Daimler India Commercial Vehicles Pvt. Ltd. Manufacturing Excellence ...
Manufacturing Excellence V.K.Tuli
Daimler India Commercial Vehicles Pvt. Ltd. V K Tuli /26th APRIL 2012
Daimler India Commercial Vehicles Pvt Ltd.
PILLARS OF MANUFACTURING EXCELLENCE
Manufacturing Excellence Best Quality-Lowest Cost-Shortest Lead time – Best Safety- High Morale Jidoka Just-In-Time Highly Motivated People (Built-in-Quality) (Right -- Part, Quantity, Time) TAKT Time Continuous flow Pull System Quick Change over Integrated Logistics
Training Responsibility Accountability Communication Family Involvement
Automatic Stops-Andon Person-Machine Error Proofing Quality control 5 Why’s
Leveled Production Standardized Work Visual Management Kaizen Safety
Good Concepts = Good Products Manufacturing Excellence/V.K.Tuli/April 2012
2
Daimler India Commercial Vehicles Pvt Ltd.
MANUFACTURING EXCELLENCE -STAKEHOLDERS Design
Suppliers
Stakeholders involved to achieve Manufacturing Excellence
Dealer Network
Manufacturing
Manufacturing Excellence/V.K.Tuli/April 2012
3
Daimler India Commercial Vehicles Pvt Ltd.
MANUFACTURING EXCELLENCE DRIVERS IN DICV •TECHNOLOGY •HUMAN
EFFICIENCY
•EQUIPMENT •PROCESS •LABOUR
EFFICEINCY
EFFICIENCY
MANAGEMENT
•SAFETY
Manufacturing Excellence/V.K.Tuli/April 2012
4
Daimler India Commercial Vehicles Pvt Ltd.
TECHNOLOGY
Manufacturing Excellence/V.K.Tuli/April 2012
5
Daimler India Commercial Vehicles Pvt Ltd.
TECHNOLOGY DAIMLER AG: •Technological, Manpower and Knowledge Transfer From Daimler AG to DICV •Design of efficient Process and Products by Daimler AG •Dedicated and Strong R&D team based in Chennai adopting Daimler AG process and Products according to Indian requirements
All these combined together is the DNA of the world class “BHARAT BENZ” Trucks FUSO: •Technological, manpower and Knowledge transfer from FUSO to DICV for LDT manufacturing •Very efficient Manufacturing practice •Implementation of efficient manufacturing practice of FUSO in DICV according to Indian requirements Manufacturing Excellence/V.K.Tuli/April 2012
6
Daimler India Commercial Vehicles Pvt Ltd.
HUMAN EFFICIENCY
Manufacturing Excellence/V.K.Tuli/April 2012
7
Daimler India Commercial Vehicles Pvt Ltd.
TRAINING – Middle Management Training is one of the most important aspects which plays a vital role in the efficiency of employees
DGM’s , AGM’s , Senior Managers and Managers underwent training program at Daimler AG- Germany , Aksaray –Turkey , Fuso- Japan respectively.
Manufacturing Excellence/V.K.Tuli/April 2012
8
Daimler India Commercial Vehicles Pvt Ltd.
TRAINING- First Line Supervisors First Line Supervisors were given Hands on Training in the German, Turkey and Japan Plants respectively.
Manufacturing Excellence/V.K.Tuli/April 2012
9
Daimler India Commercial Vehicles Pvt Ltd.
TRAINING – Shop Floor Associates Every Production shop has an in-house individual Training Island . The Shop Floor Associates are trained by the Middle management and First Line Supervisors. The Associates undergo a very effective Training program . Days 15 Days 10 Days 20 Days
Itenary ---HR Training ---Functional Training (Theory & Practical) ---Individual Department Functional Training in their respective Training Islands Followed by rigorous On the Job Training
Manufacturing Excellence/V.K.Tuli/April 2012
10
Daimler India Commercial Vehicles Pvt Ltd.
EQUIPMENT EFFICIENCY
Manufacturing Excellence/V.K.Tuli/April 2012
11
Daimler India Commercial Vehicles Pvt Ltd.
EQUIPMENT EFFICIENCY To enhance the Equipment Efficiency at DICV- implementation of Total Productive Maintenance (TPM) is in Progress. A 4 Level TPM model has been followed at DICV
Manufacturing Excellence/V.K.Tuli/April 2012
12
Daimler India Commercial Vehicles Pvt Ltd.
