~0614607

1

CSPL Sales Review for 2012-13

Month April May June July Aug Sept Oct Nov Dec Jan Feb Mar Total

Total Sales 238.08 255.07 259.10

Segment Sales April Sales May Sales June

OEM 207.63 228.10 229.91

Retail 21.22 17.50 19.95

Exports 7.42 7.23 8.14

Fleet 1.81 2.25 1.10

Total 238.08 255.07 259.10

Mn. Rs

Analysis of Raw Material cost to % of sales 2012-13

PO:

Month April May June July Aug Sept Oct Nov Dec Jan Feb Mar Total

Budgeted Material Consumption 44.70 46.06

Actual Material Consumption 48.33

51.85

Mn Rs.

3

Capacity Utilization for Year 2011 – April to Mar 2013

 Pelhar April  May  June July August Sept Oct Nov Dec Jan Feb MarInstalled Capacity ( Million Sets)

0.76 0.83 0.83

Utilized Capacity (Million Sets)

0.33 0.45 0.50

% Utilization 43% 55% 61%

8/22/2012 4

EXPORTS ProjectsPROJECTS Status on JUNE 2012

HONDA A countermeasure was given to Honda ,where CSPL-TVF-3PLE-1 material is to be used. All the materials available in Pelhar and Unit I were under deviation ,traced one roll at haridwar which was without deviation and passes HES specs hence procured that from Haridwar, on which gloss patches were printed . These patches passes in fuel oil resistance test where as fails in E10 and E20 solution for both Type 4 and Type 6 panels. Testing presently under process for original Honda Decal for E10 and E20 solution reports will be submitted by July 1st week

MIO-PINK(Yamaha Indonesia)

Printing done with following combination and test conducted results found as under,Material used as 1.PVC WB80 PA 10 11LLY2.PVC WB80 PA T1 11LLY3.CSPL-WVF-3P-14.CSPL-WVF-3P-2Printed OC with following combination 1.V3 + 45% Non silicon 8228 OC2.V3 + 8600 OC3.V3 + SIEKO 5412 UVAll the material printed with V3 + Sieko 5412 UV fails in WOM after 400hrs,where as material printed with other two OC passes in WOM till 400 hrs and is continued for 900hrs

KUBOTA Approved Drawing submitted (K7564-65231,K7311-65206,K7721-65801,K2581-65205) on 14.6.2012 and 18.6.2012. Awaiting for the release of the P.O

8/22/2012 5

Membrane Switch Projects

TYPE OF MEMBRANE SWITCH

STATUS IN JUNE 2012

LGLG samples will be submitted by 11-07-12

LG quote submitted on 2.7.2012 ,awaiting feedback from Mktg

Membrane switch production set-up

Location finalized for MS assembling (In dial post curing area) .Layout to be finalised

Membrane Switch Equipments

Testing equipments (MS tester, life tester & Hipot tester) ordered, expected by mid July 2012

Hot air oven will be ordered after positive feed back from LG

Manpower2 man power to be taken from production for involving in MS start up production activities. Existing 2 persons

8/22/2012 6

RAW MATERIAL TRACKING SHEET

Raw material

PE - No. of samples dispatched – April to Mar 2013

Month

2010-11 Apr May Jun Jul Aug Sep Oct Nov Dec Jan Feb Mar Average Target

No. of Samples dispatched

67 40 44

Development time (days)

3.76 3.3 3.7

Apr May Jun Jul Aug Sep Oct Nov Dec Jan Feb Mar0

0.5

1

1.5

2

2.5

3

3.5

4

4.5

5

TARGET 3.9 DAYS

Segments ClientsNo. of samples dispatched

No. of production from this months sdr.

No. of production previous months sdr. Ftr

OEM TWO WHEELERS

HERO 7 0 4 4BAJAJ 4 0 0 0

YAMAHA 5 0 1 1SUZUKI 1 0 0 0

OEM FOUR WHEELERS & OTHERS

MAH. & MAH. 8 1 2 3M&M SWARAJ 2 0 1 1JOHN DEERE 3 0 0 0

TAFE 10 0 2 2MARUTI SUZUKI 1 0 0 0TATA MOTORS 4 0 0 0ESCORT TRACT. 2 0 0 0

HAZARA 1 1 0 1

AUTOGRAPHIX ROYAL ENFIELD 1 0 0 0OTHERS 4 0 1 2

EXPORT

AUTOGRAPHIX 4 0 4 4

SAUD BHAWAN 2 0 0 0ALJ 1 0 3 3

BANGLADESH 1 0 0 0

INTERNAL CUSTOMER

TOTAL 61 2 18 20

HERO HONDA 15 15

PE - Product Developed – June 2012

9

PE - Analysis of FTR – April to Mar 2013

Month2010-11 Apr May Jun Jul Aug Sep Oct Nov Dec Jan Feb Mar Actual Target

No. of Samples dispatched

67 40 44

FTR 67 40 44

% FTR ( days)

