Integrating TPM & TQM - نگهداري و تعميرات بهره ور فراگير ... · PDF...
Transcript of Integrating TPM & TQM - نگهداري و تعميرات بهره ور فراگير ... · PDF...
Brakes India, Foundry Integration of TPM & TQM Page 1
Integration of TPM & TQM
through the X - Matrix
Brakes India, Foundry Integration of TPM & TQM Page 2
BRAKES INDIA LIMITEDA Joint Venture of TVS And TRW
TVS – GROUP
SALES: US$ 3.9 BILLION27,000 PEOPLE28 COMPANIES45 LOCATIONS
TRW – AUTOMOTIVE
SALES: US$ 16 BILLION80,000 PEOPLE25 COUNTRIES200 LOCATIONS
Brakes India, Foundry Integration of TPM & TQM Page 3
TVS Group – Portfolio
Auto ComponentsAuto Components Air SuspensionAxlesBrakesCastingsElectricalsFastenersFriction materialsRubber ProductsRadiator CapsTyresTurbo ChargersWheels
2 Wheeler Manufacture2 Wheeler Manufacture
Vehicle Sales & ServiceVehicle Sales & Service
Parts DistributionParts Distribution
Finance & InsuranceFinance & Insurance
Brakes India, Foundry Integration of TPM & TQM Page 4
Brakes India Limited
Foundry Division
Brakes India Ltd
Sister ConcernsBrake Division
Sholinghur Oman
Brakes India, Foundry Integration of TPM & TQM Page 5
Brakes India Foundry – Sholinghur Plant - Profile
Year of establishment 1981
Location Sholinghur, 120 Kilometer from Chennai
Number of employees 727
Total area 76 Acres
Built up area 28,000 Sq. Mts.
Sales turnover
Production volume
Exports share of turnover
Rs 4.95 Billion (US $ 124 Million)
76,843 MT
55%
Industries catered to
- Automotive
- Refrigeration & Air conditioning
87%
13%
Brakes India, Foundry Integration of TPM & TQM Page 6
TPM Journey
1998 Declaration by the Top Management
1999 Introductory Session by Mr. Kazuo Kawashima JIPM
2000 TPM Kick Off – 4th October 2000
2003 Award for TPM Excellence– First Category
Brakes India, Foundry Integration of TPM & TQM Page 7
TQM Journey
1998 Declaration by the Top Management
From 1999
BIF chose to learn TQM through cluster approach with
Quality Guru Prof. Y Tsuda spearheading the learning.
2003 Deming Application Prize
Brakes India, Foundry Integration of TPM & TQM Page 8
From Manufacturing Excellence to Business Excellence
Manufacturing Excellence
Business Excellence
Difficult to respond
conventionally
Paradigm Shift
2004
2010
Management Innovation is requiredBusiness Development should drive TPM & TQM efforts
Brakes India, Foundry Integration of TPM & TQM Page 9
The way forward
Value Chain
Premium Innovation-orientedFoundries
Cost-oriented Foundries
Full Service
supplier
ContractManufacturers/
Job shops
BIF need to m
ove in
this directio
n
Cus
tom
er
Volume
Engineering CleaningMelting Moduleassembly
PartsassemblyCasting Machining
Brakes India, Foundry Integration of TPM & TQM Page 10
The way forward
BIF should attempt to be 3 years ahead of competition
Brakes India, Foundry Integration of TPM & TQM Page 11
Business plan (every year – rolling for next five years)
Yearly objective selection process
Yearly objective (X - Matrix)
Identify company guidelines for the year
Deploy the objectives to the pillars
Identify the action plan
Review performance against set objectives for achievement
Analyse the gaps and identify countermeasures
Policy Deployment
Implement the actions
Identify the gaps
X – Matrix for CFT
No
Yes
Plan
Do
Check
Act
Brakes India, Foundry Integration of TPM & TQM Page 12
The way forward
To be 3 years ahead of competition,
Linking of objectives
Vision LTO ResultsMTO
Brakes India, Foundry Integration of TPM & TQM Page 13
To be 3 years ahead of competition
Vision LTO ResultsMTO
We shall achieve customer satisfaction by providing products and services of high quality at globally competitive prices. We shall be a leading player in our chosen area of operations in the light engineering industry.
