Sga Homework
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Homw CounselWork Given Sn ing Number On 1
14-04-09
1 2 3 4 5 6
7
8 9 10
2
28-04-09
11
12
13
14 15 16
17 18 19 20 21 22 23 24 25 26 27 28
3
13-05-09
Nature of Work
Display 8x6 Feet Company Zonal Layout with Names & Photo graphs of the Leaders Affixed. OIP - Operation Improvement Programme In A3 Sheet ZONE Layout / Map - Display Individual Zone Map at the Entrance of the Respective Zones in A4 Sheet. Red Tag - Red Tag Compaign to be Conducted Zone Wise Scrap Moved to Red Tag Area - Scrap Moved In KGS & Space Saved in sq. mtrs. Zone Wise Zone Leaders to train their people for 1 Hr within a Week time Zone Wise 1s, 2S & 3S Check Sheets 1, 2, 3, 4 & 5 x 10 = 50 for 1S, 2S & 3S Total for 150. Prepare Check Sheets for 9 Zones in English\Telugu in A3 Sheet & Display. - Audit to Be Done By Co-Ordinator for each Zone & Make a Report. All Participants to identify No. of MUDA (7x3 = 21) , MURI (1x2 = 2) & MURA (1x2=2) total = 25 wastes in their work area (Bifurcation is not necessary but the total 25 No. of wastages should be identified) Any Idea to Remove 3M (Kaizen) - Optional Ensure atleast Minimum 3 Meetings to be taken for Zone Leaders & 5S Co-Ordinator & 2 Meetings for Co-Ordinator & 5S Co-Ordinator - 5S Co-Ordinator to Train Zone Leaders On Daily Basis. From the 26 Participants of the first class & New comers to give individual 3M wastes elimination opportunities that mail to be documented & presented before next visit.60 Points is the target. 30 Points Individual Opurtunity HR Manager has to present a detailed report on training activity to the shoop floor people as per the format given - Check Point = Mr. V.M. Gunasekaran will ask any one employee in the shoopfloor randomly they have to answer his 5S questions. Please record down time with the following classification. Shift wise data. a) Waiting for Material. b) Waiting for Operator. c) Machine Break Down. d) Waiting for Decision / PPC. e) Waiting for Setting. f) General (Power Off) g) Waiting for Material in Previous Station. Note: Any Beyond 3 Minutes to be Booked. Down time Analysis Chart at all the Stages One Audit by 5S Coordinator & Cross Audit by Zone to Zone Leaders. Each Zone to take Photos samples.
1. Zone Leader (Photo) 2. Worst Point (Photo) 3. Empty Box for After photo Audit schedule to be prepared and to be circulated Visual Effect is not there for all the Sections. Visibility Boards (Lengths & Breadth must be same & Maintain standard size) List out Electricity consumption & Energy Saving Parameter (by Maintenance Dept) Bobbins are lying in Gang way. Dust on UPS Batteries. Identification not available for Master PVC storage tins. Machine No. to be display for all the Machines by Plate Hanging. Die Nozzles are not in stored Orderly. Operators Needs Training. Work instructions must be Display The next training program is scheduled on 13.05.2009. By that time Thermo Cables Ltd. shall meet the objectives given as Home work activity by the counselor.
Responsibility
Target Date
VP Operations
27-04-09
Suresh
27-04-09
Zone Leaders
27-04-09
Co-Ordinator
27-04-09
Zone Leaders
27-04-09
Zone Leaders
Continuous
MKB
20-04-09
Participants
27-04-09
Participants 27-04-09 Co-ordinator , 5S Co-ordinator , Zone Continuous leaders 30-04-09
12/5/2009
Sn Reduction of core wastages
1
Waiting for Material
2
Improper Bunched Conductor used in Insulation. Reduction of Scrap due to short length cores.
3 4
elimination of armour over riding.
5
production of excess & short lengths of finished cables.