100% 100% 94.4%

Apr May Jun Jul Aug Sep Oct Nov Dec Jan Feb Mar0%

20%

40%

60%

80%

100%

120%

% FTR

% FTR

Clients No. of samples dispatchedNo. of production from this 

months sdr. Ftr

MAH. & MAH. 8 1 1

HAZARA 1 1 1

10

PE -Dials developed and quantity dispatched in the month of June

S. No

Dial Name Hand Over Date

1HDT Daimler dial  10 nos each

NGC Dial & Diffuser 180 nos each

2HDT Daimler dial  10 nos each

3Bajaj JL dial & John Deere dial 5 Nos each

5TATA Prima dial (New option) 10 nos

6TATA Prima dial (New option) 20 nos

11

PE - ITC samples developed in the month of June

List of  jobs of JUNE 2012

SR No. JOB Customer

DATE StatusThings gone RightReceived Sales status

1 Classic Inshop- repeat order (2 artwork)repeat size ( 17.3" x 17")new size ( 22" x 14")

ITC 2-Jun PRODUCTION DONE, 11-Jun

FTR approved 

2Royal Onshop, 3'X6' ITC 9-Jun Awaiting feedback Clear and well file 

information 

3Gold Flake red Onshop Vinyl, 3'X6'

ITC 1-JunBackground : approved Brandboad : approved Clear and well file 

information 

4Gold Flake red Onshop PC, 3'X6'

ITC 1-JunBackground : approved Brandboad : approved Clear and well file 

information 

5

Flake Filter BRANDBOARD 1) flake  BB   straight Printing       2) flake  BB   reverse Printing ITC 19-Jun

Background : approved Brandboad : approved Clear and well file 

information 

6 NAVY CUT ACP,  59cmx 89cm ITC 22-Jun Awaiting feedback  

7 NAVY CUT Reverse printing 17" x

22" ITC 22-Jun

As per the instructions received by Nandini kindly stop all the sample developments on clear acrylic.We will not be using 3mm clear acrylic henceforth.We are going to try some alternate base material

12

PE - Exports samples developed in the month of Exports

Sr. No JOB Customer

Costing Sampling

1

KUBOTA (225 RFQ)

KUBOTA39 RFQ  Submitted on PC22 RFQ  Submitted on PVC22 RFQ  Submitted on PVCTotal 83 RFQ Submitted

2

KUBOTA (225 RFQ)

KUBOTA39 RFQ  Submitted on PC22 RFQ  Submitted on PVC30 RFQ  Submitted on PVCTotal 91 RFQ Submitted

3 Sample Development KUBOTA   30 pcs. Each submitted Dt. 28-06-2012

4 Sample DevelopmentSample DevelopmentSample DevelopmentSample Development

KUBOTAKUBOTAKUBOTAKUBOTA

HOLD for Customer Inputs

PO:

SCM – RM Cost Saving as % on Total Receipt April to Mar 2013

In Lac

Apr May Jun Jul Aug Sep Oct Nov Dec Jan Feb Mar0

10

20

30

40

50

60

70

80

90

100

Actual SavingsTarget

Month2010-11 Apr May Jun Jul Aug Sep Oct Nov Dec Jan Feb Mar Total Actual

Purchasing Value 817 1073 1122

Target  57 75 79

Actual Savings 5.1 89 15.5

%  9% 118% 20%

PO:

 Inventory Analysis (Material Rx Vs Consumed) April to Mar 2013

Month Apr-12May-

12 Jun-12 Jul-12 Aug-12 Sep-12 Oct-12 Nov-12 Dec-12 Jan-13 Feb-13Mar-

13 TotalMatl

Recd(in L) 817 1073 1122 3012Matl

Issued(in L) 1083 1363 1325 3771

Apr-12

May-12

Jun-12Jul-1

2

Aug-12

Sep-12

Oct-12

Nov-12

Dec-12

Jan-13

Feb-13

Mar-13

0

200

400

600

800

1000

1200

1400

1600

Matl Recd(in L)Matl Issued(in L)

PO:

 Inventory  ValuationApril to Mar 2013 

Month Apr-12 May-12 Jun-12 Jul-12 Aug-

12 Sep-12 Oct-12 Nov-12 Dec-12 Jan-

13Feb-13

Mar-13 Total

Local &Import ( Lacs)

1280 1365  1356                   4001

Target 1527 1628 1845 2080 2228 2316             11624

April May June July Aug Sep Oct Nov Dec Jan Feb Mar0

500

1000

1500

2000

2500

Local &Import ( Lacs)Target

PO:

SCM - Inventory Turn Analysis 2010-11 – April to May 2013

Months Apr-12 May-12 Jun-12 Jul-12 Aug-12 Sep-12 Oct-12 Nov-12 Dec-12 Jan-13 Feb-13 Mar-13

