Monthly Report of

Production Division
September - 2016
Sep - 2016 - Prod. (4W) 1

SAFETY LABOR ACCIDENTS

PRESS: Pressed tip of left hand index finger in die at F-Line, 40
as worker bypassed the safety device by himself. Maximum limit 30
60 30
PRESS: Fracture of left hand thumb due to missing of
28
hammering, while working in kaizen area.
26 25 30
No. Of Accidents

50 VFA: Cut injury on right hand wrist as the door of STV

23
slipped from hand due to improper holding position.
18
15 23 20
40 13 20
10 18
8
15
63

5 13 10
30 3
8
6 -
20 4 4
26

3 2 3 2
5
10 1 3 2 3 5
2 8 6 9 8 2 3 -10
6 5 2 3 33 5 5 2
4 2 3 3
4 0 2

0 -20
2015 2016 1/16 2 3 4 5 6 7 8 9 10 11 12
2015 2016 Actual-2016 Actual-2015 Target Cum. Target Cum. Actual
Sep - 2016 - Prod. (4W) 2

90
FTP (4W)
Reason:- Countermeasure:-
> Due to low skill of manpower and Daily Defect Hearing.
violation of OPS. Defect analyzing and feedback at GENMBA

83.00
> After Eid Holidays we faced acute Daily counseling of absentees

82.14
81.29
attendance issues

80.43
79.58
78.72
77.93
76.16

77.87
77.01
80 76.61

75.59
75.3
74.45
75.36
Percentage

73.43

73.59
73.45

73.51
73.15
71.81
71.98
70.90
70.07

69.81
73.59

72.85

70

71.03
65.85
70.15
69.43

69.66
72.38

71.65

67.24

60
Avg. Avg. 1/16 2 3 4 5 6 7 8 9 10 11 12
15 16
Avg. 2015 Avg. 2016 Target 2016 Actual 2016 Actual 2015
Sep - 2016 - Prod. (4W) 3

Initial Plan 100,095 units

Current Plan 112,529 units AB-OK PRODUCTION
Apr'16~Mar'17 116,965 units
73396 8264792237 101512112529
18000 62472
46122 54327 62472 73396 82557 125,000
37454
28246 37454 46122 54327 100,000
13034 18980 28246 75,000
13034 18980 50,000
16000 25,000
-
13755 -25,000
Production in Units

14000
13034 -50,000
13034 13168 12806 -75,000
12084 12179 -100,000
-125,000
12000 11017 -150,000
11026 11072 10924 12083 -175,000
11425
9266 9208
-200,000
10000 9680 -225,000
9266 10066 10924 -250,000
-275,000
11214

7441 9208 8668 9161 9275 -300,000

8000 9251 -325,000
9183

8205
8668 8205 8145 -350,000
8145 -375,000
6000 -400,000
7464 -425,000
5946 -450,000
5946 -475,000
4000 -500,000
Avg-15 Avg-16 1 2 3 4 5 6 7 8 9 10 11 12
Avg-2015 Avg-2016 Revised Plan-2016 ABOK Actual-2016
ABOK Actual-2015 Cumulative ABOK-2016 Cumulative Plan-2016
Sep - 2016 - Prod. (4W) 4

HOURS-PER-VEHICLE (HPV)
41 40.78

40

39 38.74
HPV

38.00
38 37.32
37.20 37.07 36.95 36.83
36.93 36.90 36.18 36.70 36.58
37 36.45 36.33
36.13 36.84 36.20
36.59
36 36.07 35.58 36.38 35.69
36.39
35 35.61
36.83

34.81 33.99
34 34.51
34.89

33.67 32.90
33 33.15
32.95 32.52
32

31
Avg. Avg. 1/16 2 3 4 5 6 7 8 9 10 11 12
152014 16
Avg. Avg. 2016 Actual 2016 Actual 2015 Initial Target
Sep - 2016 - Prod. (4W) 5

PARTS PROD. FOR SPARE PARTS DEPTT

15044
16000
15026 14716
13397
14000

11979 11424 11790

12000 11115 11577 11443
11386 10471 10306
11534 9886
10000
Production Units

8422 10310
9703 8410 9886 9886
8745 8132
8000 9541
7829 8135
7438
10605

6000 6635
6024
9167

6185 8068
5939 7850
4000

2000

0
Avg. Avg. 1/16 2 3 4 5 6 7 8 9 10 11 12
15 16
Avg-2015 Avg-2016 Actual-2016 Actual-2015 Revised Plan-2016
Sep - 2016 - Prod. (4W) 6

