Classification: Internal Purpose

• Tracking the Evolution of Rejection Rate

35000 3.0% 16000 4.5%

4.0%
2.7% 4.0%
30000 2.6% 2.6% 14000
2.5%
3.3% 3.5%
25000 12000
2.0% 2.8% 3.0%
2.7% 2.6%
20000 10000
1.5% 2.3% 2.5%
30970

1.4% 8000 2.0%

14775
15000
28006

1.9%

26088
1.8% 2.0%

11882
1.0%

11775
20545

10000 6000 1.4%

1.5%

9972
1.1%

9116

7750
0.5% 4000 0.8%

7167

7129

7074
5000 1.0%

6563
6317
6037
723 842 532 368
0 0.0% 2000 0.5%
Qtr2 Qtr3 Qtr4 Qtr1 491 328 265 240 140 254 175
113 100 126 71 96
2023 2023 2023 2024 0 0.0%
Apr May Jun Jul Aug Sep Oct Nov Dec Jan Feb Mar
Sum of Accepted Quantity (Back Flush) 2023 2023 2023 2023 2023 2023 2023 2023 2023 2024 2024 2024
Sum of Product-Scrap
% Accepted Quantity (Back Flush) Product-Scrap % of Scrap

In December 2023, the rejection rate ratio reached its peak, but it can be consistently reduced
less than 1% by implementing various measures.
 Classification: Internal Purpose

• Tracking the Evolution of Rejection Rate: “Insights and Improvements”

Component Level
Dec Month Rejection Component level Tracking Key Components: Understanding Their Impact

HP-400-03 7

HP-250-04 15

HP-150-01 HP-150-02 HP-150-06 HP-150-08 HP-150-09 HP-250-04 HP-400-03

HP-150-09 7
Dec 0.14 0.0117994100294 0.0264255910987 0.0436681222707 0.0046760187040 0.0785340314136 0.0107816711590
985 483 424 7482 126 297
Jan 0.0948275862068 0.0192416525183 0.0148090413094 0.0153631284916 0.0053050397877 0 0
966 928 31 201 9841
HP-150-08 9
Work Center no

Feb 0.0115131578947 0.0094658553076 0.0205680705190 0.0116731517509 0.0068581225889 0 0

368 403 989 728 4128
Mar 0.0057783820530 0.0124925639500 0.0148331273176 0.0132340777502 0.0018115942028 0 0
2515 297 761 068 9855
HP-150-06 34

Dec Jan Feb Mar

HP-150-05 2

HP-150-02 12
Text: Action taken.

HP-150-01 168

0 20 40 60 80 100 120 140 160 180

Sum of Product-Scrap
 Classification: Internal Purpose

• Tracking the Evolution of Rejection Rate: “Insights and Improvements”

Nature of Rejection
25.0%

20.0%
20.0% 18.9%

15.0%
6.8% 11.3%
10.5% 9.9%
7.4% 6.4% 9.4%
10.0%
7.2%
5.6% 5.0% 5.5% 5.3% 5.0% 5.3% 4.7% 4.6%
5.0% 8.4%
5.2% 5.1% 4.6% 2.9%
4.5%
0.0%
Apr May Jun Jul Aug Sep Oct Nov Dec Jan Feb Mar
2023 2023 2023 2023 2023 2023 2023 2023 2023 2024 2024 2024

% of Scrap - Operator % of Scrap - Raw Material

Reason for Rejection – Raw material • The level of rejection was significant in both
800
693
operators and raw materials.
700
600
500
400
300
200
100 49
16 32
2
0
Black Mark Short Mould Sticking Surface Finish White Patch

Sum of Product-Scrap
 Classification: Internal Purpose

• Tracking the Evolution of Rejection Rate: “Insights and Improvements”

Nature of Rejection – Operator level
160 2.5
Shift Analysis 142 146
140
2 2 2
120 113
107 107
6.3% 97 93
100 87 1.5
7.3% 80 79 84
1 80 68
2 60 1 531 1
42 47
3 36
40 31
0.5
20
3
0 0
A.S ANA ARU GUN JAG K.S KIR M.S MOH MUR NIT PRE RAJ SOM SUD SUR VEN VIJ

6.5% Overall Product scrab Product scrab - Mar 2024

'% of Scrap'
30% • The rejection rate was prevalent across all shifts, with data
25%
25% collected on a per-operator basis.
20%
• Subsequent training was provided to all operators.
% of Scrap

15%

10% 9%
7% 7% 7%
9% 9%
8%
7%
8% • A review in March showed a significant improvement in
6% 6% 6% 6%
5%
5% 5% 5% 4% rejection rates compared to the following months.
0%
S S S T E J J
A. AN
A
AR
U N
JA
G K. R
KI M. O
H UR D R
NI PR RA S OM S U S U VE
N VI
GU M M
 Classification: Internal Purpose

• Tracking the Evolution of Rejection Rate: “Insights and Improvements”

Reason for Rejection

2023 Apr 2023 May 2023 Jun 2023 Jul 2023 Aug 2023 Sep 2023 Oct 2023 Nov 2023 Dec 2024 Jan 2024 Feb 2024 Mar
S 0.0498687 0.0583554 0.0594679 0.0388548 0.0582403 0.0571827 0.0500568 0.0557029 0.0842911 0.0571428 0.0428696 0.0528017
h 66404199 37665782 18622848 05725971 96530359 05718270 82821387 17771883 87739463 57142857 41294838 24137931
or 5 5 2 4 4 6 9 3 6 1 2
t
M
o
ul
d
Bl 0.0857843 0.0638297 0.0827761 0.0644746 0.0682392 0.1067193 0 0.0459770 0.0909090 0.0310262 0.0163934 0.0220994
a 13725490 87234042 85928048 98176213 58635214 67588933 11494252 90909090 52983293 42622950 47513812
ck 2 6 4 7 8 9 9 6 8 2
M
ar Short Mould Black Mark Crack Surface finish
k
Cr 0.0370370 0 0.0864297 0.1864406 0 0.0704845 0.0718132 0.0535117 0.1411530 0.1639344 0.0740740 0.0687022
a 37037037 25363489 77966102 81497797 85457809 05685618 81510934 26229508 74074074 90076335
ck 5 4 7 7 1 9
S 0.0714285 0.0740740 0.0541044 0.1142857 0.0699088 0.0829268 0.0721649 0.0622222 0.1253333 0.0434782 0.3333333 0.1153846
ur 71428571 74074074 77611940 14285714 14589665 29268292 48453608 22222222 33333333 60869565 33333333 15384615
fa 4 1 3 7 7 2 2 2
c
e
fi
ni
s
h