Inv Turns 10 12 12

Target 11 11 11 11 11 11 11 11 11 11 11 11

9.00

9.50

10.00

10.50

11.00

11.50

12.00

12.50

Inv TurnsTarget

PO:

SCM -Premium Freight as % to Total Receipt - April to Mar 2013

Month April May June July Aug Sep Oct Nov Dec Jan Feb Mar

Total

Last year ( 11-12)

2.40 1.78 0.0 0.0 0.0 1.9 0.0 0.3 0.0 0.0 1.9 2.35 10.6

This Year (12-13)2.37 1.98   0.6                   4.95

Target Rs in Lakhs 4.0 4.0 4.0 4.0 4.0 4.0 4.0 4.0 4.0 4.0 4.0 4.0 48.0

April May June July Aug Sep Oct Nov Dec Jan Feb Mar0.00

0.50

1.00

1.50

2.00

2.50

3.00

3.50

4.00

4.50

Last year ( 11-12)This Year (12-13)Target Rs in Lakhs

PO:

SCM - Non Moving Stock – April to Mar 2013

Description Apr-12 May-12 Jun-12 Jul-12 Aug-12 Sep-12 Oct-12 Nov-12 Dec-12 Jan-13 Feb-13 Mar-13

Base Film 49 49 49

Application Film 32 31 31

Ink 24 24 24

Grand Total 105 104 104

Target 105 102 101 98 95 93 91 88 85 81 78 75

Apr-12

May-12

Jun-12Jul-1

2

Aug-12

Sep-12

Oct-12

Nov-12

Dec-12

Jan-13

Feb-13

Mar-13

0

20

40

60

80

100

120

Grand TotalTarget

Production Planned v/s Actual ( Rs.) – April to Mar 2013

13.48

9.48 10.22 10

.92

13.66

9.88 10.70

13.44

10.07 10

.69 12.08

02468

10121416

Avg.

(11-1

2)Ap

r-1

2

May

-12

Jun-1

2

Jul-1

2

Aug

-12

Sep-1

2

Oct

-12

Nov

-12

Dec

-12

Jan-1

3

Feb-1

3

Mar

-13

Budget Prod (Rs. Crs.)

Actual Prod (Rs.Crs.)

Sales (Rs.Crs.)

On Time Delivery to Depot – April to Mar 2013

100

100

100

100

100

100

100

100

100

100

100

100

100

99.3

5

99.2

3

99.5

6

99.1

5

70

75

80

85

90

95

100

Avg. (11-12)

Apr-12 May-12 Jun-12 Jul-12 Aug-12 Sep-12 Oct-12 Nov-12 Dec-12 Jan-12 Feb-12 Mar-12

% O

TD

Target

Actual

PPC - Transportation Cost to % of Sales - April to Mar 2013

0.54

0.63 0.62

0.46

0.07

0.22 0.20

0.10

0

0.1

0.2

0.3

0.4

0.5

0.6

0.7

Avg. 11-12

Apr-12 May-12 Jun-12 Jul-12 Aug-12 Sep-12 Oct-12 Nov-12 Dec-12 Jan-13 Feb-13 Mar-13

Target Total Freight cost (%) on sale Premium Freight (%) on sale

New models AACA & K06A

New Models AANA & AAGA

Capacity Planning for July’ 12 to Sept’ 12

Capacity Planning - July' 12 to Sep' 12 - Pelhar PlantSales Budget (Sets) Jul-12 Aug-12 Sep-12 Total

HMCL 389100 362625 387385 1139110

BAL 90900 90400 90400 271700

Yamaha 32700 45000 43600 121300

Suzuki 30000 31500 31500 93000

M&M 4200 4200 4500 12900

Total 546900 533725 557385 1638010

         Production Budget (Sets) 601590 587098 613124 1801811Planned Utilization (%) 78 76 86 80

Dial Capacity Planning July’ 12 to Sept’ 12

Capacity Planning - Jul' 12 to Sep' 12 - Pelhar PlantSales Budget - Dials Jul-12 Aug-12 Sep-12 Total

PRICOL  107850 132050 156150 396050

CONTI 39300 45300 47300 131900

TOTAL 147150 177350 203450 527950

Total Prod Budget  183938 221688 254313 659938

Capacity - Dials 452603 452603 417787 1322992

         Planned % Utilization 41 49 61 50

24

Sales & Production Plan – June ’12

Sales & Production Plan -Jul 12

Customer Sales Plan Stocking Norms

Actual Opening StkProduction Plan

Schedule ValueBSR Depot Total

HMCL 10.000 5.000 0.000 5.560 5.560 9.560 10.120

BAL 0.800 0.400 0.007 0.290 0.297 0.800 1.210

Yamaha 0.300 0.150 0.002 0.194 0.196 0.254 0.292

Suzuki 0.200 0.100 0.020 0.008 0.028 0.272 0.017

M&M 0.050 0.025 0.025 0.000 0.025 0.050 0.051

Godrej 0.020 0.010 0.000 0.000 0.000 0.035 0.025Pricol/Conti. 0.200 0.100 0.003 0.001 0.004 0.270 0.174

Export 1.150 0.000 0.000 0.000 0.000 1.150 0.530

Total 12.720 5.785 0.057 6.053 6.110 12.391 12.419

Production - Process Performance Average Printing M/C Efficiency % - April to Mar 2013

73

75 75 75 75 75 75 75 75 75 75 75 75

6665 65 65

60

62

64

66

68

70

72

74

76

Avg.

