Mc Meeting 110609

11-Jun-2009

Milestone Plan of Major Activities for 08~2009 Dept

No.

Activity

Jul 08

Aug 08

Sep 08 Preparation & evaluation of OTS harnesses

PRODUCTION

Production of new Land 1 Rover model 2

Production of 242 L Corolla model

Dec 08

Jan 09

Feb 09

Mar 09

Plant Lay out Study

SVP

Finalize

Equipment Quotation

Training of 50 JTM at Karachi plant

Equipment& Tooling arrival/ Shifting of 3 & 4m conveyors

Preparation & evaluation of frame & Engine harnesses 3rd trial of OTS at KHI Plant

Production of new 2PS city 7 model at SUNDAR PLANT

Ordering

M/c Arrival

Installation

SUPPLY CHAIN R&D

10

Shifting of Honda to Sundar Plant

11

Introduction of Plastic Boxes for IMC (Coure)

12

Annual Stock Taking in Store

13

Identification and disposal of Dead stock

Jun 09

Remarks

Implementation

New Layout plan deffered till August-09.

City 2PS Raw material shifting

Preparation of Pilot lot LT1=10units

Sunder plant start up freezed till next review on August 09 with HACPL consensus.

Final Assy & inspection at Sundar Plant

Preparation of Pilot lot R1=20units

SVP

On going activity as per plan

8 Cycle Count in Store Introduction of Lot by Lot parts supply

May 09

PO received.Partail deliveries started.

Advance Shifting of Raw Cutting,Crimping Advance Production Production at material/machin & Sub Assy at Khi plant (To built Khi plant (To ery & activity at Sundar buffer stock) built buffer stock) equipments Plant

Shifting of Civic ( 2YH ) model to SUNDAR PLANT

9

Apr 09

Mass production started as per OEM monthly supply plan.

Hiring of 50 JTM/ 5 Sundar Plant Activity plan Networking & SAP installation SUNDAR PLANT

Nov 08

HVPT/SVP

Implementation of Lean 4 manufacturing/ Quality Level Up

6

Oct 08

Study

Trial

System Modification

Finalize

HACPL started.

Start

System Development

Study

Phase #1= Cuore Model Only

Trial

Finish

Put on hold

Finalize

Put on hold

Approved by the mangement

Wiring Harness 14 development for Honda 2PS(City) Wiring Harness 15 development for Honda 2ZH (Civic)

Ordering of Raw material

LT1 Ordering for OTS and SVP

Quotation

Wiring Harness 16 development for Corolla Econo Models

Drawing updating ECI issuance

Wiring Harness 17 development for Hino P382W/AKIJ/FM2P

OTS preparation

Evaluation

SVP Preparation of OTS

SVP

Smooth SVP is started as per HACPL schedule. First lot supply date 17th April-09. SVP in progress JC connector replacement in IP harness awaiting ECI.

SVP

SVP

9 harnesses in supply. Order for rest awaited.

New Business Status with Hino Pak. S No.

Part Name

Part No.

C/L

Pages

Assy No.

P-382W

P-382W H.P

Remarks

1

Wire,Frame,No.3

82169-37100

C

1

A-339

1

1

Common with P211W

2

Wire,Engine Room No.4

82114-37030

B

1

A-343

1

1

Common with P211W

3

Wire,FR Door,RH

82151-37550

A

1

A-496

1

1

Hino Pak is using Thal made harness

4

Wire,FR Door,LH

82152-37600

A

1

A-497

1

1

Hino Pak is using Thal made harness

5

Wire,Frame,No.2

82165-37390

B

1

A-498

1

1

Hino Pak is using Thal made harness

6

Wire,Earth

82284-37121

0

1

A-499

1

1

Hino Pak is using Thal made harness

7

WIRE, ENGINE, NO.2

82122-37D30

A

1

A-500

1

8

WIRE, ENGINE, NO.3

82123-37170

0

1

A-501

1

1

9

WIRE, COWL

82135-37J72

0

9

A-502

1

1

10

WIRE, ROOF

82171-37870

0

1

A-503

1

1

Hino Pak is using Thal made harness

11

WIRE, FLOOR

82161-37750

0

1

A-504

1

1

Hino Pak is using Thal made harness

12

WIRE, ENGINE ROOM MAIN

82111-3VW92

G

7

A-508

1

13

WIRE, FRAME

82164-37N00

A

1

A-506

1

14

WIRE, ENGINE ROOM MAIN

82111-3VX01

G

7

15

WIRE, ENGINE, NO.2

82122-37D40

A

1

Under price Negociation (Material price is more then target price) Hino will switch to Thal made harness from July 2009

