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TQM Strategy for Continual Improvements the SRF Way · PDF file Associate Vice President - TQM 17th Nov 2011 TQM Strategy for Continual Improvements – the SRF Way 3rd Continual Improvement

Aug 22, 2020

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  • S. Ilango

    Associate Vice President - TQM

    17th Nov 2011

    TQM Strategy for Continual

    Improvements – the SRF Way

    3rd Continual Improvement

    and Innovation Symposium

    DQG, Dubai

  • 2

    Backbone of our TQM Journey

    We are what we repeatedly do….

    EXCELLENCE, therefore, is not an act but a HABIT

    - Aristotle

  • 3

    Contents of this Presentation

     About SRF

     The Deming Challenge

    Early Phase: 1991-1999

    Momentum Phase: 2000-2004

     TQM - for Continual Improvements

    TQM Models

    TQM Practices

     Results

  • 4

    About SRF

  • 5

    A multi-business manufacturing entity

    India, Thailand, UAE and South Africa

    5500 globally

    75 countries

    SRF – at a glance

    12 (nine in India)

    800 million USD

  • 6

    Yarn Griege Fabric

    Dipped Fabric EP - Chips

    Refrigerant Gases CMS

    Fishnet Twine Belting Fabric

    Packaging

    Film

    Coated Fabric

    Products SRF Manufactures

    TTB

    CB

    PFB

    EPB

  • 7

    CB PFB EPB TTB

    Diverse applications

    Touching your lives every day

    http://images.google.co.in/imgres?imgurl=http://www.ishopindian.com/shop/images/D/d_2575-01.jpg&imgrefurl=http://www.ishopindian.com/shop/brooke-bond-red-label-tea-pr-22133.html&h=250&w=205&sz=15&hl=en&start=37&um=1&usg=__wd6iO6J3CL-W1IBOmqzfx1BEND8=&tbnid=v3fZLXw1L6c0yM:&tbnh=111&tbnw=91&prev=/images?q=Brooke+bond+tea&start=36&gbv=2&ndsp=18&um=1&hl=en&sa=N http://images.google.co.in/imgres?imgurl=http://upload.wikimedia.org/wikipedia/commons/e/ed/Israeli-type-H-plugs-and-socket.jpg&imgrefurl=http://commons.wikimedia.org/wiki/Image:Israeli-type-H-plugs-and-socket.jpg&h=1920&w=2560&sz=325&hl=en&start=13&usg=__a7Xl-rpRtGf6zTvIPaQtymXVQHc=&tbnid=BlXJtdshoSO04M:&tbnh=113&tbnw=150&prev=/images?q=plugs&gbv=2&hl=en http://images.google.co.in/imgres?imgurl=http://i8.ebayimg.com/07/i/000/b5/23/1abd_1_sbl.JPG&imgrefurl=http://item.express.ebay.com/Other-eBay-Items___15x10-FISH-NET-FISHING-NETS-FLORIDA-CRAB-ROPE-DECOR_W0QQitemZ290158995397QQihZ019QQddnZOtherQ20eBayQ20ItemsQQptdiZ3294QQcmdZExpressItem&h=266&w=400&sz=43&hl=en&start=7&um=1&usg=__EfRwNBtxfvZnDUYi4s2NtQLuLSI=&tbnid=epJvp5FSezX-UM:&tbnh=82&tbnw=124&prev=/images?q=fish+net&um=1&hl=en

