't detect pcs without milling Remarks:- Detect without milling pcs
Remarks:- No detection of oversize pieces . Remarks:- over size pieces can not be drilled.
12
Tool Kit at Shop Floor – Tier 2

Activity Plan
Members
3. Red Bin Analysis
4. Deep Analysis
(In house rejection
3. Tool Maintenance
Monitoring
Model Line.
6. Quality circle
activity
7. Poka Yoke
2S in Grinders Cupboard – Tier 2 5S Improvements on Vendor Shop Floor

RM STORAGE AREA
BEFORE AFTER
COMMENTS: Unorganized Store Area. COMMENTS:. ORGANISED STORE AREA

WITH FIFO.
5S Improvements on Vendor Shop Floor 5S Improvements on Vendor Shop Floor

TOOL STORAGE AREA FINAL INSPECTION AREA
BEFORE AFTER BEFORE AFTER
BEFORE AFTER
COMMENTS: COMMENTS:.
DEDICATED INSPECTION STATION WITH INWARD &

COMMENTS: COMMENTS: RANDOM INSPECTION FLOW CREATING OUTWARD FLOW
INADEQUATE TOOL STORAGE TOOL CONTROL IN LINE WITH BEST MIX UPS
MANUFACTURING PRACTICE.
13
Raw Material Storage Area Improvement Visual Management Improvement
Activity Plan Lean Manufacturing Focus
Members
3. Red Bin Analysis
4. Deep Analysis
(In house rejection
3. Tool Maintenance
Monitoring
Model Line.
6. Quality circle
activity
7. Poka Yoke
IDENTIFYING WASTE IDENTIFYING WASTE
 Over production  Unnecessary Processing
 Unnecessary movement  Producing Defective parts
 Excessive inventory  Unnecessary transport
 Idle time  Unnecessary inspections
14
Lean Manufacturing Example Lean Manufacturing

“ NECESSITY IS THE MOTHER OF INVENTION”
Above quote motivated us to study the feasibility
of “Single piece model line flow”
Ist Phase : Concept of model line given by – MACE/SUBROS
and training provided
Lean Manufacturing projects implemented by cluster
vendors in different areas :
a) Man power productivity improvement
b) Reduction in MUDA of material flow
© Subros Limited. All rights reserved 1

© Subros Limited. All rights reserved
METHODOLOGY ADOPTED THE WAGON-R SINGLE PIECE FLOW

MODEL LINE SUCCESS STORY
TOOLS USED IN IMPLEMENTATION AIM : - TO MAKE A MODEL LINE FOR SUBROS

OF MODEL LINE CONCEPT CMB 646260-4361
REASONS FOR SELECTION

 TIME STUDY
 KAIZEN
 POKA-YOKE 1. Customer demand higher than Allena capacity.
 SMALL GROUP ACTIVITY 2. Low through put in existing line.
3. Mixed component causing high rejection, rework
 QUALITY CIRCLE and mixing of component.
4. Material movement very high.
5. Customer dissatisfied.

PROCESS FLOW BEFORE IMPLEMENTATION METHODOLOGY ADOPTED
MATERIAL MOVEMENT – 63 meter FISHBONE DIAGRAM MADE TO STUDY 4M CONSTRAINTS

SUSPECT CAUSES
1- ARGO VM 11 - ARGO - VM28 16 - BDM - 04 13 - BDM TP - 05 MACHINE
0
M TG F A C E M ILLIN G S LOTTIN G F IN A L C OU N TER S TU D S P OT F A C IN G MAN
15 0 P c s / 12 Hrs . 2 2 0 P c s / 12 Hrs . 2 5 0 P c s / 12 Hrs . 3 0 0 P c s / 12 Hrs .
2 - BDM - 15 10 - KAE DEE - VM33