We shall improve the quality of life of our employees and fulfil their reasonable aspirations. By creating an atmosphere of trust and care, we shall work as a cohesive team always encouraging higher standards of performance.
We shall provide an adequate return to our stock holders and facilitate the growth of the organisation.
We recognize our vendors as our partners in progress. We shall give them a fair deal and nurture a healthy relationship.
We shall conduct ourselves as a responsible corporate citizen known for integrity and ethics.
Brakes India, Foundry Integration of TPM & TQM Page 14
To be 3 years ahead of competition
Vision LTO MTO
We shall provide an adequate return to
our stock holders and facilitate the growth of
the organisation.
Establish a reputation so that share holders take
pride in the company and faith in the management
Recognize customer expectations and work towards cost
reduction year over year
Brakes India, Foundry Integration of TPM & TQM Page 15
Key focus areas from the MTO
Energy
Yield
Operation
Research & Development
Marketing
Brakes India, Foundry Integration of TPM & TQM Page 16
The Cycle of Evolution
Perf
orm
ance
Le
vels
Breakthrough
I
II
Time
Time
Perf
orm
ance
Le
vels
Retainment
Perf
orm
ance
Le
vels
Improvement
Time
None can be ignored –With increasing clock speed, this cycle rotates faster & faster!!
Brakes India, Foundry Integration of TPM & TQM Page 17
From Manufacturing Excellence to Business Excellence
Mere improvements will not do, we need breakthrough
Breakthrough
Improvement
Retainment
Breakthrough is the only way to be ahead of competition by three years
Brakes India, Foundry Integration of TPM & TQM Page 18
The way forward
Achieve Breakthrough in the Key Focus Area by
Integrating TPM and TQM through X – Matrix.
Brakes India, Foundry Integration of TPM & TQM Page 19
The X - Matrix
Focus on a shared goal.
Involve all in planning to achieve the goal.
Hold pillar chairman accountable for achieving their part of the plan.
Communicate that goal to all levels.
Brakes India, Foundry Integration of TPM & TQM Page 20
The X - Matrix
Objectives
Act
ion
Pla
n
Guide LinesGuide LinesK
ey F
ocus
Are
a fro
m M
TO
Brakes India, Foundry Integration of TPM & TQM Page 21
Integrating TPM & TQM through X-Matrix
Energy Management
Yield Management
Operation Management R&D Market
KKKK JHJH PMPM QMQM DMDM EMEM
E&TE&T SHESHE
OTPMOTPM
Policy Deployment through X - Matrix
Brakes India, Foundry Integration of TPM & TQM Page 22
Rules for making Guidelines
1. Guidelines should be such that there should be extension in
the way of thinking
2. Guidelines should not be too many. App (5 - 6) are sufficient
Brakes India, Foundry Integration of TPM & TQM Page 23
Rules for making objectives
1. Objectives should be SMART
2. Objectives should be clearly understood by all
3. Objectives should not be bureaucratic
4. Think of your “Added value” as a pillar chairman while selecting
the objectives. The objective should be challenging for the pillar.
5. Objectives an be added upon if new idea come up during the year.
6. Use as many guidelines as possible while selecting your
objectives.
Brakes India, Foundry Integration of TPM & TQM Page 24
Rules for making Action Plans
1. The action plan should be specific & should come from the pillar.
2. Action plan should not be too many.
3. Action plans should be breakthrough action plan & not routine in
nature.