(11-

12)

Apr-

12

May

-12

Jun-

12

Jul-1

2

Aug-

12

Sep-

12

Oct

-12

Nov

-12

Dec

-12

Jan-

13

Feb-

13

Mar

-13

Target Average

26

Production - Process Performance Summary – Machine wise printing Idle / down time June

Month

Description

Avg. (11-12)

Apr-12 May-12 Jun-12 Jul-12 Aug-12Sep-12 Oct-12

Nov-12

Dec-12

Jan-13 Feb-13 Mar-13

Total Loading Time (min.) 204595 162714 184178 201729

Total Down Time (min.) 61233 58657 59206 61105

Total Down Time (%) 30.00 36.05 32.15 30.29

Reasons of Down Time

Planned Shut Down13681 20864 12757

13638

Screen Related 4655 36094568

3571

Process Related 3882430045 37828

39305

Ink Related2894

3474 31403561

Maintenance Related 1180 665 9131030

27

% OT Cost to Production – April to Mar 2013

• New Model AAGA – Super Splendor processed on short lead time.• Increased changeovers in SPD due to Brand Migration at HMC• M/C Allocation for ITC Sampling

0.13 0.27

0.190.01 0.32 0.20

0.97

0.14

0.59 0.39

0.000.200.400.600.801.001.20

Avg. (11-12)

Apr-12 May-12 Jun-12 Jul-12 Aug-12 Sep-12 Oct-12 Nov-12 Dec-12 Jan-13 Feb-13 Mar-13

% OT 

Month

% OT Cost to ProductionTraget % OT Cost (Support) % OT Cost (Production) % OT Cost (Total)

28

Production- Process Performance Punching Machines Efficiency % - Pelhar - April to Mar 2013

Machine April May June July Aug Sept Oct Nov Dec Jan Feb Mar Actual (Avg)

Target (Avg)

REBOLINI -1 91 87 87

REBOLINI -2 82 82 94

BHARAT BIG -1 83 72 98

BHARAT BIG -2 89 89 81

BHARAT SMALL -1

82 78 91

BHARAT SMALL -2

76 76 70

29

In-house Rejection – Area wise % (Pelhar) April to Mar 2013

5.96%

6.85%

5.10% 5.13%

0.00%

1.00%

2.00%

3.00%

4.00%

5.00%

6.00%

7.00%

8.00%

9.00%

10.00%Av

g. (1

1-12

)

Apr-

12

May

-12

Jun-

12

Jul-1

2

Aug-

12

Sep-

12

Oct

-12

Nov-

12

Dec-

12

Jan-

12

Feb-

12

Mar

-12

Rejection %

Month

30

In-house Rejection – Value wise % April to Mar 2013

Targ

et

Apr

May Jun Jul

Aug

Sep

Oct

Nov Dec Jan

Feb

Mar

0.001.002.003.004.005.006.007.008.009.00

10.00

8.007.19

9.44

8.13

Unit 1PelharHaridwar

DIAL Rejection trend

Nov Dec Jan Feb Mar April May June July Aug Sept Oct

Pricol 16 15 20.71 10.54 14.58 9.5 9.56

Continental 50 24 52.38 30.83 34.08 28 31.44

Diffuser 0 0 41.82 64.77 43.04 27.94 39.25

Nov Dec Jan Feb Mar April May June July Aug Sept Oct 0

10

20

30

40

50

60

70

Pricol Continental Diffuser

Internal Rejection – Quantity % April to Mar 2013

Apr

May Jun Jul

Aug

Sep

Oct

Nov Dec Jan

Feb

Mar

A: 1

1-12

A: 1

0-11

012345678

Pelhar Target

  Internal Rejection  

April  May  June  July  Aug  Sept  Oct  Nov  Dec  Jan  Feb  Mar  Target Actual11-12

Actual 10-11

Pelhar 4.05 3.63 3.85 4.0% 4.0 5.7

33

Line Rejection PPM – BAL VarrocApril to Mar 2013

Actu

al:

11-

12 Apr

May Jun Jul

Aug

Sep

Oct

Nov

Dec Jan

Feb

Mar

0

2000

4000

6000

8000

10000

12000

W & C

Target

Line Rejection – BAL (2011-12)

Line rejection ppm  from Varroc - PantnagarTARGET2011-12

ACHIEVED2011-12

TARGET2012-13

APRIL 12

MAY-12

JUNE-12 JULY-12 AUG-12

SEP-12 OCT-12 NOV-12 DEC-12 JAN-13 FEB-13 MAR-13

3000 11909 3000 6001 11986

34

Vendor Rating - Bajaj

CSPL (Vendor) Rating from BAJAJ [2012-13]