Number of machines less
M TG HOLE D R ILLIN G & IN S ID E F LA N GE M ILLIN G 17 - KAY DEE - VM35 12 - PDM - 17 Lay out of machine wrong
R EA M IN G 2 2 0 P c s / 12 Hrs . TA P ER C U T S TU D D R ILLIN G & Operator skill less
12 0 P c s / 12 Hrs . 2 8 0 P c s / 12 Hrs . EN D M ILLIN G D IA 9 . 0 0 mm
2 0 0 P c s / 12 Hrs .
9-BDM 05
3 - BDM 3 B o s s t a p e r d rilling 18 - PDM - TP05
C o unt e r & Ga ug e C he c king 15 0 P c s / 12 Hrs . TA P P IN G M 8 X 1. 2 5 mm
3 0 0 P c s / 12 Hrs . 2 4 0 P c s / 12 Hrs . LOW
OUTPUT
6 - KAY DEE-VM29
S M A LL B OTTOM F LA N GE 4 - PDM - 01 14 - BDM VM31
M ILLIN G M TG HOLE S P OT F A C IN G B OTTOM F LA N GE S P OTF A C E
5 - HM - VM30 2 3 0 P c s / 12 Hrs . 2 2 0 P c s / 12 Hrs . 2 10 P c s / 12 Hrs . Material movement
LON G F LA N GE OU TER high WIP high
M ILLIN G
Dedicated machine not
15 0 P c s / 12 Hrs . 7 - CNC - 01 Material mixed
3 - B OS S TA P ER * 7 - ARGO 15 - PDM - 16
given for all operations
M ILLIN G 3 - B OS S TA P ER F IN A L S P OT F A C E 10 . 0 0 mm
8 -MULTI SPINDLE MS-02 12 0 P c s / 12 Hrs . M ILLIN G & 5. 0 0 mm C U T 2 5 0 P c s / 12 Hrs .
MATERIAL
D R ILLIN G OU TER F LA N GE. 10 0 P c s / 12 Hrs .
METHOD
2 0 0 P c s / 12 Hrs .
15
LAY OUT OF 1ST PHASE 1ST LEVEL CHANGE IN LAYOUT

1-SPM SPM 11 - PDM - 17
02M TG.F AC E M TG.F AC E
M ILLING M ILLING
10 - ARGO - VM 28 STUD DR ILLING &
SLOTTING END M ILLING DIA 9 .0 0 mm
200 P c s / 12 Hrs . 200 P c s / 12 Hrs .
2 2 0 Pcs / 12 Hrs . 2 2 0 Pcs / 12 Hrs .
2 - B D M - 15 2 - B D M - 15
M T G HOLE M T G HOLE 12 - BDM TP - 05
DR ILLING & DR ILLING & STUD SPOT FAC ING
R EAM ING 120 P c s R EAM ING 120 P c s / 3 0 0 Pcs / 12 Hrs .
/ 12 Hrs . 12 Hrs . 9 - ARGO - VM 33
INSIDE FLANGE M ILLING
2 2 0 Pcs / 12 Hrs .
3 - BDM 13 - BDM VM 31
C o unt er & Gaug e C hecking B OTTOM FLANGE SPOTFAC E
3 0 0 Pcs / 12 Hrs . 2 50 Pcs / 12 Hrs .
4 - PDM - 01 14 - PDM - 16
M TG HOLE SPOT FAC ING 8 -SPM FINAL SPOT FACE 10 .0 0 mm
2 50 Pcs / 12 Hrs . 3 BOSS TAPER DR ILLING 2 50 Pcs / 12 Hrs .
& DRILLING OUTER FLANGE.
2 50 Pcs / 12 Hrs .
15 - BDM - 04
5 - HM - VM 30 FINAL C OUNTER
LONG FLANGE OUTER 3 0 0 Pcs / 12 Hrs .
M ILLING 7 - ARGO
16 0 Pcs / 12 Hrs . 3 B OSS TAPER M ILLING & 5 M M C UT
M ILLING
10 0 Pcs / 12 Hrs . 16 - ARGO - VM 35
5-CN C M IL L IN G (AKSHARA) TAPER CUT
LONG FLANGE OUTER M ILLING 3 2 0 Pcs / 12 Hrs .
2 0 0 Pcs / 12 Hrs .
7 - CNC - 01
3 - B OSS TAPER 17 - PDM - TP05
6 - ARGO-VM 29 M ILLING TAPPING M 8 X 1.2 5mm
SM ALL B OTTOM FLANGE 150 Pcs / 12 Hrs . 2 50 Pcs / 12 Hrs .
M ILLING
2 50 Pcs / 12 Hrs .
INHOUSE TEAM FORMED FOR SPM DESIGNING KAIZENS IMPLEMENTED IN 1ST PHASE
NEW SPM INTRODUCED FOR BASE MILLING