PLANT COST / VEHICLE

42000 38444 41924
37069 22708
39000
4419 25189
36000 29823
33000
22994 13291
25704 21449 3154 21706
30000 21755 21046 22593
22994 22994 19508
27000 17724 7931 17099 19008 2939 18143
PKR / Unit

20565 23061
24000 19574 17450 22477 22361 22245
21152
21000 8275
2782
5065 4392 22129
26494

4365 20883
18000
4095 18773 20085 19498
20626

15000 3057 2526 2749 3475

9340 2480
12000 3509
9000
6556
5987
6717 17418 5675
4818 13421
6000
9770
6340 7609 6567 7619 8164
3000
Avg. 15 Avg. 16 1/16 2 3 4 5 6 7 8 9 10 11 12
Avg-2015 Avg-2016 Dir. Labor Ind. Labor Energy
Others Actual-2016 Actual-2015 Target-2016
Sep - 2016 - Prod. (4W) 7

ELECTRICITY POWER CONSUMPTION

350 3,000
2543
2395 2341 2342
2227 2289 2127 2042 2618
2427 2310
2455
300 2,000
2043 2020 2030
1467
1909 1881 1914
1488

KWh / month in '000

250 1247 229 235 225 219 1,000
KWh / Unit

220.5 219.4 220.2 220

218 217 216 185 213
219
210
197 203
199 182 195 192 199 194
200 208 192 191 190 -
217

= Press Shop, Plastic and Weld

190 189 189 188 188
195

working in late hours -SPD

186
150 -1,000
Avg-15 Avg-16 1 2 3 4 5 6 7 8 9 10 11 12

Avg.KWh/Veh-15 Avg.KWh/Veh-16 Tentative Target-2016

Act. KWh/Veh-16 Act. KWh/Veh-15 Act. KWh / month in '000
2015 KWh in '000
Kaizen & Cost Reduction
Sep - 2016
 Sep - 2016 - Prod. (4W) 8
Aug-16 Accumulated
Annual
# Dept. Major activities of the month
Target
Target Actual Plan Actual

> Yield improvement bracket Shock Absorber and reinforce seat

1 Press 10.23 0.82 0.28 7.75 3.03 hinge Center is produced from scrap of Tunnel.
> Manpower reduced
2 Weld 5.25 0.32 0.18 4.49 1.27 > Several Kaizens to reduce damages of one touch fitting by
increasing their protection.
> Reduce consumption of pre treatment chemicals (Kaizen)
3 Paint 13.78 1.70 0.66 7.00 8.87
> Cost reduction in masking tape and hosiery cloths (Kaizens)
Elimination of extra Grommet - ST308R-V
Reduce size of defogger wire - SF410
4 VFA 6.23 0.55 0.91 4.30 5.93 Eliminate of extra nut from brake paddle - SF410
Reduction of consumable
> Reduction in purging material.
5 Plastic 6.24 0.63 0.61 3.92 1.17
> Jig modification for improvement
> A1J, Engine Holding jigs is made In-house
6 Engine 1.6 0.13 0.15 1.20 0.85 from Scrap Material
> Saving through Temporary deletion & Aluminum Parts Melting.
7 MHD 8.42 0.77 13.29 6.11 195.06
> Packaging Cost Saving.
8 Maint. 19.78 1.50 5.39 13.22 13.05 > The electrodes are now locally manufactured

Total AMD 71.5 6.41 20.91 47.80 228.67

> Manpower Saving (6 Nos.)
9 MCD 4.29 0.56 0.57 3.10 3.16
> Consumable Saving & Common Consumable Items
Total MCD 4.3 0.56 0.57 3.10 3.16
Grand Total 75.8 6.97 21.49 50.90 231.83
Sep - 2016 9
1 (a). Kaizen Results Overall
Target: Kaizen per Person per Month
0.83 0.75
0.89 0.87 Plant=0.74, HO=0.74, Overall=0.74 1.0
0.84 0.76 0.73
2000 0.78 0.71
0.62 0.8
0.64
229
0.52 0.49
0.55 0.50 0.47 0.43 0.53 0.6
0.60 0.44 0.40 0.29

220

Kaizen per Person per Month

0.31
0.4
Number of Kaizen

158
0.29 0.18
0.22 0.16
0.19 0.17
1500 0.2

57
-
1749

73

42
-0
1573
1554

1524

48
1000 Kaizen Per Person Cost Saving
-0
1364

1343

44
Plant : 714 0.31 113,899

1224
1183
HO : 047 0.18
TTL : 761 0.29 113,899

1062 761 -1

986

47
-1

714
500 -1

Plant Head Office Avg-2015 Kaizen Avg-2016 Kaizen Avg-2015

Avg-2016 Kaizen / Person - Actual Plant / Person - Actual HO / Person - Actual

Sep - 2016 10
2. Cost Reduction
Yield Rate Improvement --- Percentage
65.50 2,500
15 revised sizes for improvement of yield have been 2,200
proposed to import after completion of study and trial.
But the consignment which was scheduled in 6162 1,900
September has not yet been arrived, so far. 1349 1,600
65.20
1053 1,300
853 1,000
678
487 700
276
Yield Rate (%)

