PRESENTATION ON

PRODUCT &

QUALITY MANAGEMENT

http://www.nerolac.com/commercial.mpg

THEIR GOAL

INNOVATION

KANSAI NEROLAC PAINTS

DID U KNOW……?• 6 out of 10 Cars• 8 out of 10 Refrigerator• 7 out of 10 Air Conditioners• 8 out of 10 Washing Machines• 6 out of 10 Two Wheelers …..ARE NEROLAC

PAINTED

Origin & Evolution of Nerolac:-

• BEGINNING

• GROWTH 1946, Goodlass Wall (India) Ltd.1957, Goodlass Nerolac Paints Ltd.& thus on 11th of July, 2006 its is KANSAI

NEROLAC PAINTS LTD

•Turn Over

•Second largest coating company in India

•Market leaders in Industrial Segments

HIERARCHY OF THE ORAGANIZATION

Managing Director (MD)

(Mr. Bharukha)

Vice President

General Manager

Senior Manager

Junior manager

Assistant manager

Executives

CATHODIC ELECTRO DEPOSITION COATING

Advantages Of This Concept:

No need to apply any solvent

Set up Acrylic CED line

Protection from both corrosion resistance and weather/ UV resistance

Curtail expenses

Takes less time

Departments: Purchase Quality R & D HR

I.PURCHASE / MATERIAL DEPARTMENT:

Exists within the organization Takes into consideration Raw materials and finished goods.

PURCHASE POLICY: ISO 9000 Compliance to TS 16949 to meet global standards

PURCHASE PROCEDURE:Vendor reliability management80-90 points as per production , calibration , cost, supply etc

VENDOR DEVELOPMENT:Fixed + New suppliersCross functional teamCustomers are TOYOTA, Maruti , Honda etc.

INVENTORY CONTROL:On the basis of criticality, availability, volume and cost

VED, HML, ABCA - Pigments , solventsB – extender (sand), addictives

STORES:Raw materials + finished goods

STORAGE:Tanks and racks

LAYOUT:Follow JIT as many materials require volumeThey follow FIFO management

TANKS RACKS

RAW MATERIAL STORE

MACHINERY

PRODUCTION DEPARTMENT

NEROLAC

PAINT FIFO SYSEM

HIERARCHY OF STORES:  Plant Head  Production Head    Stores Officer & Manager

STOCK VERIFICATION:SAP provides estimates of requirement and Marketing needs. Therefore, Stock is verified on daily basis.

 

II. QUALITY CONTROL DEPARTMENT:Process is standardized

TESTING OF PRODUCTION:Batch processing

ERGONOMICS: Temperature control Ventilation

PRODUCTIVITY:Productivity is measured in Liters or Kgs of paint producedIt’s a ratio of:

Productivity = Volume in liters or kg Man days or Working days

VALUE ENGINEERING:The value of quality must be based on its ability to contribute to profit. Therefore the quality costs are used by management in its pursuit of quality improvements, customer satisfaction, market shares & profit enhancement.Formulation is fixed

CODIFICATION:They have seven digit codes for all there solvents.For e.g. 2000086 – Carbon Black

2000087 – Grade 2 Carbon Black

STANDARISATION:- They Follow ISO: 14000 – Environment Control & SafetyISO: 18000 – Employee safety

CERTIFICATION:First to acquire ISO TS 16949: 2002 by accredited body BVQI ( Bureau Veritas) for Design , Development, Manufacturing of paintsand coating materials.

In category of consumables for Thermax Ltd in 2005 – 2006 for quality, delivery and cost .

Nerolac has two Emvies, or media awards for innovative executions

ENVIRONMENTAL POLICY:Objective is to utilize natural resources in an efficient manner. They Encourage continual and targeted improvements to:

Prevent waste generation at source

Reduce, recover and recycle wastes

Reduce and prevent pollution of air, water and land

For this Nerolac won GREENTECH SAFETY award in 2003 -2004

JOB ROTATION Job rotation is followed in this organization.E.g. from R & D Sales I T

BENEFITS ARE:- Creating a pool of talent in the employee Training time is less Recruitment cost goes down.

VISION FOLLOWS MISSION:-• Every department has to reach the target of

achieving the organizational profit • KRA- Key Result Area of all departments is given

WORKER PARTICIPATION:-

• Worker participate by giving valuable suggestion & idea

KAIZEN

• They follow the KAIZENS concept to increasing production efficiency & cost savings.

• KAIZEN from Chennai Plant wins 8th Kaizen Competition

• The worker gave the idea to reduce the BALL MILL Maintenance Time.

MEASURE IN CASE OF ACCIDENT:-

• Separate department known as EHS i.e. Environment Health & Safety Department.

• Controlled by EHS manager • His aims are:-

– Creating awareness– Safety Norms– Precautions to Handle Fire

QUALITY CIRCLES:-• It is the cross functional team

• i.e. it consists of production officers & also workers.

They follow 5 ‘S’ Principles & they are:-

S – Seiko i.e. Proper ArrangementS – Seiton i.e. Orderliness S – Seiketso i.e. Personal

CleanlinessS – Seiso i.e. Clean upS – Shitsuke i.e. Discipline.

The Late Shri Nandlal Madhavlal DhootFounder, the Videocon Group (26 February 1932 - 26 April 1993) A man of Ideas, A man of Substance,A man of Vision.