OPERATION NO 01 :- BASE MILLING
CONSTRAINT :- PRODUCTIVITY LOW
Change
BEFORE AFTER
BENEFITS: -
1. Manpower Saved: - 01
2. Jigs / Fixtures Saved: - 01
3. Productivity increased by: - 100 pcs. (15%)
KAIZENS IMPLEMENTED IN 2nd PHASE LAY OUT OF 2nd PHASE

NEW SPM INTRODUCED FOR TOP MILLING MODEL LINE SINGLE PIECE FLOW
OPERATION NO 04 :- TOP MILLING OPERATION NO. 1
CONSTRAINT :- QUALITY(Dimn. 104.4)& PRODUCTIVITY
OPERATION NO. 2
VERTICAL MILLING MACHINE ROTARY MILLING MACHINE
OPERATION NO. 3
OPERATION NO. 4
OPERATION NO. 5
OPERATION NO. 6
OPERATION NO. 7
OPERATION NO. 8
OPERATION NO. 9
OPERATION NO. 10
OPERATION NO. 11
OPERATION NO. 12
BEFORE AFTER
OPERATION NO. 13
BENEFIT : Considering the TACT study. We designed a new concept
OPERATION NO. 14
Rotary Milling Machine with 4 Fixtures. It increased the output
of CMB Wagon-R by 100% on this operation and the quality OPERATION NO. 15
problem is also solved.
OPERATION NO. 16
16
OVER ALL IMPROVEMENT SUMMARY OF ACHIEVEMENTS

G
G O
O O
O D
1000 800 D 0.60% 0.45%
 Reduced Zig-zag flow.
800
600 PREVIOUS 0.35% PREVIOUS
600 0.40%
 Saved 1 floor utilized for lab.
400 1st PHASE 0.20%
400 0.20% 1st PHASE
 Saved 3 Manpower.
2nd PHASE
200
0.00% 2nd PHASE
0
PRODUCTION REJECTION
 Reduced the Man & material movement.
G
 Reduced the input material movement.
80
O
O  Reduced the dispatching material time.
60
63 meter
D
 Reduced the WIP.
40
34 meter PREVIOUS  Saving of Chemicals and Energy.
20
10 meter
1st PHASE
 Dust prevention.
2nd PHASE
 5S improved drastically.
0
MATERIAL MOVEMENT
Lean Manufacturing Quality Improvement Activities

Initiative
• Design Specification Joint
Review with Tier 2.
• Tool Design Review.
• Joint Tool Maintenance
2nd Phase :
Initiative
Lean Manufacturing projects are to be taken up for
implementation SSIG Activity Launched
a) Improvement in Inventory turn ratio 2008~10
b) Reduction in energy consumption

2006~07 Initiative
c) Quality improvements Initiative
ISO/TS 16949
• MACE Cluster-1
Launched 2005~06
d) Reduction in break down time of machines & improvement of O.E.E.
Initiative
2004~05 Projects at Vendor
Cluster Members
Supplier System Improvement Group SSIG Methodology
SUBROS
SSIG
Implementation
Initiative by TEAM at
Vendor’s End
Vendor
SSIG
Subros Effectiveness
Existing monitoring
Requirement
System
17
SSIG Methodology Quality Improvement Activities

Initiative
Current System Review • Design Specification Joint
Based on Ideal System Check Sheet Review with Tier 2.
• Joint Tool Maintenance
Initiative
Gap Analysis
SSIG Activity Launched
2008~10
Implementation of New System

