Post on 15-Jan-2016
Business Analytics at TVS Motors
Agenda
• Group introduction• Why BI• BI journey at TVS Motors
Group profile
Wabco TVS• Three manufacturing Units
Group profile
5
Products-MotorcycleSold 7 million till March 2010
TVS StaR City
TVS StaR Sport
TVS Flame TVS Apache RTR
TVS JIVE
TVS Wego TVS Scooty Pep+
TVS Scooty Streak
Products-ScooterSold 2.3 million till March 2010
TVS Wego
7
Products – MopedsSold 6.2 million till March 2009
TVS XL SUPER TVS XL SUPER HD
2001
SAP R3
Evolution of IT in TVS Motor
2002
Intranet2003
DMS/CRM
• Upgrade to ECC 6.0 • Business benefit - 6 times of IT establishment cost• Enterprise portal• Web 2.0
• Upgrade to ECC 6.0 • Business benefit - 6 times of IT establishment cost• Enterprise portal• Web 2.0
•SAP BW / HR PAYROLL• SAP in group companies
2004
2005
2006
XI, SOLMAN, Sales on SMS
2007
PLMSAP EP 2008-10
Web 2.0PMSDigitized dashboard
TVS Motors BI Journey
Top 3 Areas – BI Usage
Simplicity is height of Sophistication
No training required for ATM and e-mails
Success of BI deployment
Critical Success Factors
SpeedLook and feelEase of UseInsights
What is Business Intelligence ?
People - Passive information receiver to proactive information seekers andIT from “transaction automation tool” to “IT as a Transformation Platform for Business Innovation and Best in Class Operational Efficiency “
Business Intelligence is an
Analytical tool
Reporting tool
A Decision support tool
A common platform and not restricted to any particular application
Example : SalesExample : Sales
NEED FOR BI
• SAP data – Complex reporting req• Dealership Data from dealers • CRM info • Dashboards for each user.• Avoid person dependent Reporting
Functionalities reqd. in BI
• Reporting• Broadcasting• Analytics• Alerts• Spend Analysis
BI Journey at TVSM
• Implemented BIW 3.0 in 2004
– Sales and Production modules implemented– Solution not user friendly and not used widely
BI Journey at TVSM
• Upgrade to BI.7.0 in 2007– SAP- Sales , Production – Non SAP –DMS(Oracle) and MSSQL data
integration– CRM Data– BeX Reports developed
BI –Journey cont..
• Adoption of Web Application Designer to make reports more user friendly
• BI analytics – Clustering of Customer data to understanding the customer usage pattern.
BI –Journey Cont..
• Implementation of Enterprise Portal
• Personalized dashboard for All Employees– Completed for sales staff
How BI works ??
Data captured, compiled and stored in all the above mentioned various sources are
Analyzed
Integrated
Centrally stored
Provides output in the required format
For Whom BI will be useful ?
For Business Managers and Decision makers (Micro level and Ad-hoc reports)
For Sr. Managers (Macro level reports)
When we need BI ?
“One can’t predict the need – any time for any informed business decision”
Where the BI can be accessed ?
It can be used thro Internet…..