6
Introduction of GMP`S in production line. 7 8
NC in final product due to improper data 9 entry.
To Avoide the genaration of wastages
10
Avoiding Failures Wastages
11
Reduction of Process Failures
12
Reduction of N.C Products Reduction of core Joints & Conductor Joints. Improper GI wire Joints.
13 14 15
Un even thickness of Insulation, Inner Sheath & Outer Sheath.
16
Drain wire is not meeting the actual requirement of customer.
17
At finish cable stage Insulation resistance 18 is low. Conductor Resistance due to less strand 19 diameter
Wrong movement of inprocess
20
Adherence of inspection procedure at every stage.
21
Mixup of NC Products with good ones
22
Reduce the No. Of accident.
23
Delivery Adhierance to be improved
24
Reduce the cost of manufacture.
25
Work men Absentism Late Coming
26 27
Improving the personnel discipline
28
Increase On the job skill level of operators & staff.
29
Lacke of structured Training for the operator & Staff. (Increase the No. of Training hrs & Subject covers)
30
Reduction of Excess RM consumption
31
Reduction of lead time. Reduce Stockout incidents Reduction in Break down hrs.
32 33 34
Increasing the No. of PM Machines.
35
Optimizing the specific energy.
36
Reducing the Overall power cost.
37
Maintain the power factor as per statitory 38 target. Improving shoopfloor lighting. 39 Improving shoopfloor ventilation.
40
Reduce the wastages of reuseable items 41 such as a) SOL Tracebality of Old Records
42
Production Issues Reduction of core wastages Waiting for Material
Improper Bunched Conductor used in Insulation.
Reduction of Scrap due to short length cores.
elimination of armour over riding.
production of excess & short lengths of finished cables.
Introduction of GMP`S in production line.
NC in final product due to improper data entry.
To Avoide the genaration of wastages
Avoiding Failures Wastages
Project Title To Reduce the core wastages from the present level of 1.34 % to the level of 0.5 % by 01-Aug-09. To Reduce the waiting time in the First Insulation Line due to RM supply from the present level of approximately 37 mins to 10 mins by 01-July-09.
To Reduce the incident of armour over riding in the Armour line from 5 to 0 in a day. To Reduce Rejection due to excess / short length Sheathing Line. Out of the 16 work areas Including Office introduce GMP`S in atleast 8 areas by 16-August-09. To Identify stages in each line where SOP is not displayed & ensure display of SOP company wide by 15-Oct-09. To Reduce the No. Of Incidents of improper data entry from 7 per week to 0 per week and there by reduce the No. of NC in the final product due to this reason from the present level of 3 per month to 0 per month by 01-July-09. To
FROM …. TO … BY
Quality Issues
Safety Issues
Reduction of Process Reduce the No. Of Failures accident. Reduction of N.C Products Reduction of core Joints & Conductor Joints. Improper GI wire Joints. Un even thickness of Insulation, Inner Sheath & Outer Sheath. Drain wire is not meeting the actual requirement of customer. At finish cable stage Insulation resistance is low. Conductor Resistance due to less strand diameter Wrong movement of inprocess Adherence of inspection procedure at every stage. Mixup of NC Products with good ones
Customer Issues Delivery Adhierance to be improved
SGA Leader
SGA Name
Start date
Rushikeshawulu
Core Competence
15.05.2009
Development Issues HR Issues Reduce the cost of manufacture.
Work men Absentism Late Coming Improving the personnel discipline Increase On the job skill level of operators & staff. Lacke of structured Training for the operator & Staff. (Increase the No. of Training hrs & Subject covers)
Design Issues
Finish Date 25.07.2009
TM - 1
TM - 2
Materials Issues
Maintenance Issues
Admin Issues
Reduction of Excess RM consumption
Reduction in Break down hrs.
Tracebality of Old Records
Reduction of lead time.
Increasing the No. of PM Machines.