64.90 400
0 81 64.76
64.71 100
64.65
64.60 -200

Amount in '000'
64.60
64.55 -500
64.49
64.44 -800
64.18 64.39
64.33 -1,100
64.14 64.28
64.30 64.12 64.22 64.22 -1,400
64.23 64.20 64.20 64.20 64.21
64.17 -1,700
-2,000
-2,300
64.00 64.08 64.08 64.10 64.10 64.10 64.11 64.11 64.12 64.12 64.12 64.12
-2,600
64.00 Model No. of Parts
Saving
Rs / Vehicle -2,900
SB 2 8.42 -3,200
63.70 -3,500
01/16 2 3 4 5 6 7 8 9 10 11 12

Target-2016 2016 actual Jan~Dec 15 (Actual) Cumulative Cost

1
Sep - 2016 - Prod. (2W) 3
Initial Plan 16,478 units
Current Plan 18,411 units
AB-OK PRODUCTION
Apr-16 to Mar-17 18,548 units
3400 25,000
13261 18411
16701 20,000
8423 9989 11549 13261 14997
7127 9989 11549 15,000
2900 2799 4448 5807 7127 8423
1718 4448 5807 10,000
Production in Units

1718 2799 5,000

2400 -
2286 2054 -5,000
1718 1960 2010 1712 -10,000
1900 1718 1649 1712 1710 -15,000
1649 1893 1560
1491 1806 1736 1704 -20,000
1646 1359
1400 1566 1560 1184 -25,000
1566 1431
1635

1359 1320 1296 -30,000

1473

1320 1296 -35,000

900 1081
1081 896 966 -40,000
-45,000
400 -50,000
Avg-15 Avg-16 1 2 3 4 5 6 7 8 9 10 11 12

Avg-2015 Avg-2016 Revised Plan-2016 ABOK Actual-2016

ABOK Actual-2015 Cumulative ABOK-2016 Cumulative Plan-2016
Sep - 2016 - Prod. (2W) 12
HOURS-PER-VEHICLE (HPV)
19
18.15
18 Low attendance i.e. 93%
Increase productivity 17.09
HPV

17
16.42

16
14.89
15
13.47 14.12
13.78 13.30 14.23
14 13.50
13.24
13.07
13 12.68 12.05 12.52 12.46 11.85
13.01 12.95 12.90 12.84 12.79 12.73 12.57
13.53

13.43

12 12.66 12.70 12.22 12.53

11.43 11.84 11.97

11 11.25 11.38

10
Avg. 15 Avg. 16 1/16 2 3 4 5 6 7 8 9 10 11 12
Avg. 2015 Avg. 2016 Actual 2016 Actual 2015 Initial Target
Sep - 2016 - Prod. (2W) 13

PARTS PROD. FOR SPARE PARTS DEPTT

4000
3538 3965
3538
3500
2994
3000 2821
2677
2821
2500 2397
Production Units

2216 2141
2093 2089 1894
1748 1915 1915
2000 2203 2093
2098 1699 1725 2094
2098
1915
1500 1785 1770
1624
2149
2117

1323 1349
1223 1349
1000 1184 1340

500

0
Avg. 15 Avg. 16 1/16 2 3 4 5 6 7 8 9 10 11 12
Avg-2015 Avg-2016 Actual-2016 Actual-2015 Revised Plan-2016
Sep - 2016 - Prod. (2W) 14

ELECTRICITY POWER CONSUMPTION

130 102.5 113.3 103.0
85.5 80.4 87.9 81.3 90.5 88.9
95.2 95.5 87.4 80.7 87.4 104.193.2 84.7
KWh/VEH

110 73.8 77.8 77.2 81.6

94.5
90
79.9
74.4
70 62.1 64.7 66.2
62.3 69.0
57.8 51.9 58.0 65.1
52.9 50.1
49.8 51.3 52.2 51.2 51.9
50
60.2
58.8

51.6 51.1 50.8 50.6 50.3 49.8 49.6 49.3 49.1 48.8
44.8 46.2 50.7
41.6
30
Avg. Avg. 1/16 2 3 4 5 6 7 8 9 10 11 12
15 16
Avg. 2015 Avg. 2016 Target 2016 Act. KWh/Veh-16
Act. KWh/Veh-15 2016 KWh in '000 2015 KWh in '000