At any time
At any where
At any place
Advantages of BI
Data access at any place
Updated and accurate data
Graphical view of information
Trend analysis with colour codification
Direct export to excel
Reduce dependency on paper reports
Easy for transmission thro mail
Centralized data storage
Understanding Customer
Exchange vehicle analysis – DMS Data
HP Company Analysis – DMS data
Clustering of Customer data
Clustering of Customer data
Sales Performance
Employee Personalized Portal
Vehicle Sales Dashboard•Top 20 dealers•Bottom 20 Dealers•Model - wise sales•Zero Billing dealers
Tracking stock at Dealerships
Opening Stock
Plan
Billing
Retails
Closing stock at dealer
YTD Billing/Retails
Performance and growth dashboard
Month on Month sales dashboards
Planning based on sales trend
Sales and growth indicators
BI in Manufacturing
PRODUCTION BY MODEL REPORT
INVENTORY ANALYSIS REPORT - Month wise
Inventory Not in BOM and No planExcess to the maximum NormWith in Maximum Norm
INVENTORY ANALYSIS REPORT – Week wise
Inventory Not in BOM and No planExcess to the maximum Norm
With in Maximum Norm
47
Business Objectives:- To reduce inventory by Rs.100 crores in 4 months- To improve free cash flow
Business Issues:- Due to recession, conserving cash very important
- Non availability of a dashboard to identify to identify low hanging fruits
Solution- Classification of inventory as follows
a.Qty & Value as per norms - GREEN
b.Qty & value above norms but usable for existing products – GREY
c.Items not required for the current production plan – RED
- Dashboard developed in SAP BI with facility to drill down upto part / buyer
Key Benefits- Inventory reduced by Rs.100 crores- Better inventory maintenance
Inventory dashboard
LINE STOPPAGE REPORT
LINE STOPPAGE REPORT
LINE STOPPAGE REPORT
CUSTOMER COLLECTION REPORT
Customer Collection for the Month of April 2009 for Indonesian Dealers – Hierarchy wise
Business Objectives:
• To leverage IT for live data capturing directly from bottleneck equipment in Manufacturing line
• Capture cell utilization accurately for capacity decisions
• To identify opportunity for output improvement
Actions Implemented•Digital data collected online from bottleneck machine of the cell and integrated with DAQ software
Future Plans
To implement DAQ for Vehicle assembly lines
Data acquisition system for Production monitoring
Background:
•Manual data recording of Manufacturing cells’ output•Delayed availability of production output data for Managers
Benefits
•Low cost in house developed software used for data capturing
•Accurate hour-wise data available for analysis and improvement
•Able to obtain information on machine utilization
•Patent filed for DAQ
Results Achieved
Further Improvement
To provide dash board for Plant managers for real time data monitoring for decision making
84
90 90
84
9088
70
80
90
100
'07-'08
'08-'09
Apr May Jun Jul Aug Sep Oct Nov Dec Jan Feb Mar
First hour output increased to 90%
UOM : %
Business Objectives:• Reduce customer complaint resolution time from 120 days to 30 days
• Reduce defect level by 70%
• Reduce warranty cost by 50%
Actions Implemented
• Implemented alert system thru’ statistical control limit (Monthly PDCA to Daily PDCA)• Implemented real time control system to check for effectiveness of corrective action
• Implemented electronic job card based report to identify nagging complaints
Future Plans
• Implement horizontal deployment of above system in shop floor for all critical parameters
• Digitization of FTA for all solved problems
• Reliability prediction analysis by using warranty data
• Establish MTTF / MTBF by using electronic job card
• Establish transfer function for critical performance parameters
On time correction of customer complaints
complaintsBackground:
• Customer complaint capturing process cycle 60 days
• Customer complaint resolution process cycle 120 days
Benefits
•
Results Achieved
Further Improvement
• Daily PDCA to Hourly PDCA (Real time basis) for customer complaints
Model From To % reductionNo. of part-complaints identified and resolved
XL Super 17.5 4.1 76.6 12
XL Super HD 13.6 3.84 71.8 12
Sport 5.21 1.95 62.6 11
StaR City 8.15 3.41 58.2 13
PEP+ 8.02 4 50.1 10
Streak 5.43 3.8 30.0 3
0.16
0.40 0.42 0.45
0.0
0.1
0.2
0.3
0.4
0.5A
pr-
07
Jun
-07
Au
g-0
7
Oct
-07
Dec
-07
Feb
-08
Ap
r-08
Jun
-08
Au
g-0
8
Def
./100
Veh
.
Production month
3 months in age trend
Earlier – Reaction for Customer complaint
Present – Reaction for Customer complaint
Control limit
TVS-M QAD Jun-10Warranty returns 3 months in age Model : XLSuper Series
UOM : Def./100 Veh
13.61
17.22
16.67
12.34
18.26
9.12
5.92
4.67 4.66
3.34
0
2
4
6
8
10
12
14
16
18
20
Jan-
08
Feb
-08
Mar
-08
Apr
-08
May
-08
Jun-
08
Jul-0
8
Aug
-08
Sep
-08
Oct
-08
Nov
-08
Dec
-08
Jan-
09
Feb
-09
Mar
-09
Apr
-09
May
-09
Jun-
09
Jul-0
9
Aug
-09
Sep
-09
Oct
-09
Nov
-09
Dec
-09
Jan-
10
Feb
-10
Mar
-10
Apr
-10
May
-10
Jun-
10
Def
/100
Veh
.