Reduce Stockout incidents
Optimizing the specific energy. Reducing the Overall power cost.
Maintain the power factor as per statitory target.
Improving shoopfloor lighting.
Improving shoopfloor ventilation. Reduce the wastages of reuseable items such as a) SOL
TM - 3
TM - 4
SMALL GROUP ACTIVITIES S. No.
Project Title
SGA Leader
1
Core Wastage
Rushikeshawulu
2
Non Availability of Conductor - From - hrs - To - hrs
Sampath Rao
3
Conductors Cuts - From - - - - to 25 in a Month
Sampath Rao
4
Copper Saving - From - - - - - to 4 %
5
PVC Savings
Rushikeshawulu
6
Rework - Failures From & To - N.C From & To
Muni Ram & Rushikeshawulu
7
Packing Cost Reduction
8
Workman Absentism
Manoj Agarwal
Pradeep Raghu Ram
Team Members Vidya Sagar, Ramanna, Madhu Babu, Jameelu, Nageshwar Rao & Satyanarayana Samadhan, Naidu, Mukesh & Saradhi. Mukesh, Venu Gopal, Baskar Reddy, Dharam Singh, Sharadha Singh, Parvat Singh & Umesh Mahender, Samadhan, Mukesh, Naidu, Venkateshwar Rao & Dharam Singh. Vidya Sagar, Srinivasulu, Venu Gopal, Mallesh, Appal Naidu, Murali Mohan, Trinath Sahu, Tirupathi & G.V Reddy. Vidya Sagar, Sunil, Srinivasulu, Vittal Rao, Mahmood, J.Pandit, Malla Reddy, Krishna Rao. Saxena, Sarma, Naveen, Naidu & Srinivasulu. Muni Ram, Koteshwar Rao, Srinivas Rao & Parushuram.
Finish Date 1-Aug-09
1-Aug-09
1-Aug-09
1-Aug-09
1-Aug-09
1-Aug-09
1-Aug-09 1-Aug-09
14-04-09
1 2 3 4 5 6
7
8 9 10
2
28-04-09
11
12
13
14 15 16
17 18 19 20 21 22 23 24 25 26 27 28
3
13-05-09
Nature of Work
Display 8x6 Feet Company Zonal Layout with Names & Photo graphs of the Leaders Affixed. OIP - Operation Improvement Programme In A3 Sheet ZONE Layout / Map - Display Individual Zone Map at the Entrance of the Respective Zones in A4 Sheet. Red Tag - Red Tag Compaign to be Conducted Zone Wise Scrap Moved to Red Tag Area - Scrap Moved In KGS & Space Saved in sq. mtrs. Zone Wise Zone Leaders to train their people for 1 Hr within a Week time Zone Wise 1s, 2S & 3S Check Sheets 1, 2, 3, 4 & 5 x 10 = 50 for 1S, 2S & 3S Total for 150. Prepare Check Sheets for 9 Zones in English\Telugu in A3 Sheet & Display. - Audit to Be Done By Co-Ordinator for each Zone & Make a Report. All Participants to identify No. of MUDA (7x3 = 21) , MURI (1x2 = 2) & MURA (1x2=2) total = 25 wastes in their work area (Bifurcation is not necessary but the total 25 No. of wastages should be identified) Any Idea to Remove 3M (Kaizen) - Optional Ensure atleast Minimum 3 Meetings to be taken for Zone Leaders & 5S Co-Ordinator & 2 Meetings for Co-Ordinator & 5S Co-Ordinator - 5S Co-Ordinator to Train Zone Leaders On Daily Basis. From the 26 Participants of the first class & New comers to give individual 3M wastes elimination opportunities that mail to be documented & presented before next visit.60 Points is the target. 30 Points Individual Opurtunity HR Manager has to present a detailed report on training activity to the shoop floor people as per the format given - Check Point = Mr. V.M. Gunasekaran will ask any one employee in the shoopfloor randomly they have to answer his 5S questions. Please record down time with the following classification. Shift wise data. a) Waiting for Material. b) Waiting for Operator. c) Machine Break Down. d) Waiting for Decision / PPC. e) Waiting for Setting. f) General (Power Off) g) Waiting for Material in Previous Station. Note: Any Beyond 3 Minutes to be Booked. Down time Analysis Chart at all the Stages One Audit by 5S Coordinator & Cross Audit by Zone to Zone Leaders. Each Zone to take Photos samples.