2006~07 Initiative
Initiative
ISO/TS 16949
• MACE Cluster-1
Launched 2005~06
Fine Tuning Initiative
Cluster Members
ISO-9001 / TS16949 Certification Trend Quality Improvement Activities

Initiative
G
100 82 • Design Specification Joint
O
Review with Tier 2.
90 78 O
D
73 • Joint Tool Maintenance
NUMBER OF SUPPLIER
80
70 Initiative
47 36
60 42 SSIG Activity Launched
50 42
2008~10
40
19 22 29
30
46 2007~08
20 36 Initiative
13 14 31 Initiative System Up gradation to
10 18 • MACE Cluster-1 ISO/TS 16949
6 8 Launched 2005~06 • MACE Cluster-2 Launched
0
2004 2005 2006 2007 2008 2009 Initiative
YEAR Trainings & Execution of
TS 16949 ISO 9001
Cluster Members
List of Cluster-2 Vendors Total : 6 Vendors
S.NO VENDOR LOCATION
1 SUPER SCREWS FARIDABAD

2 SANATAN MACHINE TOOLS FARIDABAD
3 GLOBAL AUTOTECH NOIDA
4 SOUTHEAST ELECTRONICS GHAZIABAD Improvement Status
5 PSPL GHAZIABAD
6 MOHINDRA FASTENERS LTD ROHTAK
Sharing of Good
Manufacturing
Practices started
between 2 Clusters.
18
VENDOR PARTS PPM TREND VENDOR PARTS DEFECTS AT SUBROS END
START OF START OF
Cluster G
Cluster
G
Improvement O Improvement
Activities O 10 Activities
O
O
D
72468
9 D
32%
8
No. of defects / month

67132 60.4%
8.08
7
PPM Rejection
93%
50500 4%
33% 6 6.25 6
45938 5 (97)
4 (75) 4.25
30945 (72) 3.92
25500 3 3.2
27%
13165 2 (51) (47)
9603 51% (16)
4636 1
2000 0
500 2004-05 2005-06 2006-07 2007-08 2008-09 2009-10
AVG.' AVG.' AVG.' AVG. AVG. AVG. AVG. Target (Aug'09)
02-03 03-04 04-05 05-06 '06-07 '07-08 '08-09 08-09 Year
SSIG CLUSTER VENDOR PPM TREND SSIG CLUSTER VENDOR DEFECT TREND
31403
56% G 12 70% G
19000 O 10.25 O
65% 33%
O O
17000 D 10 D
15000 13706
8 6.83
48% 33%
PPM
PPM
13000
10881
11000 6
4.58
141% 31%
9000 4 3.16
7000 5693 2
2
5000
3000 500 0
06~07 07~08 08~09 09~10 Target'08~09
1000
( Up to Sep
05~06 06~07 07~08 08~09 Target'08~09
Year Year 09 )
Cp/ Cpk improvement > 1.33 (Vendor End) Number of Poka Yoke / Kaizens through SQIG at
( Cumulative ) Vendor End ( Cumulative )
G
O G
O O
D O
180 D
67%
46% 23% 114 160 150
120 110
131
NUMBERS
140 13%
16%
NUMBERS
100 17% 114

88 120
15% 96
73 100
80
62 55%
80
60
60 43
40 40
20
20
0
0 05~06 06~07 07~08 08~09 Target'08~09
05~06 06~07 07~08 08~09 Target'08~09 Year
Year © Subros Limited. All rights reserved
19
Approach Vendor Improvement Review Process
Focused Improvement
Activities
Act
Activity Frequency Attended by
MACE Cluster Monthly All 1st & 2nd Cluster Members
Review Cluster Quality Meeting Quarterly Category-wise Supplier
Plan
Check
 Assess situation (Sheet Metal, Electrical)

Meetings
with Suppliers Improvement  Set Targets
Activity Low Performing Quarterly Selected Few

Vendors
Vendor Meet Annual All Vendor base
Do
Cluster Performance Review Vendor Improvement Review Process
Quality Meeting Quarterly Category-wise Supplier