Customer  Standard  APRIL MAY JUN JUL AUG   SEP OCT NOV DEC JAN FEB MAR

BAL – WC (100487)

< Level 2

2 3 3

BAL – Haridwar (111407)

< Level 2

2 2 2

35

Line PPM feedback from M&M FES

Line ppm: MM FES

  Actual 2012-13Actual 11-12 Apr May Jun Jul Aug Sep Oct Nov Dec Jan Feb Mar

TARGET LR PPM <250 ppm

618 258 13

% GR Rejection = 0 3 0 0

Actu

al 1

1-12 Ap

r

May Jun Jul

Aug

Sep

Oct

Nov

Dec

Jan

Feb

Mar

0

100

200

300

400

500

600

700

M&M FES - Line ppm  [12-13] Target: 250 ppm

36

Line PPM feedback from Tafe

Line ppm: Tafe

Actual 11-12

Actual 2012-13

Apr May Jun Jul Aug Sep Oct Nov Dec Jan Feb Mar

TARGET <100 ppm 865 250 0 0

865

250

0

100

200

300

400

500

600

700

800

900

1000 Past trend Target Actual

37

4. Summary of Complaints

  Apr May Jun Jul Aug Sep Oct Nov Dec Jan Feb Mar  

No. of Complaints 3 2 6 1  Nature of Complaints low Gloss 1 Complaints by Customer Varroc – Chakan 1    

Sr.No Customer Complaint Description Root Cause Corrective Action

1 IYM-Surajpur Graphic Cut in 1CK2 Levelling of blade on one side of die

found out to be uneven.

1] Work instruction amended for the method of visual checking of deepcut,2] job training provided to the inspectors.

2 IYM-Surajpur

Ink peel off in Yamaha Emblem (5KAB CRUX)

Uncoated metallic particles have less cohesive force as compared to coated metallic particles used in ink preparation.

Coated metallic particles to be used. Bill of material amended and also the process routing changes in SAP.

3 IYM-Surajpur Air Bubbles in 1CK3 New material was used - inadequate

validationPPAP methodology to be followed for new material introduction

4 Bajaj - Waluj

Disc. 125 ST Shade Variation found in Flame red for batches 446052012 & 70062012

Variation in deposition of metallic partcile on base film during printing in single batch.

Uniform stirring during ink issue also stirring prior to pouring ink on the screen.

5 Continental-Bengaluru

Smoke Variation found in HDT Diamler in 1 pieces in lot size of 300 of batch number 2021211 at customer assembly line at Continental, Bangalore on 20/06/2012.

Setup sheet is not identified at printing stage before proceeding for further operation leading to mixing of setup sheets/dials with Ok sheets/dials at final inspection.

Setup Sheets/Dials to be crossed completely using permanent marker in printing stage itself.Illumination inspection to be done on Cluster instead of light table.

6 Continental-Bengaluru

Green and white dots found in HDT Daimler in 59 pieces in lot size of 300 of batch number 2021211 at customer assembly line at Continental, Bangalore on 20/06/2012.

Leakage in screen due to removal of emulsion coating from non image area leading to green and grey ink transfer on image area while printing 5th Colour and 6th colour respectively

Before commencing printing a pc sheet with lamination and/or rough pc sheet will be printed and checked for ink leakage and same will be done after every 100th and for last sheet and leakages if any will be touched up by PVA

5. Summary of Corrective actions - June

HMC-G– Quality Failure ReportPlant SL

No.Material Code

Material Description

Problem Analysis Action Type Reason Counter Measures

HMC-G 1.

2.

240512

5940312=09

2470512=09

3160612=09

CBZ Stripes

KWAH Front Cowl Blk Blue

KVEG CVG

KWAH Front Cowl cover BHG

Incomplete back cut

Incomplete back cut(10-12%)

-Incomplete back cut(25-30%)

-Incomplete back cut(3-5%)

-Samples sent to plant

-Samples sent to plant

-Samples sent to plant

-Samples sent to plant

-Process lapse

-Process and inspection lapse

-Process and inspection lapse

-Process and inspection lapse

-Yet to be received

-Yet to be received

-Yet to be received

-Yet to be received

HMC-D – Line feedback

Customer Issue Batch No.  Observation CAPA / Comments HMC-D 1.Craters observed in model 

splender plus AAEA   

2.Skinning observed in stripes of model AAEA SBK   -model AAEA P.maroon

3.Top film removal hard observed in stripes of model AADA BLK Sil 

-Splendor pro color SBK

4.Hole punching in stripes

5.Incomplete back cut at tab location in side cover color SBK

5560412  

2640512 

0320120376

3100512   

0520120425

          -

0520120425

-Observed after lacquering process.-Reduces after cleaning with IPA.