Thal will quote on 24th of April,2009 1

Hino will switch to Thal made harness from July 2009

A-

1

Thal will quote on 24th of April,2009

A-

1

Hino will switch to Thal made harness from July 2009

Hino pak is using Thal made harnesses Under Negociation

Hino Pak is using Thal made harness

Quotation not approved by customer

PRODUCTION HIGHLIGHTS • 100% on time deliveries have been achieved with zero line stoppage complaints at OEM side. 2. THAL won the annual 2008-2009 suppliability award of IMC. 3. First OTS of Landi Renzo sample has been passed by LR Italy. 4. HACPL ranked THAL “WORST” in quality in May ’09.

MHPP & MAN POWER CHART Target = 108

155

156

157

160

160

160

159

158

157

155

147

180

YTD

MSPP Jan~May '09

149

Monthly

200

MSPP Oct '08~Dec '08 154

151

148

144

140

124

Nov

126

Oct

125

Sep

133

Aug

149

Jul

146

164

60

170

150

80

164

100

177

120

Feb

Mar

Apr

May

40 20 0 May

Jun

Dec '08 Jan '09

Approved Strength

Existing Strength

Shortage

MSPP Target

MSPP Actual

42

33

9

9

10

Crimping

100

78

22

23

28

Sub Assembly

100

81

19

22

23

Final Assembly

200

166

34

54

63

Total

442

358

84

108

124

Department Cutting

Honda Instrument Panel

MSPP

80 60

48

40

100 80

54

MSPP

100

HARNESS WISE MSPP 43

40 20 Mar

Apr

65

50

52

Mar

Apr

40

0

May

Honda Floor/Rear

150 107

118

82

80

101

75 50

0

0

MSPP

Mar

100

Target Vs Actual MSPP

80

70

75

Apr

May

60

54

40 20 0 Target MSPP

72

53

71

40 20

Apr

65

60

25 Mar

May

Honda Room Main

100

MSPP

100

MSPP

42

20

0

125

60

Honda Engine

Apr

May

JTM COST / POINT 6

5.45

Rupees/Point

5

4

3.39 2.93

3

2.72

2.97

3.22

3.07 2.48 1.94

2

1.93

1.9

1

0 Jul '08

Aug

Sep

Oct

Nov

Dec '08

Months

Jan '09

Feb

Mar

Apr

May

(Values Rs. ‘000,000)

MONTHLY OVERTIME COST 1.0 0.85

0.9 0.8 0.7

0.9

0.95 0.85

Currently 84 JTM’s not hired against approved vacancies. Monthly Cost down Rs. 0.673 Million

0.7

0.62 0.64

Rs. In Million

0.6 0.5 0.4 0.3 0.2

0.32

0.31 0.19

0.19

0.1 0.0

Jul Aug Sep Oct Nov Dec Jan Feb Mar Apr May '08 '09 Months

0.35

ELECTRICITY COST / POINT 0.31

0.30

Rupees/Point

0.25

0.27 0.21

0.20 0.15

0.17 0.14

0.15 0.10

0.15

0.1

0.1

0.1

0.1

0.05 0.00

Jul Aug Sep Oct Nov Dec Jan Feb Mar Apr May '08 '08 '09 Months

KAIZEN STATUS 70

68

60 51

48

Number of Kaizen

50 40

53

36

47 34

33

30 20 10 0

9

7

5

Jul Aug Sep Oct Nov Dec Jan Feb M ar Apr M ay '08 '08 '09 Months

MACHINE DOWN TIME (Hours) 40

40 35 30

32

31

30

• KOMAX 1 and 2 • Ultra Sonic 1 and 2 • Resistance Welding • Power Press 25 Ton • Joint Press

