MAI Location Chakan Fact - Files Production 2010-2011 SS/ 08.Feb. 2011
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Fact - File SBC
Production in Chakan plant
1H10
2H10 Total10
Jan-11
Feb-11
Mar-11
2Q11 2H11 Total11
PRODUCTION ( Mio Pieces)Budget ( MioPieces)
0.4 12.2 12.6 2.4 3 3 7.9 16.8 33.1
Production ( MioPieces)
0.56 12.55 13.1 1.4 - - - - -
Forecast ( MioPieces)
- - - 2.46 2.72 3.05 8.84 17.95 35
MANPOWERStaff Budget 4 6 6 6 6 6 6 6 6
Staff Actual 3.5 5 5 5 - - - - -
Operatives Budget 2 6 6 10 10 10 12 12 12
Operatives Actual 1 6 6 6 - - - - -
SCRAP RATIO ( %)
Scrap RatioTarget ( %)
0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5
Scrap RatioActual ( %)
0.38 0.2 0.29 - - - - -
EXTERNAL PPMPPM Target 2 2 2 10 10 10 10 10 10PPM Actual 0 0 0 - - - - - -
Capacity coating system SBC: > 50 Mio pieces/year
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SBC PRODUCTION 2010/11
SS/Operations06/22/11 3
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SBC OPERATIVE MANPOWER
• Only Operative Team
• Common Staff Like
Maintenance /
Logistic / Quality
function are divided in
equal proportions.
• Mubea + Contactor employees considered
Operative ManpowerDetails
SS/Operations06/22/11 4
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SBC STAFF MANPOWER
• Only White collar
• Common Staff Like
Maintenance /
Logistic / Quality
function are divided in
equal proportions.
Staff manpower Details
SS/Operations06/22/11 5
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SBC PPM
06/22/11 7SS/Operations
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Fact - File VS
Production in Chakan plant
1H10 2H10 Total10 Jan-11 Feb-11 Mar-11 2Q11 2H11 Total11
PRODUCTION ( Mio Pieces)Budget ( MioPieces)
1.9 4.25 6.15 0.8 1.3 1.5 4.4 8 16
Production ( MioPieces)
2.22 4.39 6.6 0.6 - - - - -
Forecast ( Mio
Pieces)
- - - 0.6 1.3 1.4 4.1 9 16
MANPOWERStaff Budget 7 8 8 8 8 8 8 8 8
Staff Actual 6.5 7.5 7.5 7.5 - - - - -
Operatives Budget 3 7 7 7 10 10 10 10 10
Operatives Actual 3 7 7 7 - - - - -
SCRAP RATIO ( %)
Scrap RatioTarget ( %)6% 6% 6% 2% 2% 2% 2% 2% 2%
Scrap RatioActual ( %)
1.49%
1.34% 1.41% 1.2% - - - - -
EXTERNAL PPMPPM Target 2 2 2 2 2 2 2 2 2PPM Actual 0 0 0 0 - - - - -
Capacity VS line: 1piece / Sec; GEFF 75 %; 21 WD;16.5 Mio pieces/year
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VS Production 2010/11
06/22/11 9SS/Operations
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VS STAFF MANPOWER
06/22/11 10
• Only White collar
• Common Staff Like
Maintenance /
Logistic / Quality
function are divided in
equal proportions.
Staff manpower Details
SS/Operations
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VS OPERATIVE MANPOWER
06/22/11 11
• Only Operative Team
• Common Staff Like
Maintenance /
Logistic / Quality
function are divided in
equal proportions.
• Mubea + Contactor employees considered
Operative ManpowerDetails
SS/Operations
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VS SCRAP %
06/22/11 12
Action – UPS Back up provided
SS/Operations
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VS PPM
06/22/11 13SS/Operations
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Continuous improvment and Trainee
Programm s Chakan Plant
Trainee program for coling process.
2 Trainee´s to Bedano from week 7 to week 15 2 Trainees Under Hot presetting machine ( Under Mr Prasad)
Continuous improvment results (last 8 weeks) :
reduction HPS setting time from 1.5 hour to 0.5hour due to standard
setting sytem
better pipe system to avoid stopage of line. Achieved Zero rejection of Fall down spring ( Before – After -
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Forcast Stock of SBC
All values in millions Revised forecast date 02.02.2011
SBC INVENTORY ANALYSIS
Feb Mar Apr May1Forecast Sales 2.86 3.10 3.25 2.59 Slow Moving 0.44 0.55 0.48 0.56
Moving 2.42 2.55 2.77 2.03
2ORDER / TANSIST 1.9 0.56 0.2
3Total Stock ( Chakan +CGN)
13.55 12.59 10.05 7.00
Slow Moving 5.68 5.24 4.69 4.21
Moving 7.87 7.35 5.36 2.78
4Closing Stock 12.59 10.05 7.00 4.40 Slow Moving 5.24 4.69 4.21 3.65
Moving 7.35 5.36 2.78 0.75
Actions For Inventory Reduction
Weekly Order strategy -Implemented
Slowing inventory to be sold other required Mubea locations- Under
progressClear DSI implementation
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Investigation DSI Target ´s for VS
DSI total (sales base 4.Q11)= 33 DSI DSI transit = 6 DSI DSI inhouse = 27 DSI
Actual DSI: 34
Lead time in total; wire ordering to shipping FG VS to EU: 114 days (5,7 month)
Detailed steps of suplier- chain
days DSI related
Average time order and processing VS-W 50 NO
Suncall/Japan 80%; Suzuki-Garphytan/China 20%
Transit /Shipping Japan/China – India 20 NO
Customs/Clearance & Transit Mumbai pune 9 YES
Stock raw material Chakan 20 YES
Production 5 YES
Stock FG Chakan (incl. monthly Container fill up) 10 YES
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Investigation DSI Target ´s for SBC
DSI total (sales base 4.Q11)= 60 DSI transit = 27 DSI inhouse = 33
Actual DSI : 74 days
Lead time in total; order uncoated SBC to domestic indian customer (north): 94 days
Detailed steps of supplier chain days DSI related
Average time order and processing SBC uncoated 26 NO
MUB-Taican60%; MUB Attendorn 40%
Average Transit /Shipping from China/Germany - India 24 YES
Customs/Clearance 5 YES
Transit Mumbai-Pune 2 YES
Stock raw material Chakan 20 YES
Production 2 YES
Stock FG Chakan (35% Volumes) 10 YES
Transit FG Dehli (65% Volumes) 5 YES
Stock FG Delhi (65% Volumes) 10 (target) YES
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Project Plan Stab Bar
06/22/11 18SS/Operations
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Layout for Stab Bar project
(project plan see extra chart )
Stab bar production• end heating (Oven LPG)• end punching (Press)• bending ( Pulzer )• correction (Correction Work Station)• process flow from backside to front