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Point of Discussion• Finding• Learning

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Important Findings• Decentralization• Outsourced Transportation• Outsourced Bike Parts Manufacturing ( Ex – ABM and

Omax Bikes Ltd.)• Yong Workers (Mostly Men)• Recreation Zone• Separate Smoking Zone• Safety Concern• Environment Friendly Plant

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Important Learnings• Plant Manger’s Role and Responsibility• Production Management System• Focus and Participation on R&D • Sustainability Approach• Wastes Management

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Important Learnings

• Plant Manger’s Role and Responsibility

• Rejection Rate• Labor Cost Per Hour• Supply Chain Management of Raw and Processed Goods

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Important Learnings.. Contd..Rejection Rate

RR = (Rejectedpieces / ProcessedPieces)x100

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Labor Cost Per Hour (total annual labor costs + taxes + benefits + paid time off) / (total annual hours worked – breaks and training time). This is your direct labor cost per hour.

Important Learning.. Contd..

8

Supply Chain Management

Upstreamsuppliers

Upstreamsuppliers SuppliersSuppliers Your

CompanyYour

CompanyDistribution

channelsDistribution

channels CustomersCustomers

Integrated Supply chain

Information flow sharing

Important Learning.. Contd..

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Production Management System

Important Learning.. Contd..

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Production Management System

5s“A place for everything necessary and everything necessary in its place, clean and ready for use”

Important Learning.. Contd..

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Production Management System

3G“In case of an abnormality, all the concerned members should actually go to the place where the problem has occurred, see the actual thing & take realistic action to solve the problem”

Important Learning.. Contd..

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Production Management System

3k 3K concept is “What has been decided must be followed exactly as per the standard”

These concepts are displayed prominently at work place across the company

Important Learning.. Contd..

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Focus and Participation on R&D

•Open R&D Department•Reward for Best Ideas

Important Learning.. Contd..

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Sustainability Approach

•CO2 emission reduction•Energy Conservation•Water Conservation•Solid Waste Management•Fuel Efficiency

Important Learning.. Contd..

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Motion – inefficient people movementWaiting – people utilizationInventory – stuff laying around (often a symptom of another waste)Defects/Correction – Time spent fixing defects, including defect that get thrown away and the time make the product correctlyUnderutilized People – not dedicated to Value-Added 100%, untapped human creativity

Wastes Management

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• Systematic approach to Productivity and Quality Improvement

• Operators play a significant role in Business Excellence

Conclusion

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Thank You