4. Action plans should be selected after formulating the objectives &
not vice versa
5. There should be a target date for each plan.
Brakes India, Foundry Integration of TPM & TQM Page 25
x x x
x x xOTPM E & T
May-08 May-08 May-08
x x
x x x
x x
x x
Ene
rgy
Mon
itorin
g an
d R
epor
ting
Sys
tem
Impa
rting
the
know
ledg
e on
the
ener
gy
cons
erva
tion
tech
niqu
es
Elim
inat
e th
e E
lect
ric d
rive
by in
trodu
cing
th
e G
ravi
ty fe
ed s
yste
m in
the
Flap
Val
ve
Driv
e
Customer loyalty
Create new customer / markets
Business excellence x x x x x x x xIncrease CAGR
New value proposition
Be 3 years ahead of competition x x x x x x x xPM PM KK KK QM DM PM KK
Jun-08 Dec-08 May-08 May-08 Jul-08 As per Plan May-08 Aug-08
Rs. 17 Million
Reduce the melting energy consumption to 525 kWh / Ton of metallics x x x x x x
Rs. 7 Million
Reduce the auxiliary energy consumption to 200 kWh / Ton of metallics x x
Rs. 25 Million
Reduce the energy tariff by increasing the proportion of renewable energy usage
Rs. 6 Million
Reduce the energy tariff by improving the powerfactor
Incr
ease
the
Out
put /
Inpu
t Rat
io in
the
Patte
rn P
late
s
Elim
inat
e th
e co
nvey
or b
y R
e-de
sign
ing
the
layo
ut
"Kar
akur
i" - R
edire
ct th
e SB
C a
ir Ex
haut
fo
r Mou
ld B
low
Off
Incr
ease
the
Den
sity
of C
harg
e m
ater
ial
from
x to
y
Red
uce
the
Ener
gy lo
ss th
roug
h R
adia
tion
in th
e La
dles
Con
duct
a D
esig
n O
f Exp
erim
ents
for
Opt
imis
atio
n of
the
Inpu
t Mat
eria
ls
Mod
ify th
e D
esig
n of
the
Furn
ace
for
ener
gy e
ffici
ency
Red
uce
the
char
ging
cyc
le ti
me
loss
by
mod
ifyin
g th
e C
rane
s
Reduce energy
cost from 22% to
15% of the Turn over
Objectives
Guidelines
Actio
n Po
ints
Com
pany
Obj
ectiv
es
Deriv
ed fr
om M
TO
Integrating TPM & TQM through X-Matrix
Brakes India, Foundry Integration of TPM & TQM Page 26
x x x
x x xOTPM E & T
May-08 May-08 May-08
x x
x x x
x x
x x
Ene
rgy
Mon
itorin
g an
d R
epor
ting
Sys
tem
Impa
rting
the
know
ledg
e on
the
ener
gy
cons
erva
tion
tech
niqu
es
Elim
inat
e th
e E
lect
ric d
rive
by in
trodu
cing
th
e G
ravi
ty fe
ed s
yste
m in
the
Flap
Val
ve
Driv
e
Customer loyalty
Create new customer / markets
Business excellence x x x x x x x xIncrease CAGR
New value proposition
Be 3 years ahead of competition x x x x x x x xPM PM KK KK QM DM PM KK
Jun-08 Dec-08 May-08 May-08 Jul-08 As per Plan May-08 Aug-08
Rs. 17 Million
Reduce the melting energy consumption to 525 kWh / Ton of metallics x x x x x x
Rs. 7 Million
Reduce the auxiliary energy consumption to 200 kWh / Ton of metallics x x
Rs. 25 Million
Reduce the energy tariff by increasing the proportion of renewable energy usage
Rs. 6 Million
Reduce the energy tariff by improving the powerfactor
Incr
ease
the
Out
put /
Inpu
t Rat
io in
the
Patte
rn P
late
s
Elim
inat
e th
e co
nvey
or b
y R
e-de
sign
ing
the
layo
ut
"Kar
akur
i" - R
edire
ct th
e SB
C a
ir Ex
haut
fo
r Mou
ld B
low
Off
Incr
ease
the
Den
sity
of C
harg
e m
ater
ial
from
x to
y
Red
uce
the
Ener
gy lo
ss th
roug
h R
adia
tion
in th
e La
dles
Con
duct
a D
esig
n O
f Exp
erim
ents
for
Opt
imis
atio
n of
the
Inpu
t Mat
eria
ls
Mod
ify th
e D
esig
n of
the
Furn
ace
for
ener
gy e
ffici
ency
Red
uce
the
char
ging
cyc
le ti
me
loss
by
mod
ifyin
g th
e C
rane
s
Reduce energy
cost from 22% to
15% of the Turn over
Objectives
Guidelines
Actio
n Po
ints
Com
pany
Obj
ectiv
es
Deriv
ed fr
om M
TO
PMModify the Design of the
Furnace for Energy Efficiency
Increase the Density of the Charge by modifying the equipment design.