1. Zone Leader (Photo) 2. Worst Point (Photo) 3. Empty Box for After photo Audit schedule to be prepared and to be circulated Visual Effect is not there for all the Sections. Visibility Boards (Lengths & Breadth must be same & Maintain standard size) List out Electricity consumption & Energy Saving Parameter (by Maintenance Dept) Bobbins are lying in Gang way. Dust on UPS Batteries. Identification not available for Master PVC storage tins. Machine No. to be display for all the Machines by Plate Hanging. Die Nozzles are not in stored Orderly. Operators Needs Training. Work instructions must be Display The next training program is scheduled on 13.05.2009. By that time Thermo Cables Ltd. shall meet the objectives given as Home work activity by the counselor.
Responsibility
Target Date
VP Operations
27-04-09
Suresh
27-04-09
Zone Leaders
27-04-09
Co-Ordinator
27-04-09
Zone Leaders
27-04-09
Zone Leaders
Continuous
MKB
20-04-09
Participants
27-04-09
Participants 27-04-09 Co-ordinator , 5S Co-ordinator , Zone Continuous leaders 30-04-09
12/5/2009
Sn Reduction of core wastages
1
Waiting for Material
2
Improper Bunched Conductor used in Insulation. Reduction of Scrap due to short length cores.
3 4
elimination of armour over riding.
5
production of excess & short lengths of finished cables.
6
Introduction of GMP`S in production line. 7 8
NC in final product due to improper data 9 entry.
To Avoide the genaration of wastages
10
Avoiding Failures Wastages
11
Reduction of Process Failures
12
Reduction of N.C Products Reduction of core Joints & Conductor Joints. Improper GI wire Joints.
13 14 15
Un even thickness of Insulation, Inner Sheath & Outer Sheath.
16
Drain wire is not meeting the actual requirement of customer.
17
At finish cable stage Insulation resistance 18 is low. Conductor Resistance due to less strand 19 diameter
Wrong movement of inprocess
20
Adherence of inspection procedure at every stage.
21
Mixup of NC Products with good ones
22
Reduce the No. Of accident.
23
Delivery Adhierance to be improved
24
Reduce the cost of manufacture.
25
Work men Absentism Late Coming
26 27
Improving the personnel discipline
28
Increase On the job skill level of operators & staff.
29
Lacke of structured Training for the operator & Staff. (Increase the No. of Training hrs & Subject covers)
30
Reduction of Excess RM consumption
31
Reduction of lead time. Reduce Stockout incidents Reduction in Break down hrs.
32 33 34
Increasing the No. of PM Machines.
35
Optimizing the specific energy.
36
Reducing the Overall power cost.
37
Maintain the power factor as per statitory 38 target. Improving shoopfloor lighting. 39 Improving shoopfloor ventilation.
40
Reduce the wastages of reuseable items 41 such as a) SOL Tracebality of Old Records
42
Production Issues Reduction of core wastages Waiting for Material
Improper Bunched Conductor used in Insulation.
Reduction of Scrap due to short length cores.
elimination of armour over riding.
production of excess & short lengths of finished cables.
Introduction of GMP`S in production line.
NC in final product due to improper data entry.
To Avoide the genaration of wastages
Avoiding Failures Wastages
Project Title To Reduce the core wastages from the present level of 1.34 % to the level of 0.5 % by 01-Aug-09. To Reduce the waiting time in the First Insulation Line due to RM supply from the present level of approximately 37 mins to 10 mins by 01-July-09.