Venugopal N DhootChairman

Today, Videocon is household name across the nation- India's No. 1 brand of Consumer Electronics & Home Appliances, trusted by over 50 million people to improve their quality of life.

Corporate Profile

Today the group operates through 4 key sectors they are:-

Consumer Durables

Thomson CPT

CRT Glass

Oil & Gas

Videocon mission: A reflection of continuity & change

Hierarchy:Director

Vice President

General Manager

SR. Manager

Manager

Executive

Officer

Assistant

PURCHASE DEPARTMENT

STORES MANAGEMENT

ORGANIZATIONAL HIERARCHY

S R A T H O DM O -1

(O F F IC E R -1 )

T H A R EM O -1

(O F F IC E R -1 )

S D G A IK W A DE -1

(E N G IN E E R -1 )

B V R A N JN IK A RM E -2

(E X E C U T IV E )

V A C A N T

P C B S T O R E S

S P A T H A KM O -1

(O F F IC E R -1 )

F A S T O R E S

S D V Y A W A H A REM O -1

(O F F IC E R -1 )

M A H E S H M IS A LM O -1

(O F F IC E R -1 )

IN W A R D S T O R E S

R M O H A N T YM S -2

(A S S IS T A N T -2 )

C P T / B U L K Y S T O R E S

K A N T ILA L A G A R W A LM E -2

(E X E C U T IV E )

V A C A N T

L C D S T O R E S

A N IL K U M A R G A RGM M -3

(M A N A G E R )

S S K A S T U REM H -2

(A G M )

S U N IL M E H T A(J t. P R E S ID E N T )

JUST IN TIME(JIT)

SUPPLIER DEVELOPMENT

INVENTORY CONTROL

QUALITY CONTROL DEPARTMENT

•PRODUCTIVITY

STEPS TAKEN TO IMPROVE PRODUCTIVITY:

•KANBAN

•LEAN

•SIGMA

•SMALL QUALITY CIRCLES

R & D DEPARTMENT

Introduction

• Specific Areas In Which R & D Is Carried Out

• Benefits Derived• Future Plans Of Action• Standards Adopted

Specific Areas In Which R & D Is Carried

• Home Theatres-High End Models And HTIB Models.

• Larger Screen Television.• True Flat Televisions.• Plasma Televisions.• Cosmetic Design And New Out Look To The TV’s.• Manufacturing Of Components For CTV,

Refrigerators and Air conditioners.• Efforts to Reduce Power Consumption.

Benefits Derived

• Development Of New Design.• Can Face Competition.• Increase In Productivity.• Reduction In Power Consumption.

Future Plans Of Action

• Manufacturing Of Components.• Multimedia TV.• Plasma Televisions.• Launching Of New Brands.• Better Features, Better Quality & Improved

Reliability.

LATEST TECNOLOGY

Vediocon plasma TV 42”

Standards Adopted

• CE Standard-Capillary Electrophoresis.

• BIS Standard-Bureau Of Indian Standard.

• IEC Standard-International Electro Technical Commision.

HR Department

• Salary/Incentives.• Team Targets.• Job Performance.• Job Safety Design.• Job Evaluation.• Ergonomics.• Quality Circles.

• Salary Incentives:-

Monthly attendance incentives.Quarterly attendance incentives.Half Yearly attendance incentives.Yearly attendance incentives.

• Team Targets:-Diwali Or Festival Gifts.Cash Rewards.

• Job Performance:-Internal Training.Brain Storming session.Workshops.

• Job Rotation:-Motivation Without Monetary Increase.Skill Development.Innovative Ideas.

• Job Safety Design:-Safety is given atmost importance in videcon.

WORKSHOPS

• Job Evaluation:-Productivity.Discipline.Consistency.Dependability.

• Ergonomics:-Individual Cabin.Every dept is provided with a/c’s.Every dept Has Exhaust Fans.Storage Space For Documentation.

Quality Circles:-

Component Falling From PCB.Damage Of Component Due To

Overlapping PCB Running Production line.

•Kaizen Concept:-

Continuous Interaction with down the line.

Production and productivity importance awareness training.

Some Motivation Rewards.

COMPARISON BETWEEN VIDEOCON & NEROLAC PAINTS

VIDEOCON NEROLAC PAINTS

COMPANY IT IS AN ELECTRONIC GOODS MANUFACTURING CO

IT IS A PAINT MANUFACTURING CO

SALARY STRUCTURE

SALARY IS FIXED SALARY IS FIXED AS WELL AS VARIABLE (DEPENDING ON PERFORMANCE)

INCENTIVES INCENTIVES ARE GIVEN IN FORM OF GIFTS

INCENTIVES ARE NOT GIVEN

CONCEPT USED KAIZEN, LEAN & SIGMA

ONLY KAIZEN CONCEPT IS USED

QUALITY CHECK CONTINUOUS CHECKING IS DONE

BATCH CHECKING IS PERFORMED

INNOVATIONS PLASMA TV , LCD TV, SLIM TV

ACRYLIC CATHODIC ELECTRODEPOSITION PAINT

PRODUCTIVITY MEASURED

SETS PRODUCED IN UNITS/ WORKING DAYS

VOLUME IN LITERS OR KG/ MAN DAYS OR WORKING DAYS

SOFTWARE USED CAD, CAM, ROBOTICS ARE THE SOFTWARES USED

SAP IS THE SOFTWARE USED

THANK YOU