26

Hours

25 20

15

15 10 5 0

13

6 0

0

3

Jul Aug Sep Oct Nov Dec Jan Feb Mar Apr May '08 '09 Months

MACHINE WISE DOWN TIME DATA 35

32

31 30 25

23

20 15 15 10

13

12 8

8 6

5 0

0

5 0 0 00 0

Jan

1

2

4

3 0 0 0 00 0 0 0 Feb

6

5 0 0 00 0

Mar

5

5

4 0 0 00 0 0 Apr

0

00 0 00 May

25T Press

Komax 01

Komax 02

Ultrasonic 01

Ultrasonic 02

Resistance welding

Joint Press

Twisting M/C

Centre Stripping

LSR REPORT 38,839

40000 35000

32,250

Rupees

30000 25000 19,496

20000

15,130

15000 13,460 7,412

10000

7,618

5,000

5000

1,599 599

4,100

0 Jul

Aug Sep

Oct

Nov Dec '08

Months

Jan '09

Feb Mar

Apr

May

COST SAVING WH PRODUCTION Jul ~ May 2009

9.0

8.0

7.0

7.19

7.44

7.69

7.86

7.89

6.0

Rs. In Million

6 5.0

Expected Cost Saving until June ’09 Rs. 11.5M

4.0 3.4 3.0

2.6

2.0 1.19 1.0 0.25

0.25

0.18

Crimping Press

Clamp

VT Racks

0.03

0.0 Applicator

Dead OMI Tester

Dead Cable & TerminalsUsed

Dead Micro meter

5’S AUDIT CHART 100 98 96 94

93.4

93.4

94.3 93.3 91.9

92

91.7

91.3

90.5

90 88 86 84 82 80 Cutting Crim ping

S/A

Final

Quality

Station

R&D

Disp.

Store

FUTURE CHALLENGES •

To verify the SAP Vs actual WIP stock available at different locations (Like QAD, FAS, Sub assembly, Crimping & cutting) before 30th June-09.

3. Enhance the conveyor productivity & ensure that the B-shift back flushing should complete before start of “A” shift. 5. Implementation of Lean Manufacturing (Review in Jul ’09) 4. Reduce tool setup time Target Cutting = 50% Crimping = 25%

Achieved 40% 18%

5. With IS Support * Bar Code implementation at S/A, F/A, & QA for on-line back flushing by Oct ‘09. * Availability of SAP 24Hrs for on time back flushing by Oct ’09. * All BOM will be locked on the basis of operation & location to control the stock variance by 30th Jun 2009.

ORDERING TREND 250 212.7 202.4

Rs. In Million

200

159.0 157.2

150 113.2 105.7 100

106.0

101.9

89.6

87.0 95.8

92.1

87.9

70.9

80.1

85.4 69.5

50

10.3 0

19.4 10.218.9 0.5 13.6

11.3

27.1

62.9

82.9

61.5

31.2 21.8

84.8

81.4

29.6

5.3

1.6

1.6

1.5

1.8

1.7

1.3

1.4

1.9

May '08

Jun

Jul

Aug

Sep

Oct

Nov

Dec '08

Jan '09

Feb

Mar

Apr

May '09

Jun

Im ported

202.43

101.88

92.08

95.82

18.87

21.836

29.56

85.38

69.49

157.18

87.94

80.116

61.47

82.93

Local

10.27

11.34

13.64

10.2

0.52

5.285

1.6

1.63

1.45

1.77

1.68

1.3

1.4

1.87

Total

212.7

113.22

105.72

106.02

19.39

27.121

31.16

87.01

70.94

158.95

89.62

81.416

62.87

84.8

Imported

Local

Total

GR Vs SALES

250

224.29 225 200

Rs. In Million

173

165.32

175

147

142.06

150

164

112 100

99

100 107

82.29

126.72

112 95

90.91

125.6

94 91.67

75

101

93.16

56

64.87 66.98

50

170

143

130

123 125

146

161

65.81 58.28

46.80

45.01

45.6

25 0

Feb '08

Mar

Apr

May

Jun

Jul

Aug

Sep

Oct

Nov

Dec '08

Jan '09

Feb

Mar

Apr

May

Jun

GR

45.01

64.87

66.98

82.29

90.91

142.06

224.29

165.32

46.80

65.81

91.67

58.28

45.6

93.16

125.59

126.72

101

Sales

106.57

99.97

99.16

112.4

111.66

55.93

94.94

123.22

147.03

129.79

94.22

145.9

143

164.16

172.58

161.43

170

GR

Sales

INVENTORY TREND

(Values Rs. ‘000,000)

MONTH END STOCKS 600 524 500

471 466 422

400

200

Pak Rs.