Road Map : 4 Level TPM Model (All levels)
Note: A period of approx 6 months is provided between each level to ensure sustainability and to prepare for next Level TPM APPROACH Manufacturing Excellence/V.K.Tuli/April 2012
13
Daimler India Commercial Vehicles Pvt Ltd.
PROCESS EFFICIENCY
Manufacturing Excellence/V.K.Tuli/April 2012
14
Daimler India Commercial Vehicles Pvt Ltd.
PROCESS EFFICIENCY To achieve Manufacturing Excellence it is vital to have a very good process in place. Implementation of Lean Manufacturing is essential to achieve such a process. Living LEAN at Daimler with the 9 Lean Principles
Manufacturing Excellence/V.K.Tuli/April 2012
15
Daimler India Commercial Vehicles Pvt Ltd.
STANDARDIZATION Standardization is defined as the systematic method which ensures that a particular activity or process is achieved using optimum resources
•Standards assures the process quality
•Standards are the basis for improvements
Manufacturing Excellence/V.K.Tuli/April 2012
16
Daimler India Commercial Vehicles Pvt Ltd.
STATION DEVELOPMENT WORKSHOP (SDW) – SDW was conducted for every Production shop prior installation. A 6 Step Procedure was followed to finalize the Station Design. SDW ensures that there is Leveled Production.
Disassembling
2
6
Continuous Improvement 6c
2a 2b
Part by Part
2c
5 Standardization 3a
5a
Station by Station
1e 1a
6b
6a
3
1d 1b
1c
1 Understand Process
4a
SWS* by SWS*
X Classroom
X
Shopfloor
Manufacturing Excellence/V.K.Tuli/April 2012
3b
4b
4c
Station preparation
4 Process 3c Validation 3d 17
Daimler India Commercial Vehicles Pvt Ltd.
SHOP FLOOR MANAGEMENT - (VISUAL MANAGEMENT) A Shop Floor management team board is a shop floor representation and means of communication of any information relevant to the activities of the team. Shop Floor management is important because it helps stabilize the business by managing processes visually. It also increases transparency of goals and goal achievement at all levels by making problems visible by displaying “normal vs. abnormal”
Manufacturing Excellence/V.K.Tuli/April 2012
18
Daimler India Commercial Vehicles Pvt Ltd.
LABOUR MANAGEMENT
Manufacturing Excellence/V.K.Tuli/April 2012
19
Daimler India Commercial Vehicles Pvt Ltd.
LABOUR MANAGEMENT Labour Management is the Biggest challenge for a manufacturing industry in India in the current Scenario. To achieve Manufacturing Excellence it is critical to have a efficient and disciplined Labour unit •In
order to deal with Labour issues , 10+2 fresher’s have been recruited for shop
floor staff and have been trained intensively with a 3 year Training Progrsm •Right
proportion of home state and other state -shop floor employees have been
recruited in order to avoid Labour issues •Very
good Travel and Canteen facilities provided for the employees
Manufacturing Excellence/V.K.Tuli/April 2012
20
Daimler India Commercial Vehicles Pvt Ltd.
SAFETY
Manufacturing Excellence/V.K.Tuli/April 2012
21
Daimler India Commercial Vehicles Pvt Ltd.
SAFETY Safety plays a crucial role in achieving Manufacturing Excellence. DICV SAFETY MANAGEMENT CONCEPT:
MEN
MACHINE
METHOD
1. Induction training. 2. Daily TBT / 3. Job specific training 4. PPE
1. Pre entry check, 2. DICV safety Tag, 3. Daily check 4. Weekly inspection
1. Method Statement, 2. Risk Assessment, 3. Work Permits, 4. Check sheets 5. Daily reporting system
Manufacturing Excellence/V.K.Tuli/April 2012
MANAGEMENT (Implementing Authority) 1. Close work monitoring by Supervisory staff and safety officers, 2. Daily Joint Audit, 3. Weekly Review, 4. Monthly HSE Meetings
22
Daimler India Commercial Vehicles Pvt Ltd.
SAFETY ACHIEVEMENT DICV achieved a milestone of 13 Million Safe Man hours
Manufacturing Excellence/V.K.Tuli/April 2012
23
Daimler India Commercial Vehicles Pvt Ltd.
DICV –ORAGADAM PLANT
Manufacturing Excellence/V.K.Tuli/April 2012
# Image Source: Google Earth
24
Daimler India Commercial Vehicles Pvt Ltd.
