Success story of Carrier Engineers, an SME Cluster Member of CII

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CARRIER ENGINEERS PVT. LTD.

Corporate Office :- Plot No. 21, Sector-27A, Faridabad – 121003 Haryana (India)

Phone : 0129 4101673-74

Email : [email protected], Web : www.carrierengineers.com

Presentation On

SUCCESS STORY

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• Established in year : 1995

• No. of Employees : 120

• Products : High Pressure Hydraulic Fittings

& Transmissions Components.

• Production Facilities :

(In-House) Band Saw Cutting

Rough Turning

CNC Turning

VMC Machining

Cylindrical Grinding

Straightening

Induction Hardening

Automation Drilling

Crimping & MPI Testing

JCB India & United Kingdom

CLAAS India, Germany & France

Terex Equipment Pvt. Ltd.

Telco Construction

• Key Customers :

Unit - I

Unit - III

Unit - II

Export – 30%

Transmission – 35%

Agriculture – 30%

Others – 5%

Company Profile

3

Problem Identification

62.0%

3.0%

87.5%

10.8% 72%

22 Nos./Year5.1%

52 Hrs./Mc

18%

010

2030

405060

7080

90100

Product

Efficency

Quality (In-

house)

Delivery Absenteeism Awarness Complaints Rework M/c Breakdowm

(Hrs.)

Non Value

Activity

2009

Awareness

4

Productivity:- Productivity was low so we have installed more

machines but we were not able to achieve 100% Delivery.

Process Time:- More Process time required due to lack of knowledge of

advance technique & process capability study.

Absenteeism :- Absenteeism was high as our workforce was plagued with

Low Morale.

Awareness :- Low awareness in our employees for better working culture

& continuous improvement.

Rejection/Rework :- Rejection & rework was high as our operators were

lacking proper training.

Breakdown:- Breakdown was high due to improper monitoring.

Wastage :- More wastage due to not aware to control Non Value Activity &

various types wastage i.e. Oil, Air, Water, Coolant, Energy etc.

Before Joining Cluster Program

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One of our Major Customer M/s

JCB India Ltd. Started a Cluster

Program with CII (Confederation of

Indian Industry) and they have

selected us as one of the participant

in that Cluster Program .

Our 1st visit was held on May-

2010 & Our mentor Mr. Amit Sanghvi

(CII) describe the lot of scope for

improvements in our organization.

On that day our mind set has been

change drastically .

Inspiration of Journey

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Activities started during JCB CII Cluster Program &

create Seven Zones with their Zone Leaders

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Distinctive TEI Initiatives

All activities started during JCB CII Cluster Program

CEO Weekly Contact Program for Operators

In-house Training

Suggestion Day Celebration

Kaizen Day Celebration

Best Working Culture Development

Quality Forum Activity

KENT RO Drinking Water

Safety Awareness Activities

Talent Development Program

Reward & Recognition

CEO Monthly Gate Meeting

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All activities started during JCB CII Cluster Program

KENT RO Plant

CEO Monthly Address

Gloves used for

Safety

In-House Training

Facility

Self Safety Culture

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Safety Culture Develop

Safety

Instruction

Safety

Goggles &

Apron

Safety

Gloves

Fire

Extinguisher

(210 Accident Free Days From Jan-2012 to till date )

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CEO Gate Meeting Program


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CEO Weekly Contact Program for Operators


12 Birth Day Celebration of Employee


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Best Suggestion Award Celebration of Employee

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Best Kaizen Award Celebration of Employee

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Initial Cluster Program Organize on 13-04-2011

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Initial Cluster Program Organize on 13-04-2011

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Advance Cluster Program Organize on 25-06-2012

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Advance Cluster Program Organize on 25-06-2012

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Improvement Journey During Cluster Program

ONE Gms. RM Saving Project – : 266 Kaizen Implemented &

Saving per year Rs. 2.23 Lacs.

ONE Sec. Cycle Time Saving Project – : 478 Kaizen Implemented &


Reduce Setting Time Project (SMED) – : 321 Kaizen Implemented total

saving per year Rs. 4.28 Lacs.

Cutting & Hydraulic Saving Project – : 28 Kaizen Implement total

annual saving Rs. 0.71 Lacs.

Energy Saving Project – : 51 Kaizen Implemented total

saving per year Rs. 0.63 Lacs.

Loading/Unloading Time Reduce Project – : 249 Kaizen Implemented &


Quality Improvement Project – : 342 Kaizen Implement & total

saving Rs. 2.72 Lacs. per year.

WIP Process Time Reduce Project – : 41 Kaizen Implemented and

total saving Rs. 1.56 Lacs. Per

year

Process Time Reduce Project – : 356 Kaizen Implemented &

Saving Rs. 3.6 Lacs. Per Year

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CEPL KAIZEN TREE

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AFTER

Converted into Slot

type forging – Raw

material required 320

Gms/Pc

86 Sec. Processing

time required . Total Benefit Achieved (Raw Material + Cycle Time Reduce) = Rs. 2.32 Lacs Per Year

BEFORE

Use Flat Type forging –

Raw Material required 380

Gms/Pc

140 Sec. processing

time required for Slot

cutting.

380

320

0

50

100

150

Before After

Forging Weight

140

110

0

50

100

150

Before After

Cycle Time ( Sec.)

1 Gms Saving Project – Forging Process Improvement TOTAL KAIZEN IMPLEMENTED – 197 Nos.

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AFTER

Chuck mounted on

Rotary Table converted

into Horizontal Milling

process.

Benefit Achieved Reduce process Time Rs. 3.65 Lacs

BEFORE

Low Productivity & more

Loading / Unloading time

required due to Vertical

Milling Process.

One Second Saving Project - Productivity Improve

Horizontal Deployment

in Three Components

TOTAL KAIZEN IMPLEMENTED – 378 Nos.

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Employees at all levels are effective problem-solvers and are able to utilize Root Causes Analysis and Corrective Action to solve many operational challenges. Such efforts support the continuous improvement process and have become a routine part of everyone's job function.

Problem-Solving Capability

Best Manufacturing Practices

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PERFORMANCE INDICATORS

SUMMARY

S. No. Key Indicator Name UOM Jun-2010 Jun-2012

1 Customer Complaints Nos. 8 1

2 Customer Return PPM 297 67

3 In-Process Rejection PPM 3759 1132

4 Inventory Turnover Ratio (ITR) Ratio 16.9 24.5

5 VAPCO Ratio 3.8 5.7

6 Delivery Schedule Adherence % 93.9 100

7 Machine Breakdown Hours Hrs. 337 87

8 Absenteeism % 11 2

9 Employee Involvement in

Kaizen

% 34 95.3

10 Sales Turnover (Month Wise) In Cr. 0.88 1.61

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Major Achievements During Cluster Program

Best Quality Award From Our Esteemed

Customer JCB on 09-12-2011

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Best Quality Improvement Award From

Our Esteemed Customer JCB on 20-09-2011


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Certification of CII Yr. 2011


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For sparing your

valuable time

Our Journey towards Improvement Will be Continue.....

Success story of Carrier Engineers, an SME Cluster Member of CII

Business

year rs

process time rs

year process time

total saving rs

advance cluster program

initial cluster program

hydraulic saving project

total annual saving