PM Pillar on Energy Management
Brakes India, Foundry Integration of TPM & TQM Page 27
x x x
x x xOTPM E & T
May-08 May-08 May-08
x x
x x x
x x
x x
Ene
rgy
Mon
itorin
g an
d R
epor
ting
Sys
tem
Impa
rting
the
know
ledg
e on
the
ener
gy
cons
erva
tion
tech
niqu
es
Elim
inat
e th
e E
lect
ric d
rive
by in
trodu
cing
th
e G
ravi
ty fe
ed s
yste
m in
the
Flap
Val
ve
Driv
e
Customer loyalty
Create new customer / markets
Business excellence x x x x x x x xIncrease CAGR
New value proposition
Be 3 years ahead of competition x x x x x x x xPM PM KK KK QM DM PM KK
Jun-08 Dec-08 May-08 May-08 Jul-08 As per Plan May-08 Aug-08
Rs. 17 Million
Reduce the melting energy consumption to 525 kWh / Ton of metallics x x x x x x
Rs. 7 Million
Reduce the auxiliary energy consumption to 200 kWh / Ton of metallics x x
Rs. 25 Million
Reduce the energy tariff by increasing the proportion of renewable energy usage
Rs. 6 Million
Reduce the energy tariff by improving the powerfactor
Incr
ease
the
Out
put /
Inpu
t Rat
io in
the
Patte
rn P
late
s
Elim
inat
e th
e co
nvey
or b
y R
e-de
sign
ing
the
layo
ut
"Kar
akur
i" - R
edire
ct th
e SB
C a
ir Ex
haut
fo
r Mou
ld B
low
Off
Incr
ease
the
Den
sity
of C
harg
e m
ater
ial
from
x to
y
Red
uce
the
Ener
gy lo
ss th
roug
h R
adia
tion
in th
e La
dles
Con
duct
a D
esig
n O
f Exp
erim
ents
for
Opt
imis
atio
n of
the
Inpu
t Mat
eria
ls
Mod
ify th
e D
esig
n of
the
Furn
ace
for
ener
gy e
ffici
ency
Red
uce
the
char
ging
cyc
le ti
me
loss
by
mod
ifyin
g th
e C
rane
s
Reduce energy
cost from 22% to
15% of the Turn over
Objectives
Guidelines
Actio
n Po
ints
Com
pany
Obj
ectiv
es
Deriv
ed fr
om M
TO
KK
Reduce the charging cycle time loss by
modifying the crane.
Reduce the operating temperature by 50 Deg C
by reducing the temperature loss.
KK Pillar on Energy Management
Brakes India, Foundry Integration of TPM & TQM Page 28
125mm430
130
400
950Ø120
2 3 41
40oC reduction in Operating temperature results in energy saving of 20kwh/Ton
Combined effect of kaizens for reducing Temperature losses
15001495
14851480
1460
1450
1470
1490
1510
Before 1 2 3 4
Kaizen
Ope
ratin
g Te
mp
in D
eg C
Other major benefit:40oC reduction in treatment temperature reduces the expensive Fe-Si-Mg alloy consumption. This results in 30% reduction in the cost of alloy addition.