THANK YOU
Manufacturing Excellence/V.K.Tuli/April 2012
25
Daimler India Commercial Vehicles Pvt. Ltd. V K Tuli /26th APRIL 2012
Daimler India Commercial Vehicles Pvt Ltd.
PILLARS OF MANUFACTURING EXCELLENCE
Manufacturing Excellence Best Quality-Lowest Cost-Shortest Lead time – Best Safety- High Morale Jidoka Just-In-Time Highly Motivated People (Built-in-Quality) (Right -- Part, Quantity, Time) TAKT Time Continuous flow Pull System Quick Change over Integrated Logistics
Training Responsibility Accountability Communication Family Involvement
Automatic Stops-Andon Person-Machine Error Proofing Quality control 5 Why’s
Leveled Production Standardized Work Visual Management Kaizen Safety
Good Concepts = Good Products Manufacturing Excellence/V.K.Tuli/April 2012
2
Daimler India Commercial Vehicles Pvt Ltd.
MANUFACTURING EXCELLENCE -STAKEHOLDERS Design
Suppliers
Stakeholders involved to achieve Manufacturing Excellence
Dealer Network
Manufacturing
Manufacturing Excellence/V.K.Tuli/April 2012
3
Daimler India Commercial Vehicles Pvt Ltd.
MANUFACTURING EXCELLENCE DRIVERS IN DICV •TECHNOLOGY •HUMAN
EFFICIENCY
•EQUIPMENT •PROCESS •LABOUR
EFFICEINCY
EFFICIENCY
MANAGEMENT
•SAFETY
Manufacturing Excellence/V.K.Tuli/April 2012
4
Daimler India Commercial Vehicles Pvt Ltd.
TECHNOLOGY
Manufacturing Excellence/V.K.Tuli/April 2012
5
Daimler India Commercial Vehicles Pvt Ltd.
TECHNOLOGY DAIMLER AG: •Technological, Manpower and Knowledge Transfer From Daimler AG to DICV •Design of efficient Process and Products by Daimler AG •Dedicated and Strong R&D team based in Chennai adopting Daimler AG process and Products according to Indian requirements
All these combined together is the DNA of the world class “BHARAT BENZ” Trucks FUSO: •Technological, manpower and Knowledge transfer from FUSO to DICV for LDT manufacturing •Very efficient Manufacturing practice •Implementation of efficient manufacturing practice of FUSO in DICV according to Indian requirements Manufacturing Excellence/V.K.Tuli/April 2012
6
Daimler India Commercial Vehicles Pvt Ltd.
HUMAN EFFICIENCY
Manufacturing Excellence/V.K.Tuli/April 2012
7
Daimler India Commercial Vehicles Pvt Ltd.
TRAINING – Middle Management Training is one of the most important aspects which plays a vital role in the efficiency of employees
DGM’s , AGM’s , Senior Managers and Managers underwent training program at Daimler AG- Germany , Aksaray –Turkey , Fuso- Japan respectively.
Manufacturing Excellence/V.K.Tuli/April 2012
8
Daimler India Commercial Vehicles Pvt Ltd.
TRAINING- First Line Supervisors First Line Supervisors were given Hands on Training in the German, Turkey and Japan Plants respectively.
Manufacturing Excellence/V.K.Tuli/April 2012
9
Daimler India Commercial Vehicles Pvt Ltd.
TRAINING – Shop Floor Associates Every Production shop has an in-house individual Training Island . The Shop Floor Associates are trained by the Middle management and First Line Supervisors. The Associates undergo a very effective Training program . Days 15 Days 10 Days 20 Days
Itenary ---HR Training ---Functional Training (Theory & Practical) ---Individual Department Functional Training in their respective Training Islands Followed by rigorous On the Job Training
Manufacturing Excellence/V.K.Tuli/April 2012
10
Daimler India Commercial Vehicles Pvt Ltd.
EQUIPMENT EFFICIENCY
Manufacturing Excellence/V.K.Tuli/April 2012
11
Daimler India Commercial Vehicles Pvt Ltd.
EQUIPMENT EFFICIENCY To enhance the Equipment Efficiency at DICV- implementation of Total Productive Maintenance (TPM) is in Progress. A 4 Level TPM model has been followed at DICV
Manufacturing Excellence/V.K.Tuli/April 2012
12
Daimler India Commercial Vehicles Pvt Ltd.
