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CARRIER ENGINEERS PVT. LTD.
Corporate Office :- Plot No. 21, Sector-27A, Faridabad – 121003 Haryana (India)
Phone : 0129 4101673-74
Email : [email protected], Web : www.carrierengineers.com
Presentation On
SUCCESS STORY
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• Established in year : 1995
• No. of Employees : 120
• Products : High Pressure Hydraulic Fittings
& Transmissions Components.
• Production Facilities :
(In-House) Band Saw Cutting
Rough Turning
CNC Turning
VMC Machining
Cylindrical Grinding
Straightening
Induction Hardening
Automation Drilling
Crimping & MPI Testing
JCB India & United Kingdom
CLAAS India, Germany & France
Terex Equipment Pvt. Ltd.
Telco Construction
• Key Customers :
Unit - I
Unit - III
Unit - II
Export – 30%
Transmission – 35%
Agriculture – 30%
Others – 5%
Company Profile
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Problem Identification
62.0%
3.0%
87.5%
10.8% 72%
22 Nos./Year5.1%
52 Hrs./Mc
18%
010
2030
405060
7080
90100
Product
Efficency
Quality (In-
house)
Delivery Absenteeism Awarness Complaints Rework M/c Breakdowm
(Hrs.)
Non Value
Activity
2009
Awareness
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Productivity:- Productivity was low so we have installed more
machines but we were not able to achieve 100% Delivery.
Process Time:- More Process time required due to lack of knowledge of
advance technique & process capability study.
Absenteeism :- Absenteeism was high as our workforce was plagued with
Low Morale.
Awareness :- Low awareness in our employees for better working culture
& continuous improvement.
Rejection/Rework :- Rejection & rework was high as our operators were
lacking proper training.
Breakdown:- Breakdown was high due to improper monitoring.
Wastage :- More wastage due to not aware to control Non Value Activity &
various types wastage i.e. Oil, Air, Water, Coolant, Energy etc.
Before Joining Cluster Program
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One of our Major Customer M/s
JCB India Ltd. Started a Cluster
Program with CII (Confederation of
Indian Industry) and they have
selected us as one of the participant
in that Cluster Program .
Our 1st visit was held on May-
2010 & Our mentor Mr. Amit Sanghvi
(CII) describe the lot of scope for
improvements in our organization.
On that day our mind set has been
change drastically .
Inspiration of Journey
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Activities started during JCB CII Cluster Program &
create Seven Zones with their Zone Leaders
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Distinctive TEI Initiatives
All activities started during JCB CII Cluster Program
CEO Weekly Contact Program for Operators
In-house Training
Suggestion Day Celebration
Kaizen Day Celebration
Best Working Culture Development
Quality Forum Activity
KENT RO Drinking Water
Safety Awareness Activities
Talent Development Program
Reward & Recognition
CEO Monthly Gate Meeting
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Distinctive TEI Initiatives
All activities started during JCB CII Cluster Program
KENT RO Plant
CEO Monthly Address
Gloves used for
Safety
In-House Training
Facility
Self Safety Culture
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Safety Culture Develop
Safety
Instruction
Safety
Goggles &
Apron
Safety
Gloves
Fire
Extinguisher
(210 Accident Free Days From Jan-2012 to till date )
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CEO Gate Meeting Program
Distinctive TEI Initiatives
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CEO Weekly Contact Program for Operators
Distinctive TEI Initiatives
12 Birth Day Celebration of Employee
Distinctive TEI Initiatives
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Distinctive TEI Initiatives
Best Suggestion Award Celebration of Employee
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Distinctive TEI Initiatives
Best Kaizen Award Celebration of Employee
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Initial Cluster Program Organize on 13-04-2011
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Initial Cluster Program Organize on 13-04-2011
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Advance Cluster Program Organize on 25-06-2012
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Advance Cluster Program Organize on 25-06-2012
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Improvement Journey During Cluster Program
ONE Gms. RM Saving Project – : 266 Kaizen Implemented &
Saving per year Rs. 2.23 Lacs.
ONE Sec. Cycle Time Saving Project – : 478 Kaizen Implemented &
Saving per year Rs. 3.65 Lacs.
Reduce Setting Time Project (SMED) – : 321 Kaizen Implemented total
saving per year Rs. 4.28 Lacs.
Cutting & Hydraulic Saving Project – : 28 Kaizen Implement total
annual saving Rs. 0.71 Lacs.
Energy Saving Project – : 51 Kaizen Implemented total
saving per year Rs. 0.63 Lacs.
Loading/Unloading Time Reduce Project – : 249 Kaizen Implemented &
Saving per year Rs. 1.24 Lacs.
Quality Improvement Project – : 342 Kaizen Implement & total
saving Rs. 2.72 Lacs. per year.
WIP Process Time Reduce Project – : 41 Kaizen Implemented and
total saving Rs. 1.56 Lacs. Per
year
Process Time Reduce Project – : 356 Kaizen Implemented &
Saving Rs. 3.6 Lacs. Per Year
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CEPL KAIZEN TREE
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AFTER
Converted into Slot
type forging – Raw
material required 320
Gms/Pc
86 Sec. Processing
time required . Total Benefit Achieved (Raw Material + Cycle Time Reduce) = Rs. 2.32 Lacs Per Year
BEFORE
Use Flat Type forging –
Raw Material required 380
Gms/Pc
140 Sec. processing
time required for Slot
cutting.
380
320
0
50
100
150
Before After
Forging Weight
140
110
0
50
100
150
Before After
Cycle Time ( Sec.)
1 Gms Saving Project – Forging Process Improvement TOTAL KAIZEN IMPLEMENTED – 197 Nos.
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AFTER
Chuck mounted on
Rotary Table converted
into Horizontal Milling
process.
Benefit Achieved Reduce process Time Rs. 3.65 Lacs
BEFORE
Low Productivity & more
Loading / Unloading time
required due to Vertical
Milling Process.
One Second Saving Project - Productivity Improve
Horizontal Deployment
in Three Components
TOTAL KAIZEN IMPLEMENTED – 378 Nos.
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Employees at all levels are effective problem-solvers and are able to utilize Root Causes Analysis and Corrective Action to solve many operational challenges. Such efforts support the continuous improvement process and have become a routine part of everyone's job function.
Problem-Solving Capability
Best Manufacturing Practices
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PERFORMANCE INDICATORS
SUMMARY
S. No. Key Indicator Name UOM Jun-2010 Jun-2012
1 Customer Complaints Nos. 8 1
2 Customer Return PPM 297 67
3 In-Process Rejection PPM 3759 1132
4 Inventory Turnover Ratio (ITR) Ratio 16.9 24.5
5 VAPCO Ratio 3.8 5.7
6 Delivery Schedule Adherence % 93.9 100
7 Machine Breakdown Hours Hrs. 337 87
8 Absenteeism % 11 2
9 Employee Involvement in
Kaizen
% 34 95.3
10 Sales Turnover (Month Wise) In Cr. 0.88 1.61
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Major Achievements During Cluster Program
Best Quality Award From Our Esteemed
Customer JCB on 09-12-2011
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Best Quality Improvement Award From
Our Esteemed Customer JCB on 20-09-2011
Major Achievements During Cluster Program
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Certification of CII Yr. 2011
Major Achievements During Cluster Program
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For sparing your
valuable time
Our Journey towards Improvement Will be Continue.....
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