  • 8

    Business

    TTB

    CB

    PFB

    EPB

    Port Elizabeth

    Dubai Thailand

    Manali

    Thailand

    Gwalior

    Gummidipoondi

    Trichy

    Pantnagar

    Kashipur

    Indore

    Bhiwadi

    Dahej

    Present in four countries

  • 9

    Meeting requirements of customers in more than 75 countries

    Global Foot Prints for SRF Products

  • 10

    SRF – Proud Winner of Deming Application Prize

  • 11

    The Deming Challenge

  • 12

    Adverse union

    relationship

    Low desire for change

    of Management way

    TQM Way Chosen

    • QC Circles born 1981 and ended

    1987

    • Any way we are making good profit

    Opportunity to become

    World class

    Exposure to Denso

    TQM programme for

    Top Management at JUSE

    Economic reforms

    from 1991

    How TQM was chosen

    • Import of tyrecord fabric

    • Possible closure

    Positive forces Negative forces

    How TQM was chosen as SRF Management Way

  • 13

    JUSE Program – attended by TOP Management

    Decision to adopt TQM

    Creation of TQM Cell

    Design of TQM Frame Work

    Communication from Chairman

    TQM Education

    5S Training and Introduction

    TQM Introduction: Early Phase: 1991-99

  • 14

    Quality First Approach

    People Development and

    Involvement

    Strengthening System

    TQM Introduction: Momentum Phase: 2000-04

    14 Elements of Quality

    Modernization - Technology

    Breakthrough Equipment Design

    5S, Kaizens

    QCC and PSP

    Maintenance Practices

    People Red Book

    Daily Management

    Policy Management

    Management Diagnosis

  • 15

    TQM – The SRF Way , for Continual Improvements

  • 16

    Annual Planning

    Design of TQM Frame Work

    Management Diagnosis

    Improvement Hierarchy

    People Participation Initiatives – Internal

    Continual Improvement Framework

    People Participation Initiatives - External

    ARC- Acknowledgement , Recognition and Celebrations

    Cherokee Wisdom

    Constant Training and Communication

  • Thank You

    He who has a hundred miles to walk should reckon

    ninety as half the journey.

  • 18

    Cultural change

    Awareness

    Leap of

    Faith

    Action

    Attitude

    Transformation Model

    — adapted from Don Wheeler

    Theory-in-use

    Sensei

    Master (Truth sayer)

    Guru

  • 19

    Message from the then Vice-chairman

    19

    It is vital that SRF builds up its strengths and

    becomes a world class company, able to

    compete with the world’s best. TQM is a means

    to that end.

    The road to Total Quality will be a long

    one, spanning many years. In fact, over

    the next nine months, we are simply

    going to prepare ourselves to

    introduce TQM.

    Arun Bharat Ram (Chairman and

    Managing Director)

    1992

    Message from the then Vice-Chairman

  • 20

    Kaizen Training Program

    Control Points Training Program

    Constant Training and Communication

    5S Training Basic TQM Training Program

    AM Training Program PSP Training Program Training

    Action

  • 21

    5S – Coordinator’s training

    APC Training 5S Introduction – Mass Cleaning

    5S – Introduction of Trophies

    Progress of 5S

    View of Stores

    5S Recognitions Factory External View Factory – Internal View

    Arrangement for all items

    Filing System

    Gangway Markings

  • 22

    14 Dimensions of Quality

    Upstream QA

    (Q0)

    Product

    planning

    (Q1)

    Product

    development

    (Q2)

    Preparation for mass production

    (Q3)

    Sign off for

    mass

    production

    Down stream

    QA (before

    supply)

    (Q4)

    Vendor items

    (Q5)

    Intermediate

    product

    (Q6)

    Physical

    properties

    (Q7)

    Roll rating (Q8) Packing

    and logistics

    Down steam

    (after supply)

    (Q9)

    Tyre

    processability

    (Q10)

    Tyre

    Performance

    (Q11)

    Application

    Service

    (Q12)

    Commercial

    service

    (Q13)

    Relationship

  • 23

    Production

    came

    first

    Demonstrating Quality First:

    Investing in Technology & Facilitates

    Yarn

    Before Economic

    Reforms,

    Conventional

    Education

    on

    Quality First

    “We believe in the principles of

    Quality First and Market In…”

    Quality First

    Spin draw

    Weaving Shuttle Shuttle less

    Dipping Multiple , Slow Single, High Speed

    Power Elec Board Captive Power Plant

    Shed Uncontrolled AC Conditioning

    Flooring and

    Roofing Old Epoxy Flooring

    Technology Before Now

  • 24

    285 parts

    converted

    WACKY IDEA

    Cost: 25% of

    new twister

    Twisting Machine

    Convert 2-stage

    twisters uniquely to

    single stage

    • Half the lead time, waste rate, power

    cost, space, maintenance cost.

    • Double the productivity

    Results

    Revolutionary Equipment Design

    Cabling Machine SADC Machine

  • 25

    Problem:

    Blue

    (Workmen)

    Blue

    (Officers &

    Supervisors)

    Silver

    Gold

    Local Business Process Business Unit

    Im p a c t

    o f

    Im p ro

    v e m

    e n t

    Problem Solving Process

  • 26

    Autonomous Maintenance

    • Ownership of Machines People

    • Daily Cleaning, Lubrication,

    Abnormality Tagging and Minor

    Corrections

    • Knowledge on machine parts,

    operation, process and inspection

    Machine

    cleaning and

    Inspection

    Ma