(Sheet Metal, Electrical)
Low Performing Quarterly Selected Few

Vendors
Sheet Metal Group Vendor Review Vendor Improvement Review Process


Vendors
20
Repeat Complaint Vendor’s Review Vendor Improvement Review Process


Vendors
Subros Vendor Meet - Sep 2009 Award Distribution at Subros Vendor Meet
Chief Guests with Subros Top Management
Vision & Mission

Commitment for Future A Growing
Award
Commitmen
Winner
t each year
Customer Voice by Mr S Maitra (MEO –Supply Chain MSIL) s
Approach Next Phase of Improvement Activities

Focused Improvement
Activities
Act
 Tool & Gauge Design
 Tool Maintenance Support.

Review
Cluster
Plan
Check
 Assess situation
Meetings
with Suppliers
Improvement  Set Targets  Lean Manufacturing implementation at
Activity Cluster II Vendors.
 Guidance & Training on Cost of Poor

Do
Quality at Tier 2.
21
CHANGE POINT - TOOL DEVELOPMENT TOOL MAINTENANCE SUPPORT TO VENDORS
-Data collection of vendor tools.

Change
BEFORE
-Quality problem history regarding the tool &
Phase 1 component
Part Quality Tooling Tool Tool
Trial
Drawing Standard concept Design making -Joint review with vendor for scope of
-maintenance support
By vendor
By Subros
-Subros team visit for tool status review
Part Quality Tooling Review Phase 2
Drawing Standard Concept by -Identification of critical issues
Subros
CHANGE By vendor FOCUS

POINT By Subros AREA
-Development of solutions
Tool Subros Tool

Phase 3 -Implementation support at vendor end
Trial
Making Approval Design
By vendor
By vendor
Vendor End Tool Maintenance Support Activity Findings Vendor End Tool Support Activity Findings
Tier 2 – Tool Maintenance Joint Review

Tier 2 – Tool Maintenance Joint Review
Observations
Tool drawings not
adequate.
Observations
Spares drawings not
available. Tool Condition
inadequate
Tool preventive
maintenance check
sheet not maintained. Critical entries of
No preventive preventive are not made
maintenance plan for
low volume tool.
Periodic maintenance
schedule not mentioned
in tool history card.
Tier-2 Cost Performance Status
COST REDUCTION TREND

1.0%
G
0.8%
0.75% O
Other Initiatives O
PE R CE N T A G E
0.6%
0.56% D
0.4%
Improvement Journey not complete 0.2%
without improving other aspects of 0.0%
QCDD AVG.'02-03 AVG.'03-04

YEAR
22
Cost Reduction Activities Alternate sourcing for high value items
INITIATIVE
ZERO BASED COSTING OF ‘A’
CLASS COMPONENTS
2008~10
2006~07
INITIATIVE
INITIATIVE
 Alternate
sourcing for high 2005~06 Cost Reduction Kaizens
value items
INITIATIVE YEAR
2004~05 MPS INTRODUCED AT
VENDORS
Cost Reduction Activities Tier 2 Lean Manufacturing Projects Status
PROJECTS PROJECTS
S.No. Vendor IDENTIFIED COMPLETED
INITIATIVE 1 SWASTIKA, FBD 2 2
Zero based costing of ‘A’
Class components 2 SPECIAL TOOLS, GZD 2 2
3 ALLENA, MOHALI 2 1
2008~10
4 SUMATI, FBD 2 0
5 PYN, FBD 2 0
2006~07 6 INTERFACE, GGN 1 1
INITIATIVE
INITIATIVE
 Alternate 7 SUNVISOR, GGN 2 2
value items 8 NRB BEARINGS 1 1
INITIATIVE Overall Cluster 14 9

2004~05 Lean Manufacturing
Introduced at
Vendors
Lean Manufacturing Introduced at Vendors Lean Manufacturing Introduced at Vendors
M/s Swastika Automatics, Faridabad M/s Interface Microsystem, Gurgaon

