2010 Performance Summary

Name: : BALAKRISHNAN M Business Unit: WASHER OPERATIONS

Job Title: Sr Executive Performance Period: 01.01.2010 – 30.06..2010

Extraordinary Result
Stretch Deliverable
Results: (What: Operational/Strategic)
Objectives: Results:
1. Experienced & perceived Quality
Wtge : 30%

 CAL Score reduction PLAN 500PPM (Detectable) Actual: 325

Status:
 OP – 500 PPM Stretch – 300 PPM
Testing Line Layout change and Strengthening
 Detectable – 200 the BIQ had helped to reduce the CAL PPM.
 Non detectable - 300 Main line and Testing conveyor speed matched
for maintain the uniform gap
Water level increased in Chandini model to
improve the Detachability.

FPY-Washer
PLAN 1000PPM Actual: 12485 PPM
 OP – 10000 Stretch – 5000 Status
 Assembly : 2500  Assembly : 1015
 Short fitment : 2000  Short fitment : 595

• Single piece flow introduced for Sub assy

 Resolve Top 10 assy related
issues ( cal and FPY )
 OP – 10
• Inspection time added in work content for all
critical issues.
• New conveyor with fixture fixed conveyor
itself to avoid scratches.
• New conveyor provided for cabinet assy to
avoid scratch.
• CFT approach
• Ensure Trained operators in critical work
stations
• Effective communication through Morning
Meeting with All production employee and
SMT
Stretch – 15
• Mistake proof ensured in some of critical
assy.
• Focused flow up with concern people

PLAN 10 Actual: 7
Status

• Lid Spring Not Assy – TT

• Basket Not Tightened –TT
• Agitator Not Tightened –TT
• Program selector Switch con interchanged.
 2010 Performance Summary

• Control Panel scratches- A-72H

• Cabinet dent - TT & WW
• Cabinet scratches – TT & WW
 Resolve two Vendor \ Design
related issues ( cal and FPY ) with • Top plate came off / war page- TT
co ordination of cross functional • Dump valve cap leak-WW
• Dump valve cap Leak – Splash
 OP – 2 Stretch – 4 • Timer Knob Loose- (A-65b )

 IC
PLAN : 2 Actual: 2
 OP – 20 Stretch - 30 Status

• Mechanical pump Assembly difficulty.

• Dump valve cap Leak.

 Built-in Quality – Next level

 OP – All critical station

PLAN 10 Actual: 14
Status

Productivity improvement project successfully

completed and saved 39 Manpower.

 On Line Data capturing system PLAN :APP Actual: APP

for FPY Status

 OP – Q2 Stretch - Q1 As part of Build in quality, Inspection time is

added in work content itself for all critical
stations.
During the Cell deign workshop we coved all
quality related requirement like Integrated
2.Manufacturing Excellence –Lean Control panel Fixture , one piece flow, drum
coupling assy bellow assy New Cabinet conveyor,
Wtge: 20% Loop conveyor, testing line layout change and
 OEE etc.
 Stretch – 88% .

PLAN Q2 Actual:
Status
 Eliminate waste – Washers Due to Integrated logistics the Activities postponed to next
year
OP – 30
 2010 Performance Summary

PLAN 76 Actual: 85
 Scrap Cost per machine Status

OP – 0.50 Stretch – 0.25 • Daily Review with Maintenance, quality and

Planning
• Down Time awareness & monitoring thro’
Trend Charts.
• Performance improved from 86 to 93%
( through Cell Design )
• Effective focus in FPY By Build in quality

PLAN 15 Actual: 18
Status

Good saving from Contract Manpower cost,

consumable cost, over time cost and Scrap
cost.
We are using the both cabinet line parallely to
save Energy cost

 BOM cost saving (cabinet )

OP – 8 L Stretch – 10 L PLAN 0.50 Actual: 0.36

Status

New conveyor provided for Cabinet and Control panel to

 Efficiency against std. time- avoid Scratch and Dent.
Washers
We are reusing the possible rejected Wrapper basket, cabinet
 OP 92 Stretch – >93 by doing RT work with skilled tinker.

• Daily / Weekly / Monthly Review.

• Awareness through Morning Meeting
 Cycle time Improvement - Work • Cabinet Line Program changed to avoid BOC
Content & EOC sheet rejections.
• Monitoring thro’ Area wise updating.
 OP 15% Stretch 20%
• High value items are Rectified, Converted &
Reused after corrn.
• Proper analysis before rejecting the part.
• Visual displays at all assemblies.
• BOM Vs Actual Prodn. Verification ( 3 BOMS/
 CELL DESIGN Month) progress is going on.
Q1 – SA Q2 – FA
PLAN 4L Actual: 5L
Status
 6S BOC and EOC Rejection has reduced by In-house handling
 OP 90 Stretch 95 improvement and Loading and unloading process change.

PLAN: 89% Actual: 93.5%

Status
 Spares Actualizations As per plan we have completed all cell design
 2010 Performance Summary

OP – 100% activity by this we saved 39 Manpower and

Reduced balancing error and NVA

 Production Actualization
OP – 100%
PLAN: 15% Actual: 20%
Status
 Visual management
OP – APP
By the result of cell design we have reduced
NVA and Improving the part presentation. This
is resulted reduce the cycle time.
Configuration increases in 105 to 120 Per Hrs
 Cell concept for All Sub assy. ( WW )
OP – APP .