Brakes India, Foundry Integration of TPM & TQM Page 29
x x x
x x xOTPM E & T
May-08 May-08 May-08
x x
x x x
x x
x x
Ene
rgy
Mon
itorin
g an
d R
epor
ting
Sys
tem
Impa
rting
the
know
ledg
e on
the
ener
gy
cons
erva
tion
tech
niqu
es
Elim
inat
e th
e E
lect
ric d
rive
by in
trodu
cing
th
e G
ravi
ty fe
ed s
yste
m in
the
Flap
Val
ve
Driv
e
Customer loyalty
Create new customer / markets
Business excellence x x x x x x x xIncrease CAGR
New value proposition
Be 3 years ahead of competition x x x x x x x xPM PM KK KK QM DM PM KK
Jun-08 Dec-08 May-08 May-08 Jul-08 As per Plan May-08 Aug-08
Rs. 17 Million
Reduce the melting energy consumption to 525 kWh / Ton of metallics x x x x x x
Rs. 7 Million
Reduce the auxiliary energy consumption to 200 kWh / Ton of metallics x x
Rs. 25 Million
Reduce the energy tariff by increasing the proportion of renewable energy usage
Rs. 6 Million
Reduce the energy tariff by improving the powerfactor
Incr
ease
the
Out
put /
Inpu
t Rat
io in
the
Patte
rn P
late
s
Elim
inat
e th
e co
nvey
or b
y R
e-de
sign
ing
the
layo
ut
"Kar
akur
i" - R
edire
ct th
e SB
C a
ir Ex
haut
fo
r Mou
ld B
low
Off
Incr
ease
the
Den
sity
of C
harg
e m
ater
ial
from
x to
y
Red
uce
the
Ener
gy lo
ss th
roug
h R
adia
tion
in th
e La
dles
Con
duct
a D
esig
n O
f Exp
erim
ents
for
Opt
imis
atio
n of
the
Inpu
t Mat
eria
ls
Mod
ify th
e D
esig
n of
the
Furn
ace
for
ener
gy e
ffici
ency
Red
uce
the
char
ging
cyc
le ti
me
loss
by
mod
ifyin
g th
e C
rane
s
Reduce energy
cost from 22% to
15% of the Turn over
Objectives
Guidelines
Actio
n Po
ints
Com
pany
Obj
ectiv
es
Deriv
ed fr
om M
TO
QMConduct a Design of
Experiments for Optimisation of the process parameters
QM Pillar on Energy Management
Brakes India, Foundry Integration of TPM & TQM Page 30
x x x
x x xOTPM E & T
May-08 May-08 May-08
x x
x x x
x x
x x
Ene
rgy
Mon
itorin
g an
d R
epor
ting
Sys
tem
Impa
rting
the
know
ledg
e on
the
ener
gy
cons
erva
tion
tech
niqu
es
Elim
inat
e th
e E
lect
ric d
rive
by in
trodu
cing
th
e G
ravi
ty fe
ed s
yste
m in
the
Flap
Val
ve
Driv
e
Customer loyalty
Create new customer / markets
Business excellence x x x x x x x xIncrease CAGR
New value proposition
Be 3 years ahead of competition x x x x x x x xPM PM KK KK QM DM PM KK
Jun-08 Dec-08 May-08 May-08 Jul-08 As per Plan May-08 Aug-08
Rs. 17 Million
Reduce the melting energy consumption to 525 kWh / Ton of metallics x x x x x x
Rs. 7 Million
Reduce the auxiliary energy consumption to 200 kWh / Ton of metallics x x
Rs. 25 Million
Reduce the energy tariff by increasing the proportion of renewable energy usage
Rs. 6 Million
Reduce the energy tariff by improving the powerfactor
Incr
ease
the
Out
put /
Inpu
t Rat
io in
the
Patte
rn P
late
s
Elim
inat
e th
e co
nvey
or b
y R
e-de
sign
ing
the
layo
ut
"Kar
akur
i" - R
edire
ct th