Production month
3M
Implemented IT support trigger system
TVS-M QAD Jun-10Warranty returns 5000 Kilometers in age Model : 3Wheeler - 2S
UOM : Def./100 Veh
119.15
106.91
97.69
77.51
68.10
83.59
49.10 48.41 47.71 46.64
30.07
22.51 21.21
0
25
50
75
100
125
150D
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08
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Production month
5000 KmsImplemented IT support trigger system
Business Objectives:•Provide project management tool to manage multiple projects & resources and integrate functional & supplier plans
• Provide project management dashboard
Actions Implemented• Implemented SAP project system and cProjects •Project templates provided• Time logging functionality integrated with project system• Tracking Reports developed• Alerts developed• Training provided to all the members of NPD functions
Future Plans
• Portfolio and resource management
•Innovation process management
Project Management
Background:• Every year,
• Around 25 major NPD projects implemented.
• Approximately 700 engineering change projects implemented
• Around 2000 improvement projects carried out
• Around 500 members are involved in NPD projects•Most of the projects are delayed due to improper planning•Changes to the project plan is cumbersome• Project progress tracking is paper based
Benefits
•Dynamic project management leading to better control over the project.
Results Achieved
•Paper based project management eliminated•Versions & change details available for analysis•Tracking of bottleneck activity •Alerts to all project members for any pending activity and activities due for the next 6 weeks
Further Improvement
•Integration of supplier plans with the NPD project plans
•Make the system user friendly
Business Objectives:•Provide part development dashboard of status to all project members •Capture versions of the State Of Builds at various stages of development
Actions Implemented•Dashboard with drill down provided by
• Collating information from various applications
Future Plans
Capture the snap shot version of the State Of Build at various points of time during the prototype builds
State Of Build application
Background:•The NPI process has Alpha, Beta & QP stages. •Prototype vehicles to be built as per planned State Of Build.•Record is useful in analyzing the failure modes during Alpha, Beta and QP. •The State Of Build information is not readily available
Benefits
-Project team takes timely decisions on building prototypes and analysis of the failures.
- Provides visibility of progress status
Results Achieved –
•The State Of Build report made available to all the project team members
•The drill down links provided to know the details
•Improved productivity
Further Improvement –
- Add Quality Status, Ordering status, PPAP status etc.
- Have Versions State Of Builds at various stages of NPD
Business Objectives:•Electronic Workflow to obtain comments and approval
•Should be able to know the progress status of the approval
Actions Implemented –• Workflow provided for DR0 approval in the intranet•Flexibility built in to accommodate 2W, 3W and ASEAN approval•Lead time report for all stages and each product provided•The report captures comments from all the members
Future Plans
•Development of workflows for DR1 to DR5
DR workflow
Background:•Each project starts with a Product Development Initiation approval•There are around 25 major NPDs being initiated on an average. •System for Initiating the product development to cater to the above•The product initiation process is paper based•The comments given in the form of Post-it-stickers often get lost. •Cumbersome process to obtain approval
Benefits
•Facilitate review online / live • Elimination of physical movement of paper from desk to desk • Transparency of comments & feedback to all stakeholders•Timely approval of DR0
Results Achieved –
-The lead time for product initiation approval reduced
- Paper saving
Further Improvement –
•Extend DR0 Approval workflows for exports and institutional sales requirements
•Concept change approval workflows
•Workflows for DR1, DR1A, DR2, DR3, DR4 and DR5 stage gates
Dashboard in Dealership Management
MAP Based Sales InfoAll India Data
MAP driven ReportDealer level sales figures
SALES INFORMATION ON MAPZone wise, state wise and dealer wise sales info on MAP
Billing Details output - Area Level / Segment wise Drill down
Billing Details output - Model wise Drill down
BI- PLATFORMS UNDER EVALUATION
BOCOGNOSMICROSTRATEGY
SAP ACE 2008For Implementing SAP PLM Solutions
SAP ACE 2007For innovative use of SAP Netweaver
Thank You