Project: Reduction in Wastages in manufacturing process
Project 1: Reduction in product Project 2: Improvement at Receipt
change over time. Store while issuing / receiving of Project: Reduction in Wastages in manufacturing process
material from Vendor
8
8
G G G
O O
7 O
5 5 O 40 O
40
O 6
4.5 D D D
Man Hour/Day
4 35 5
3.5 30
MAN HOURS/DAY
2.5 24 4
HOURS
3 25
Man
2.5
3
2
Hour 20
/ day
2
1.5
15 2
1 10
0.5
1
5
0 0 0
Before After Before After Before After
23
Over All Trend – Numbers of Lean Manufacturing

Lean Manufacturing Introduced at Vendors Projects – Tier 2
M/s Sumati, Faridabad
10
Project 1: Reduction in Die Project 2:Reduction in Material 9

changeover time in 40 Ton dispatches Projects Under Progress
8
machine Projects Completed
7
Numbers of Projects
6
120 120 G 7
G O 5
60 54 O
MINUTES/DESPATCH
100 O
50 O D 4
D 80
40
3 6
MINUTES
60
30 5
20 40 30 2
20
20 1 2 2
10
0
0 Before After 0
Before After
2006~07 2007~08 2008~09 2009~10
Savings Trend – Lean Manufacturing Projects – Tier 2 Cost Reduction Activities
INITIATIVE
ZERO BASED COSTING OF ‘A’
CLASS COMPONENTS
2008~10
2006~07
INITIATIVE
INITIATIVE
 Alternate
value items
INITIATIVE
VENDORS
Zero Based Costing of ‘A’ Class Components Cost Reduction Activities
G
O
O INITIATIVE
D ZERO BASED COSTING OF ‘A’
CLASS COMPONENTS
2008~10
2006~07
INITIATIVE
INITIATIVE
 Alternate
value items
INITIATIVE
VENDORS
24
Cost Reduction Kaizens Cost Reduction Kaizens
Savings due to Cost Reduction Kaizens Tier-2 Delivery Performance Status
160.0 12
G
140.0 O
O
10
DELIVERY FAILURE 93
GOOD
120.0
D 100
8
85
No. of Proposal
Savings (Lacs)
100.0
80
PERCENT A GE
80.0 6
60
60.0
4
40.0
40
2
20.0 20
0.0 0
FY
2004- 2005- 2006- 2007- 2008- 0
05 06 07 08 09
AVG.'02-03 AVG.'03-04
Savings (Lacs) 27.4 139.2 110.0 72.8 144.5 YEAR
No.of Proposals 3 6 6 1 10
Delivery Improvement Activities Methodology for Local Material
OLD
PROCESS
Schedule sent to Supplier receives Individual Supplier

INITIATIVE Schedule generated One week material
at SL from Forecast Supplier through Weekly schedule sends bulk material
received at SL
courier on weekly basis
• Improvement in
Ordering System &
Delivery to Subros
2008~10
2006~07  Milk Run System for NCR

 Material Requirement
supplier
Planning through SAP.
INITIATIVE  DOL Suppliers establishment
 MRP Run on weekly basis
 Single piece flow at Cluster
2005~06  BAR Coding Implementation  Vendor Extranet
Supplier 8 no.s
 Local Suppliers Base within Implementation
same State
 Extranet for entire supply
2004~05 chain
25
IT Support to Supply Chain Delivery Improvement Activities

Methodology for Local Material
INITIATIVE
NEW Real-time Schedule Daily material
received through receiving at SL • Improvement in
PROCESS Ordering System &
Extranet
Delivery to Subros
BENIFITS 2007~09
10
Safety Stock
2 2006~07
INITIATIVE
Year 2004
2005~06 BAR Coding Implementation
7 Present

 Local Suppliers Base within
Lead Time same State
2  Extranet for entire supply
2004~05 chain
In No. of days
Bar Coding System
Activity initially started with 13 Suppliers

Now cover the entire Vendor Base
 Material Receipt Processing

Time Reduced from 10 Mins. to
1 Minute
90% MRR
Processing  Supplier Schedule adherence
Time
Improvemen
 Error proof system
t
Delivery Improvement Activities