e SB
C a
ir Ex
haut
fo
r Mou
ld B
low
Off
Incr
ease
the
Den
sity
of C
harg
e m
ater
ial
from
x to
y
Red
uce
the
Ener
gy lo
ss th
roug
h R
adia
tion
in th
e La
dles
Con
duct
a D
esig
n O
f Exp
erim
ents
for
Opt
imis
atio
n of
the
Inpu
t Mat
eria
ls
Mod
ify th
e D
esig
n of
the
Furn
ace
for
ener
gy e
ffici
ency
Red
uce
the
char
ging
cyc
le ti
me
loss
by
mod
ifyin
g th
e C
rane
s
Reduce energy
cost from 22% to
15% of the Turn over
Objectives
Guidelines
Actio
n Po
ints
Com
pany
Obj
ectiv
es
Deriv
ed fr
om M
TO
DMIncrease the Output / Input ratio (Yield) in the Pattern Plates
DM Pillar on Energy Management
Brakes India, Foundry Integration of TPM & TQM Page 31
x x x
x x xOTPM E & T
May-08 May-08 May-08
x x
x x x
x x
x x
Ene
rgy
Mon
itorin
g an
d R
epor
ting
Sys
tem
Impa
rting
the
know
ledg
e on
the
ener
gy
cons
erva
tion
tech
niqu
es
Elim
inat
e th
e E
lect
ric d
rive
by in
trodu
cing
th
e G
ravi
ty fe
ed s
yste
m in
the
Flap
Val
ve
Driv
e
Customer loyalty
Create new customer / markets
Business excellence x x x x x x x xIncrease CAGR
New value proposition
Be 3 years ahead of competition x x x x x x x xPM PM KK KK QM DM PM KK
Jun-08 Dec-08 May-08 May-08 Jul-08 As per Plan May-08 Aug-08
Rs. 17 Million
Reduce the melting energy consumption to 525 kWh / Ton of metallics x x x x x x
Rs. 7 Million
Reduce the auxiliary energy consumption to 200 kWh / Ton of metallics x x
Rs. 25 Million
Reduce the energy tariff by increasing the proportion of renewable energy usage
Rs. 6 Million
Reduce the energy tariff by improving the powerfactor
Incr
ease
the
Out
put /
Inpu
t Rat
io in
the
Patte
rn P
late
s
Elim
inat
e th
e co
nvey
or b
y R
e-de
sign
ing
the
layo
ut
"Kar
akur
i" - R
edire
ct th
e SB
C a
ir Ex
haut
fo
r Mou
ld B
low
Off
Incr
ease
the
Den
sity
of C
harg
e m
ater
ial
from
x to
y
Red
uce
the
Ener
gy lo
ss th
roug
h R
adia
tion
in th
e La
dles
Con
duct
a D
esig
n O
f Exp
erim
ents
for
Opt
imis
atio
n of
the
Inpu
t Mat
eria
ls
Mod
ify th
e D
esig
n of
the
Furn
ace
for
ener
gy e
ffici
ency
Red
uce
the
char
ging
cyc
le ti
me
loss
by
mod
ifyin
g th
e C
rane
s
Reduce energy
cost from 22% to
15% of the Turn over
Objectives
Guidelines
Actio
n Po
ints
Com
pany
Obj
ectiv
es
Deriv
ed fr
om M
TO
OTPM
Design and Implement an Energy Monitoring & Reporting System
OTPM Pillar on Energy Management
Brakes India, Foundry Integration of TPM & TQM Page 32
OTPM - Monitoring & Reporting systems110 KV
10500 KVA33 KV
9950 KVA33KV
9850 KVA
SAP
Energy Report
Total demand - 30300 KVA
Brakes India, Foundry Integration of TPM & TQM Page 33
x x x
x x xOTPM E & T
May-08 May-08 May-08
x x
x x x
x x
x x
Ene
rgy
Mon
itorin
g an
d R
epor
ting
Sys
tem
Impa
rting
the
know
ledg
e on
the
ener
gy
cons
erva
tion
tech
niqu
es
Elim
inat
e th
e E
lect
ric d
rive
by in
trodu
cing
th
e G
ravi
ty fe
ed s
yste