310 251

365

311

244

376

391

346

317 316

314

335

245 199

203

44.0

33.0

100

0

367 361

418

357 300

408

7.4 Jan '08

7.2

8.0 Feb

Mar

62.0

39.0

Apr May Jun

Jul

Material

47.0 36.0 51.9 52.0 50.0 11.4 5.7 8.2 8.2 11.0 6.0

46.0

0.6 Aug Sep

Oct

WIP

FG

Nov Dec Jan '08 '09 Total

Feb

Avg

Mar

Apr May Jun

PROJECTED INVENTORY 600 524

May Revised

500

Rs. In Million

481 452

444

400

471

408 422

403 367

357

361

377

391 389

300

344

335

319

320

May Closing

200

100

Projection 0 Jul '08

Aug

Sep

Oct

Nov

Dec

Actual

Jan '09

Feb

Proj-May

Mar

Apr

Rev. May

May

Jun

Jul

Aug

Analysis of Slow Moving Items (Values Rs. ‘000,000) upto May. 31, 2009 500

469 433

417

408

399

400

363

Rs. In Million

299

316

338

311

304

Feb

Mar

Apr

May

300 202

208

May '08

Jun

Jul

Aug

Sep

Oct

Nov

180 Days >

37

19

21

26

22

18

27

43

36

35

36

32

34

120 Days >

1

0

8

4

13

24

17

3

4

9

12

6

16

90 Days >

5

7

2

11

18

2

2

3

15

14

4

14

2

60 Days >

3

3

11

18

2

2

3

17

18

7

18

2

5

60 Days <=

156

179

257

358

414

353

384

342

290

246

234

261

281

Total

202

208

299

417

469

399

433

408

363

311

304

316

338

200

100

0

Dec '08 Jan '09

Slow Moving Parts Analysis (For Write-Off) AS OF May-09 November

Write Off.

December Updated

February

March

April

Values in PKR May

Honda City, Civic 0 CIVIC YA7,CIVIC YC6 20,085 Honda Civic Honda LK YC5-CVT 1.5 57,761 2ST CITY, CIVIC 65,362 Honda Civic Honda XH 170,496 OLD HILUX / OLD COROLLA 205,422 Honda Civic (XH) Honda XH 207,318 International Tractor, Adam Motor, Daewoo, Karakoram, Gilgit, Kalash 313,510 CITY, CIVIC 637,906 Alsons 795,154 Land Rover 850,226 Miscellaneous Models 2,336,312 Not in Bom 5,049,221 HILUX 0 HINO 211W 30 HONDA CITY 2ST 0 Suzuki 0

0 0 57,761 65,362 75,115 205,419 207,318 203,583 0 795,154 850,225 1,358,490 4,643,024 113,151 816,715 184,011 95,792

0 0 57,302 69,021 75,115 189,207 207,318 201,390 0 786,364 823,780 1,359,785 4,618,165 113,185 807,993 184,011 80,252

0 0 57,302 69,021 75,115 189,202 207,318 200,628 0 786,364 823,769 1,356,278 4,607,591 79,415 806,432 184,011 80,252

0 0 41,234 69,039 75,017 189,144 207,314 200,598 0 42,638 823,446 1,313,725 4,603,973 79,424 806,316 184,011 80,252

0 0 41,234 69,039 75,017 189,147 207,314 200,535 0 42,638 823,443 1,313,526 4,599,679 79,410 805,565 184,011 80,252

10,708,804

9,671,122

9,572,888

9,522,698

8,716,131

8,710,809

Remarks

Approved in GEC Meeting Held on April 2009

STORE CYCLE COUNT TREND 3704 P KR0

600

500

No. of Items Counted

500

520

1698 PKR 1801 PKR

3,48 3 PKR

490 460

440

5458 PKR

2,20 4 PKR

480

4,10 8 PKR 3,88 3 PKR

560

3,65 7PK R 540

590

2901 PKR

10

510

460

8

420

417

12

3158 PKR

7

400 6 6 5

300 4

4

4

4 4 3

200

3

3

2

3 2 2

100

0

0 May

Jun

Jul

Aug

Sep

Oct

Nov

NO OF ITEMS COUNTED

Dec '08 Jan '09

Feb

NO OF ERRORS

Mar

Apr

May

No. of Errors

700

INVENTORY DAYS – Plan Vs. Actual

300

241

250

231 231

200

181 150

150

127

127 115

98

108

111 110 113

101 104

121

117 95

105

100

92 50

Months

Aug

Jul

Jun

May

Apr

Mar

Feb

Jan '09

Dec '08

Nov

Oct

Sep

Aug

Jul

Jun

May

Apr

Mar

Feb

Jan

0 Dec '07

No. of Days

167

Cost Saving Activities S#

Activity

1

Cost saving through re-negotiated prices of imported parts (Avg 15% price reduction)

2

Cost saving through re-negotiated prices of local cables.

3

Cost saving through recovery from dead / obsolete stock

4 Others

Grand Total

(Values Rs. ‘000,000)

Plan Till June '09

Actual As on June '09

35.20

28.54

9.16

9.00

16.76

4.00

2.54

2.38

63.66

43.92