-Observed in 10-15% stripes  -obsd. In 20-25% pcs.

-Observed in 30-40% stripes

-observed in 30-40% stripes

-Repeated problem & Observed in  the materials belonging to march 12

-Observed in 30-35% pcs.

-Yet to be received from plant  -IPA cleaning introduced prior to lacquering and after that no problem has been reported.

-Yet to be  received from plant .  

                         -do-

-Yet to be received from plant.

-Yet to be received

-Inform to all concerned with compiled data.

-Yet to  be received.

Customer Line feedback-Yamaha SP

Customer Issue Batch No.  Observation CAPA / Comments IYM-SP  1.Ink peel off in yamaha 

emblem model 5KA

2.Craters in stripes of model 1CK3

5470412

0120120743

-Ink peel off while removal of top application film

-Problem repeated 

-Problem observed at edges in different locations after lacquering

-Submitted on 23.04.2012

-Submitted on 26.06.2012-Fresh batch yet to be delivered

-Submitted on 26.06.2012-Fresh batch after c/m yet to be received

Major Highlights (Quarter-1)

• April12: First Surveillance Audit inline with TS:16949/2009 conducted by Bureau Veritas.

• May12: Supplier Surveillance Audit (QAV-1) conducted by Mahindra 2 Wheeler.

• May12: Visit of John Deere to Pelhar Plant.• June12: Green Vendor Development Program

(GVDP), certificate received by HMCL Gurgaon.• June12: Supplier Development Audit conducted

by Royal Enfield.

43

Ink Lab – Issues report for June

Job Details Issue    Root Cause  Corrective Action AANA GLM CARB CB RED ABS PART & KTRM Glm. FI CB RED ABS part ( HMCL)

OC & Ink peel off Uncoted silver particles in CSPL 057 (accurate silver)

(CSPL 2285) New Accurate Silver by Coated Stapa VK 903/904 ECN raised

KVEG CBZ EXTREME - HMCL

OC & Ink peel off SG 700 Base coat Eliminate

SG 700 Conc White HD White

CSPL 1007 (425 OC) CSPL 2120 (8228 OC)   ECN raised

YAHAHA Emblem OC & Ink peel offVK901 in CSPL 438 Pastel Gold Shade Used Stapa 801 silver particles

CSPL 1007 (OC 425) CSPL 1007 (OC 425) ECN raised

OC Peeloff Problems

44

Ink Lab – OC Wastage for June

PO no. Machine Description Qty. 8600 OC Wastage Qty.Kg

% Wastage OC Average

100068194 SPS-XP KWAH BLK H. GREY F/COWL (T-3) [4 SETS] 2000 8.8 1.781 20.20%

100068200 SPS-XP BAJAJ DISC 125ST BLK RED SEAT/FR.COWL(1S 2000 16 3.6 22.50%

100068001 SPS-XP KTPJ C.B.RED T-2 FUC 'A', BC 'A' (1SET) 2600 11.2 2.544 22.70%

100068691 SPS-XP BAJAJ DISC 125ST BLK RED SEAT/FR.COWL(1S 1860 6.4 1.384 21.50%

100068615 ATMA-6 EXPORT 1000 5.8 1.19 20.50%

100070565 ATMA-6 EXPORT 500 4.5 1 22.20% 21.65%

PO no. Machine Description Qty. CSPL 2120 of NazdarWastage Qty.Kg

% Wastage OC Average

100067055 SPS-XP AACA PASSION PRO BLK H.GREY SC (2SETS) 2272 10.5 2.44 23.20%

100068298 SPS-XP AAFA SPL.NXG BLK RED ABS PARTS(1SET) 3000 16.8 4.27 25.40%

100067415 SPS-XP AACA[PASS.PRO]BLK H.GREY ABS (1SET) 2300 11.2 3.5 31.25%

100068271 SPS-XP BAJAJ PULSAR 135 RED ABS(4SETS) 600 3.5 1.2 34.20%

100068001 SPS-XP KTPJ C.B.RED T-2 FUC 'A', BC 'A' (1SET) 1100 5.6 1 17.80%

100068604 SPS-XP KWAH BLK RED/BLUE /H.GREY R/COWL(5SETS) 2500 14.4 3.4 23.60% 26%

45

MACHINE-WISE DOWNTIMES FOR CYLINDER PRESSES – April to Mar 2013

MTBF – Mean Time Between Failures; MTTR – Mean Time To RepairDowntime for Rolt is not considered as there are some manufacturing defects which lead to downtimes.

Machine Total Downtime(mins.)

Avg. Downtime per day (mins.)

Avg. MTBF (mins.)

Avg. MTTR (mins.)