To Reduce the incident of armour over riding in the Armour line from 5 to 0 in a day. To Reduce Rejection due to excess / short length Sheathing Line. Out of the 16 work areas Including Office introduce GMP`S in atleast 8 areas by 16-August-09. To Identify stages in each line where SOP is not displayed & ensure display of SOP company wide by 15-Oct-09. To Reduce the No. Of Incidents of improper data entry from 7 per week to 0 per week and there by reduce the No. of NC in the final product due to this reason from the present level of 3 per month to 0 per month by 01-July-09. To
FROM …. TO … BY
Quality Issues
Safety Issues
Reduction of Process Reduce the No. Of Failures accident. Reduction of N.C Products Reduction of core Joints & Conductor Joints. Improper GI wire Joints. Un even thickness of Insulation, Inner Sheath & Outer Sheath. Drain wire is not meeting the actual requirement of customer. At finish cable stage Insulation resistance is low. Conductor Resistance due to less strand diameter Wrong movement of inprocess Adherence of inspection procedure at every stage. Mixup of NC Products with good ones
Customer Issues Delivery Adhierance to be improved
SGA Leader
SGA Name
Start date
Rushikeshawulu
Core Competence
15.05.2009
Development Issues HR Issues Reduce the cost of manufacture.
Work men Absentism Late Coming Improving the personnel discipline Increase On the job skill level of operators & staff. Lacke of structured Training for the operator & Staff. (Increase the No. of Training hrs & Subject covers)
Design Issues
Finish Date 25.07.2009
TM - 1
TM - 2
Materials Issues
Maintenance Issues
Admin Issues
Reduction of Excess RM consumption
Reduction in Break down hrs.
Tracebality of Old Records
Reduction of lead time.
Increasing the No. of PM Machines.
Reduce Stockout incidents
Optimizing the specific energy. Reducing the Overall power cost.
Maintain the power factor as per statitory target.
Improving shoopfloor lighting.
Improving shoopfloor ventilation. Reduce the wastages of reuseable items such as a) SOL
TM - 3
TM - 4
SMALL GROUP ACTIVITIES S. No.
Project Title
SGA Leader
1
Core Wastage
Rushikeshawulu
2
Non Availability of Conductor - From - hrs - To - hrs
Sampath Rao
3
Conductors Cuts - From - - - - to 25 in a Month
Sampath Rao
4
Copper Saving - From - - - - - to 4 %
5
PVC Savings
Rushikeshawulu
6
Rework - Failures From & To - N.C From & To
Muni Ram & Rushikeshawulu
7
Packing Cost Reduction
8
Workman Absentism
Manoj Agarwal
Pradeep Raghu Ram
Team Members Vidya Sagar, Ramanna, Madhu Babu, Jameelu, Nageshwar Rao & Satyanarayana Samadhan, Naidu, Mukesh & Saradhi. Mukesh, Venu Gopal, Baskar Reddy, Dharam Singh, Sharadha Singh, Parvat Singh & Umesh Mahender, Samadhan, Mukesh, Naidu, Venkateshwar Rao & Dharam Singh. Vidya Sagar, Srinivasulu, Venu Gopal, Mallesh, Appal Naidu, Murali Mohan, Trinath Sahu, Tirupathi & G.V Reddy. Vidya Sagar, Sunil, Srinivasulu, Vittal Rao, Mahmood, J.Pandit, Malla Reddy, Krishna Rao. Saxena, Sarma, Naveen, Naidu & Srinivasulu. Muni Ram, Koteshwar Rao, Srinivas Rao & Parushuram.
Finish Date 1-Aug-09
1-Aug-09
1-Aug-09
1-Aug-09
1-Aug-09
1-Aug-09
1-Aug-09 1-Aug-09
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