Local Supplier Base Within Same State
INITIATIVE
Six A Class Suppliers have
• Improvement in put up their Plant near to
SUPPLIER
Ordering System &
COMMITMENT Subros Plant
Delivery to Subros
TOWARDS
SUBROS
2007~09
2006~07  Proximity to customer

INITIATIVE
 Daily Shipment
2005~06  BAR Coding Implementation
 Local Suppliers Base within
same State
 Reduction in Inventory level
2004~05 chain
26
Delivery Improvement Activities IT Support to Supply Chain
INITIATIVE
• Improvement in
Ordering System &
Delivery to Subros
2007~09
2006~07 Training and

Guidance to
INITIATIVE
Entire
2005~06  BAR Coding Implementation Supplier
 Local Suppliers Base within base.
same State
2004~05 chain
Effectiveness of Delivery Improvement Initiatives Tier-2 Development Performance Status
START OF DEVELOPMENT LEAD TIME (RFQ TO SAMPLE APPROVAL)

Cluster 80
100 Improvement G
70
67
No. of delivery failures / year
Activities
GOOD
N UM BER O F DAYS
99 O
90 O
60
80
D
50 45
70 89.9 % 40
60 30
50 20
40 10
30 0
92% 12%
20 100%
100% AVG.'02-03 AVG.'03-04
10
100% YEAR
8 7 0 0
0
2004-05 2005-06 2006-07 2007-08 2008-09
© Subros Limited. All rights reserved Year © Subros Limited. All rights reserved
Development Improvement Activities New Product Development Process

DEVELOPMENT
REQUEST FOR QUOTATION
INITIATIVE
SUPPLIER SPECIFICATION MEETING
Development Lead cycle MEET
reduction planning INVOLVEMENT CUSTOME
based on bottleneck PRICE NEGOTIATION R PRICE
processes. TARGETS
PPAP SUBMISSION
GAUGE / TOOLING APPROVAL

2007~09 FOCUS ON
FIRST
JOINT
TIME RIGHT
INSPECTION SAMPLE APPROVAL
INITIATIVE
INITIATIVE 2006~07 1. Supplier Involvement at
ONE SHIFT Cp, Cpk APPROVAL
Expert Resources Initial Development Stage
2. Green Supply Chain
PRODUCTION
with Domain
Knowledge eg Sheet
CAPACITY PLANNING
metal , Electricals 2005~06
Recruited INITIATIVE
Pre- Assessment audits FPP LOT APPROVAL
started to evaluate
vendor capability
2004~05
SOP
27
CHANGE POINTS - Design Review Process With Vendor Development Improvement Activities
Change
Before INITIATIVE
Development Lead cycle
reduction planning
based on bottleneck
Proto Spec fix processes.
Proto Trial at Final Quality
Part Meeting
Sample Subros Drawing Standard With Vendor
Drawing
By Subros By Vendor By Subros Jointly 2007~09
Proto
Proto Trial at
Learning INITIATIVE
Part
Sample Subros
From INITIATIVE 2006~07 1. Supplier Involvement at
Change Drawing Vendor Expert Resources Initial Development Stage
Point with Domain 2. Green Supply Chain
Knowledge eg Sheet
Change
metal , Electricals 2005~06
Recruited INITIATIVE
Spec fix
Quality Part Design Pre- Assessment audits
Meeting started to evaluate
With Vendor Standard Drawing Review
vendor capability
2004~05
Green Supply Chain Effectiveness of Development Initiatives
All Plated parts
GOOD
converted to Trivalent
Plating within G
3 Months in 05~06 O
O
D
25
90 82 22
80 69
70
NUMBERS
60
50
40
30
20 13
10
0
Total Vendors EMS 14001 Certified Activity yet to be started 2005 - 2008 - Target
Vendors
07
07 09 08 -09
Subros Continuous Achievements… Benefits of Cluster Activities
 Vendor’s own initiatives started in a big way to resolve