m in
the
Flap
Val
ve
Driv
e
Customer loyalty
Create new customer / markets
Business excellence x x x x x x x xIncrease CAGR
New value proposition
Be 3 years ahead of competition x x x x x x x xPM PM KK KK QM DM PM KK
Jun-08 Dec-08 May-08 May-08 Jul-08 As per Plan May-08 Aug-08
Rs. 17 Million
Reduce the melting energy consumption to 525 kWh / Ton of metallics x x x x x x
Rs. 7 Million
Reduce the auxiliary energy consumption to 200 kWh / Ton of metallics x x
Rs. 25 Million
Reduce the energy tariff by increasing the proportion of renewable energy usage
Rs. 6 Million
Reduce the energy tariff by improving the powerfactor
Incr
ease
the
Out
put /
Inpu
t Rat
io in
the
Patte
rn P
late
s
Elim
inat
e th
e co
nvey
or b
y R
e-de
sign
ing
the
layo
ut
"Kar
akur
i" - R
edire
ct th
e SB
C a
ir Ex
haut
fo
r Mou
ld B
low
Off
Incr
ease
the
Den
sity
of C
harg
e m
ater
ial
from
x to
y
Red
uce
the
Ener
gy lo
ss th
roug
h R
adia
tion
in th
e La
dles
Con
duct
a D
esig
n O
f Exp
erim
ents
for
Opt
imis
atio
n of
the
Inpu
t Mat
eria
ls
Mod
ify th
e D
esig
n of
the
Furn
ace
for
ener
gy e
ffici
ency
Red
uce
the
char
ging
cyc
le ti
me
loss
by
mod
ifyin
g th
e C
rane
s
Reduce energy
cost from 22% to
15% of the Turn over
Objectives
Guidelines
Actio
n Po
ints
Com
pany
Obj
ectiv
es
Deriv
ed fr
om M
TO
E & T
Imparting the knowledge on the energy conservation techniques
Comprehensive and systematic building of competencies through Competency-based Management
E&T Pillar on Energy Management
Brakes India, Foundry Integration of TPM & TQM Page 34
E&T Pillar on Energy Management
Develop the identified competencies for the identified
individuals
Identify the Competencies required for the project
Competency Required Pillar
Energy Auditing EM
Casting Methoding DM
ERP Programming OTPM
Equipment Design
Manufacturing System Engineering
DOE / Process Optimization Technique QM
PM
KK
Brakes India, Foundry Integration of TPM & TQM Page 35
Overall Results
Brakes India, Foundry Integration of TPM & TQM Page 36
Energy cost as a % of Sales
BETTER
12
15
18
21
24
2002-03
2003-04
2004-05
2005-06
2006-07
2007-08
2008-09
Years
Pere
cnta
ge o
f Sal
es
Actua l Targe t
Brakes India, Foundry Integration of TPM & TQM Page 37
Effects of Integration of TPM & TQM
Emerging “scale & substance” outfit
Strong global foot-prints
Quality embedded in BIF culture
Improved product development process & innovation in technology
Robust process management
Increased awareness & participation of everyone.
Improved morale and pride in work.
Improved quality of work life.
Empowerment and ownership.
Transparency & trust in communication.
Becoming a learning organisation.
Improving customer satisfaction.
Brakes India, Foundry Integration of TPM & TQM Page 38
Journey towards Excellence
“Vision to innovatePassion to perform”
Thank you