Sakurai-01 465 18.6 21367.65 465

Sakurai-02 115 4.6 7408 38

SPS-01 205 8.2 8599 51.25

SPS-02 60 2.4 21570 60

SPS-03 0 0 43200 0

SPS-04 30 1.2 14390 15

SPS-XP 320 12.8 8576 80

Others 430 35.33 2177.62 57.63

TOTAL (JUN’ 12) 1700 68.00 1507.73 95.86

TOTAL (MAY’ 12) 1960 40.80 1579.80 42.70

TOTAL (APR’ 12) 982 40.80 1579.80 42.70

TOTAL (Mar’ 12) 2429 83.29 879.40 51.68

46

TOTAL MAINTENANCE DOWNTIME (MINS.) – April to Mar 2013

Monthly Downtime Limit

is 2000 mins.

Ap

ril

Ma

y

Ju

ne

Ju

ly

Au

g

Se

pt

Oc

t

No

v

De

c

Ja

n

Fe

b

Ma

r0

500

1000

1500

2000

2500

3000

3500

1517

2201

1506

1735

2580

1957

2448

2148

1653

3147

25822429

Downtime 2011-12

Downtime 2012-13

June12 205 60 0 30 320 465 115May12

0 245 0 200 0 20 130Apr’12

40 65 0 0 40 0 110Mar’12

75 70 00 113 223 345 15Feb.’12

144 155 128 337 200 200 30Jan’12

202 375 86 147 182 87 30Dec’11

130 192 30 405 90 0 0Nov’11

0 175 285 145 270 20 110Oct’11

5 428 20 198 80 5 220Sept’11

115 0 165 40 105 0 25Aug’11

110 119 30 125 30 0 75July’11

240 145 0 105 410 70 240TOTAL 1266 2029 759 1845 1950 1212 1100

Average 105.5 169.08 63.25 153.75 162.5 101 91.66

Machine/Month

SPS-01 SPS-02 SPS-03 SPS-04 SPS-XP SK-01 SK-02

CYLINDER PRESS DOWNTIME FOR LAST 12 MONTHS (mins)

48

ELECTRICITY CONSUMPTION (UNITS) – April to Mar 2012

Sudden increase is due to increased HVAC load and machine load. 

Ap

ril

Ma

y

Ju

ne

Ju

ly

Au

g

Se

pt

Oc

t

No

v

De

c

Ja

n

Fe

b

Ma

r0

100000

200000

300000

400000

500000

600000

700000

800000

527070

560790 566430 564000 555180

513840

547590

493710 496020 492535506576

559709

435450

475710

430266 425790 437071

589080

521501 504090

492390 488250

551910

Electricity Units 2010-11

MAINT. BREAKDOWNS & PREVENTIVE ACTIONS

Machine Breakdown Reason

DownTime Corrective Action Preventive Action

SPS XP Machine wasnot running due to faulty cable of PLC

input Contacts..

320 mins.

Damaged Cable replaced with the New Cable.

PLC’s input ,output function ‘Check Point’ will be checked in ‘Preventive Maintenance’.

SK-1 Shear Key of the Gear-box was broken.

465 mins.

Shearkey replaced with new Shearkey.

Shear Key Check Point included in the ‘Preventive Maintenance’.

SK-2 Timer Belt damged of the Vaccum Pump.

165 mins.

Timer Belt replaced with new one.

Timer Belt will be replaced once in a year.

50

SALES (RS.) PER ELECTRICAL UNIT – April to Mar 2013

Ap

ril

Ma

y

Ju

ne

Ju

ly

Au

g

Se

pt

Oc

t

No

v

De

c

Ja

n

Fe

b

Ma

r0

50

100

150

200

250

300

350

400

450

500 Sales (Rs.) per Electrical Unit 2011-12Sales (Rs.) per Electrical Unit 2012-13

Monthly Target for Sales (Rs.) per Elec. Unit is Rs. 300.

51

ELECTRICAL EXPENSES % TO PRODUCTION – April to Mar 2012

Ap

ril

Ma

y

Ju

ne

Ju

ly

Au

g

Se

pt

Oc

t

No

v

De

c

Ja

n

Fe

b

Ma

r0

100000

200000

300000

400000

500000

600000

700000

800000Electricity Units 2011-12

Electricity Units 2012-13Sudden increase is due to increased HVAC load and machine load. 

52

UNITS CONSUMED BY DIESEL GENERATORS – April to Mar 2013

1 2 3 4 5 6 7 8 9

10

11

12

0

1000

2000

3000

4000

5000

6000

7000

8000

9000

555

5412

1836

7657

5370

2378

501

0

1275998

2576

4238

8200

3797

337

Units consumed by DG Sets 2011-12Units consumed by DG Sets 2012-13

Total Manpower - April to Mar 2013

Sr. No DescriptionAs on March 2011

As on March 2012

April May June July Aug Sept Oct Nov Dec Jan Feb Mar

1 No. Of Staff 87 106 100 99 94

2No. Of Company Workmen 94 118 119 117 117

3No. of Contract Workmen 423 432 381 405 398

  Total Manpower 604 656 600 621 609

54

Total Manpower Cost for Pelhar April – Mar 2013

Description April  May-11 Jun-11 Jul-11 Aug-11 Sep-11 Oct-11 Nov-11 Dec-11 Jan-12 Feb-12 Mar-12

Total Production.  98.8 107.0 106.9

Salary & Wages  to % of Production. Mn. Rs. 