Quality Issues.
MSIL Awards for 2006-08
 Lower & Middle Level involvement in Quality Drive at Tier 2.
 Productivity and Quality Improvement through Lean

Manufacturing.
MSIL Supplier Up gradation
Award
for  Major Improvement in ‘5S’ at some of the vendors.
4th Consecutive Year
 Motivated & Dedicated Supply Chain
MSIL Awards for 2008-09 ( Over All Excellence / Quality / Tier 2 Up gradation / R&D ..)
28
Take Away -Tier 2 Cluster Activity Subros Cluster Relationship ‘Mantra’
 A strong and dedicated supply chain is a key factor in

achieving OEM targets.
 Improvement initiatives work best after understanding

Tier 2 constraints and evolving improvement programs
accordingly.
 Benchmarks need to be set with horizontal implementation

of Kaizens across Tier 2.
 Continuous support with constant reviews is must for

sustained quality levels at Tier 2.
We can not spell s“U”ccess without “U”
Thank You .
29

Subros: An Update

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Subros: An Update

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National Workshop on “Enabling MSME

to be Competitive through Quality Tools”

Established in 1985, Subros is the Largest AC company in India. A Joint

Subros : An Update R&D Center Noida Plant

Manesar Plant OHSAS 18001 Pune Plant

Sanand Plant (2012) Chennai (Oragadam) Plant (2012)

Facilities Product Range

Engine Cooling Commercial

Building (Sq 71,910

Engineering & Development Centres :

Subros customers Manufacturing Infrastructure

No clok Brazing Furnace

Chip less Cutting Machine Vacuum Brazing

Product Development Infrastructure:

Calorimeter Wire EDM

Our People, Our Strength Achievements

Chairman & Senior Management Team

Capacity Plan to Meet Future Customer Demand

2500 Sales Volume HVAC Basis(no. in K) Projected 25000

2000 Net Sales Value (Rs. Million) 20000

Subros Defects Trend at MUL Line In House PPM Trend

Background Trend of Customer Complaints

 Between 2004-2011 Subros has made

In-house PPM Trend Background

 Between 2004-2011 Subros has made

30000 tremendous effort to improve Quality.

 Analysis shows - 50~60% problem is

Defects Distribution Background

Year  Between 2004-2011 Subros has made tremendous

 Sustenance of Quality Improvement not feasible

Subros Vision 2015 for TIER 2 Improvement Targets - Tier 2 Development

Demand Chain Management

 Replicate the OEM experience of Tier-1 vendor up- ZERO DEFECT

Approach History – Vendor Parts PPM Trend

Focused Improvement High Vendor

 Assess situation 18000

Abnormally High Production Downtime /

No. of delivery failures

Vendor parts defect stratification Vendor Parts Defects Distribution

Approach Vendor Targets

Meetings Improvement  Assess situation

Vendor Targets Vendor Targets

2004~07 2007-11 2007-11

Vendor Targets Approach

Focus of Improvement Activities Back Bone of Cluster Activity

 Implement effective Change Control

 System to eliminate set up piece mix up.

 Poka Yoke for fitment parameters of OEM’s.

Quality Improvement Activities List of Cluster-1 Vendors Total : 8 Vendors

SSIG Activity Launched

5 ALLENA AUTO P. LTD. MOHALI

Quality Improvement Activities Activity Plan

Phase-1 (2005-06) Phase-2 (2006~07) Phase-3 (2007~09)

Customer Satisfaction Report Monthly Quality Feedback – Tier 2

1 Rejection at PPM 7132 0 0 0 0 0 500

2 Defect noted at Nos 3 1 1 0 1 0 0 0 2

3 Supplier Quality 0-100

Activity Plan Training Program Conducted for Cluster vendors

Phase-1 (2005-06) Phase-2 (2006~07) Phase-3 (2007~09)

Cluster Member Training – Problem Solving Cluster Member Training – 5S

Cluster Member Training – Lean Manufacturing Trainings impact

Single piece flow

LEARNING FROM CLUSTER Activity Plan