 No Part Missing in Kitting PLAN APP Actual: APP

OP – APP Status

All Design activities completed as per plan.

This has resulted 30% productivity
3.C2C,OPEX & Cadence of Innovation improvement ,Fatigue reduced and improved
Quality also
 Innovation - Idea Pipeline - Mfg Process /
Method PLAN 90% Actual: 90%
 OP 1 Stretch >2 Status
6S Work shop Going start from second off
( H2 )

PLAN 100% Actual: 100

Status
All in-house related spares fulfilled without any bending

PLAN 100% Actual: 100%

Status

PLAN : APP Actual: APP

Status

4.WPQS & Process Discipline All KPI related and Main Displays corrected and
Wtge: 10% we are going to focus on Line related display
 ISO -9001 - Major NCR by H2
 OP - NIL

 ISO -14001 -Major NCR PLAN : APP Actual: NIL

 OP - NIL Status
Basket line and Tub Line Completed
 SOX -Major NCR
 OP - NIL
PLAN : APP Actual: APP
Status
Missing parts is reduced as compare to earlier.
 2010 Performance Summary

 EHS -Major NCR/Incidents Bar Code introduced for Loose parts pocket to
 OP - NIL avoid parts missing
Weighing scale added in Line. ( 100 % Ensure )

 OLD NCR's closure -ISO-9001,14001,EHS PLAN : 2 Actual: 4

 OP - Q1 Status

Loop conveyor introduced in Testing conveyor

 Design & implement Daily, weekly, Monthly to improve Quality and Productivity. This has
action plans - System in place + Execution helped to reduced RT person fatigue, machine
 OP - Q1 damage, reduce the changeover time.

Integrated fixture Conveyor provided for

5.New Projects Wtge: 5%
control panel assy. This has resulted
productivity, quality and scrap cost.
Integrate logistics
VARI Cuft & Support for CUFT Machine
New conveyor provided for cabinet loading
feedback
station both FA and SA.
VARI Regular production
This has resulted productivity, quality and
Readiness & support for CUFT and Feed back
scrap cost.
Readiness & support for Regular Production.
New modified Fixture develops for Tub reverse
assy. It has resulted to reduce the fatigue and
Cycle time reduction.
6.Cost Management-Washer Wtge : 15 %
We introduced double side scanning system for
motor to avoid additional Manpower and
 CL cost saving reduced NVA and fatigue.

Stretch – 90L Pit provided for shaft fix plate assy by this
change assy error (FPY and CAL) cycle time
and fatigue reduced.
 Consumables

Stretch – 7 L

PLAN NIL Actual: NIL

 OT Control Status

Stretch – 15 L
PLAN NIL Actual: NIL
Status

 Monthly rejection reconciliation & disposal-

report on 3rd of every month.
PLAN NIL Actual: NIL
MRB meeting & proper disposal
Status
7.People Engagement & Development
Wtge: 10%
 Job Rotation PLAN NIL Actual: NIL
 OP - 15% Stretch 15% Status

 Skill development for Casuals

 OP - APP
PLAN : Q1 Actual: Q1
 2010 Performance Summary

Status
 Drive Extra Ordinary performance
 OP - APP

PLAN : Q1 Actual: Q1
Status

PLAN : APP Actual: APP

Status

• Line related feedback given well an advance.

• We involve shop floor employee all new
project to resolve the exciting issue and cycle
time reduction.

PLAN 90 L Actual: 45L

Status

39 Manpower saving has given Good impact in CL cost.

PLAN 7L Actual: 2.7 L

Status

Effective action and planning in all consumable

related item given good result

PLAN : 8.2 L Actual: 3.4 L

Status

• Cabinet Buffer stock production…Thus

reduced overall Production over Time.

PLAN : APP Actual: APP

Status

PLAN : 15% Actual: 25%

Status

PLAN : APP Actual: APP

 2010 Performance Summary

Status

PLAN : APP Actual: APP

Status

Behaviors: (How: Diversity and Inclusion, Integrity, Respect, Teamwork, and Spirit of Winning,)

Note: This section is a reminder to consider “How” an individual has delivered their results achieved when determining
overall rating assessment.
     My Plan: (Developmental objectives)
Objectives: Wtge: 10% Results:
1. Management skills
Demonstrates effective time management, personally and By interaction of cross functional and superiors has help
with other to understand the important of getting positive and
exceeds the target.

2. Communications Presentation skills Training program is helping to improve

Drives communication through the organization my communication approach.

3. Customer champion I can able to understand customer expectation by regular

interaction with field and CAL. It has helping to improve
Aligns key processes against customer expectation the Quality Drive.

Overall Performance Rating (Check only one)

Level 5 Level 4 Level 3 Level 2 Level 1
Unacceptable Results Need Strong Very Strong Extraordinary
Results to be Improved Results Results Results

Employee Signature:       Supervisor Signature:      

Date:       Date:      

2010 Performance Summary