7.33% 8.59% 7.74%

Contract Wage Bill % to sales 3.16% 3.11% 3.03%

On Roll Overtime  Cost  to % of Production   

0.06% 0.15% 0.12%

Contract Overtime  Cost  to % of Production. 

0.07% 0.44% 0.34%

Figures in Mn.Rs

55

Description April  May-11 Jun-11 Jul-11 Aug-11 Sep-11 Oct-11 Nov-11 Dec-11 Jan-12 Feb-12 Mar-12 Total

ELECTRICITY/POWER EXPENSE - MANUF

2.81

2.88

2.85

3.96

5.44

5.29

5.40

5.90

6.17

5.99

5.60

5.76

58.06

ACTUAL EXPENSES 4.25 2.91

FUEL EXPENSES - MANUFACTURING

-

0.08 - 0.08 0.08 0.08 -

0.08 -

0.08

- 0.08

0.56

ACTUAL EXPENSES - 0.12

REPAIRS & MAINT-MACHINERY

2.50

2.50

2.50

2.00

2.00

2.00

2.00

1.20

2.00

1.50

1.20

1.20

22.60

ACTUAL EXPENSES 2.45 0.71

Analysis Operating Expense - Engineering

56

Description April  May Jun Jul Aug Sep Oct Nov Dec Jan Feb Mar Total

CONSUMABLE SUPPLIES

0.92

0.93

1.05

1.43

1.73

1.76

1.91

1.98

2.16

2.20

2.45

2.69

21.20

ACTUAL EXPENSES 1.11 0.49

DIE PURCHASES & DEVELOPMENT

0.28

0.28

0.32

0.43

0.52

0.53

0.57

0.59

0.65

0.66

0.73

0.81

6.36

ACTUAL EXPENSES - 0.31

POSITIVE & NEGATIVE

DEV.CHARGS 0.07

0.07

0.08

0.11

0.14

0.14

0.15

0.16

0.17

0.18

0.20

0.22

1.70

ACTUAL EXPENSES 0.02 -

PRODUCT DEVELOPMENT

CHGS 0.18

0.19

0.21

0.29

0.35

0.35

0.38

0.40

0.43

0.44

0.49

0.54

4.24

ACTUAL EXPENSES 0.21 0.06

Analysis Operating Expense

57

Description April  May-11 Jun-11 Jul-11 Aug-11 Sep-11 Oct-11 Nov-11 Dec-11 Jan-12 Feb-12 Ma-12r Total

SCREEN MAKING EXPENSES

1.01

1.02

1.16

1.57

1.90

1.93

2.10

2.17

2.38

2.42

2.69

2.96

23.32

ACTUAL EXPENSES 0.90 2.20

LABOUR CHARGES 4.46

4.46

4.48

4.83

5.35

5.99

6.02

6.50

6.85

6.77

6.99

7.04

69.73

ACTUAL EXPENSES 4.36 5.06

TRANSPORT CHARGES BY ROAD-OUTWARD

0.17

0.18

0.20

0.27

0.33

0.33

0.36

0.38

0.41

0.42

0.47

0.51

4.03

ACUTAL EXPENSES 0.03 0.11

TRANSPORT CHARGES OTHERS-OUTWARDS

0.55

0.56

0.63

0.86

1.04

1.06

1.15

1.19

1.30

1.32

1.47

1.61

12.72

ACTUAL EXPENSES 0.46 0.54

Analysis Operating Expense

58

Description April  May-11 Jun-11 Jul-11 Aug-11 Sep-11 Oct-11 Nov-11 Dec-11 Jan-12 Feb-12 Mar-12 Total

REPAIRS & MAINT-BUILDING

0.18

0.18

0.18

0.18

0.18

0.18

0.53

0.53

0.53

0.53

0.53

0.53

4.20

ACTUAL EXPENSES -

MOTOR CAR / CYCLE FUEL EXPENSES

0.20

0.20

0.20

0.20

0.20

0.20

0.20

0.20

0.20

0.20

0.20

0.20

2.40

ACTUAL EXPENSES 0.12

SECURITY CHARGES

0.33

0.33

0.33

0.33

0.33

0.33

0.33

0.33

0.33

0.33

0.33

0.33

3.90

ACTUAL EXPENSES 0.24

GARDENING EXP

0.05

0.05

0.05

0.05

0.05

0.05

0.05

0.05

0.05

0.05

0.05

0.05

0.60

ACTUAL EXPENSES -

HOUSE KEEPING EXPENSES

0.35

0.35

0.35

0.35

0.35

0.35

0.35

0.35

0.35

0.35

0.35

0.35

4.20

ACTUAL EXPENSES 0.33

Analysis Operating Expense - HR