Road Map : 4 Level TPM Model (All levels)
Note: A period of approx 6 months is provided between each level to ensure sustainability and to prepare for next Level TPM APPROACH Manufacturing Excellence/V.K.Tuli/April 2012
13
Daimler India Commercial Vehicles Pvt Ltd.
PROCESS EFFICIENCY
Manufacturing Excellence/V.K.Tuli/April 2012
14
Daimler India Commercial Vehicles Pvt Ltd.
PROCESS EFFICIENCY To achieve Manufacturing Excellence it is vital to have a very good process in place. Implementation of Lean Manufacturing is essential to achieve such a process. Living LEAN at Daimler with the 9 Lean Principles
Manufacturing Excellence/V.K.Tuli/April 2012
15
Daimler India Commercial Vehicles Pvt Ltd.
STANDARDIZATION Standardization is defined as the systematic method which ensures that a particular activity or process is achieved using optimum resources
•Standards assures the process quality
•Standards are the basis for improvements
Manufacturing Excellence/V.K.Tuli/April 2012
16
Daimler India Commercial Vehicles Pvt Ltd.
STATION DEVELOPMENT WORKSHOP (SDW) – SDW was conducted for every Production shop prior installation. A 6 Step Procedure was followed to finalize the Station Design. SDW ensures that there is Leveled Production.
Disassembling
2
6
Continuous Improvement 6c
2a 2b
Part by Part
2c
5 Standardization 3a
5a
Station by Station
1e 1a
6b
6a
3
1d 1b
1c
1 Understand Process
4a
SWS* by SWS*
X Classroom
X
Shopfloor
Manufacturing Excellence/V.K.Tuli/April 2012
3b
4b
4c
Station preparation
4 Process 3c Validation 3d 17
Daimler India Commercial Vehicles Pvt Ltd.
SHOP FLOOR MANAGEMENT - (VISUAL MANAGEMENT) A Shop Floor management team board is a shop floor representation and means of communication of any information relevant to the activities of the team. Shop Floor management is important because it helps stabilize the business by managing processes visually. It also increases transparency of goals and goal achievement at all levels by making problems visible by displaying “normal vs. abnormal”
Manufacturing Excellence/V.K.Tuli/April 2012
18
Daimler India Commercial Vehicles Pvt Ltd.
LABOUR MANAGEMENT
Manufacturing Excellence/V.K.Tuli/April 2012
19
Daimler India Commercial Vehicles Pvt Ltd.
LABOUR MANAGEMENT Labour Management is the Biggest challenge for a manufacturing industry in India in the current Scenario. To achieve Manufacturing Excellence it is critical to have a efficient and disciplined Labour unit •In
order to deal with Labour issues , 10+2 fresher’s have been recruited for shop
floor staff and have been trained intensively with a 3 year Training Progrsm •Right
proportion of home state and other state -shop floor employees have been
recruited in order to avoid Labour issues •Very
good Travel and Canteen facilities provided for the employees
Manufacturing Excellence/V.K.Tuli/April 2012
20
Daimler India Commercial Vehicles Pvt Ltd.
SAFETY
Manufacturing Excellence/V.K.Tuli/April 2012
21
Daimler India Commercial Vehicles Pvt Ltd.
SAFETY Safety plays a crucial role in achieving Manufacturing Excellence. DICV SAFETY MANAGEMENT CONCEPT:
MEN
MACHINE
METHOD
1. Induction training. 2. Daily TBT / 3. Job specific training 4. PPE
1. Pre entry check, 2. DICV safety Tag, 3. Daily check 4. Weekly inspection
1. Method Statement, 2. Risk Assessment, 3. Work Permits, 4. Check sheets 5. Daily reporting system
Manufacturing Excellence/V.K.Tuli/April 2012
MANAGEMENT (Implementing Authority) 1. Close work monitoring by Supervisory staff and safety officers, 2. Daily Joint Audit, 3. Weekly Review, 4. Monthly HSE Meetings
22
Daimler India Commercial Vehicles Pvt Ltd.
SAFETY ACHIEVEMENT DICV achieved a milestone of 13 Million Safe Man hours
Manufacturing Excellence/V.K.Tuli/April 2012
23
Daimler India Commercial Vehicles Pvt Ltd.
DICV –ORAGADAM PLANT
Manufacturing Excellence/V.K.Tuli/April 2012
# Image Source: Google Earth
24
Daimler India Commercial Vehicles Pvt Ltd.
THANK YOU
Manufacturing Excellence/V.K.Tuli/April 2012
25
