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Achieved optimum inventory (RM + WIP) of 3.42 Cr. in Q4 with all present product lines ,
which includes KS3/KU3,KS4/KU4,KS6to 9.
Various CFTs are working for cost reduction, material conservation and system
improvements.
This is a proprietary document of Kirloskar Brothers Limited
Initiatives
Unit
Target Target
14-15 15-16
Target Target
16-17 17-18
Reduction in (RM+WIP)
Cr.
4.6
4.2
3.8
Ton
75
100
125
150
Cr.
1.7
1.9
2.1
2.3
Mn
0.25
0.35
0.4
0.45
No.
120
100
90
80
No. of
bundle
250
200
180
160
KW
15
20
25
30
Nos.
90
35
40
45
Study the
consumption
pattern of
component
Monitoring of
KANBAN
through SAP
Responsibility
: Materials
Head
Start Date:
01/04/2014
Review Date :
31/12/2014
9
MCR (Credit 2.1) - Strategies adopted for awareness creation and employee
involvement
Teams working towards Lean & Green Procurement Practices:-1. Score Team Cost Reduction Team
2. Supplier Self Certification Team On line material supplier team (Quality improvement)
3. Vendor Portal team:--Paperless communication
4. KANBAN team:--a) Physical Implementation of KANBAN at Supplier end to reduce
inventory
b) System (SAP) Implementation at Supplier end to reduce paper
5. Inventory reduction team:--Reduce unwanted purchasing and remove non moving
6. Process improvement team:-- Implementation of lean practices to remove Muda from
processes both at in-house and supplier end
7. New product development team:-- To develop cost effective green product
8. SMDS team:--To improve planning through supply chain to minimize wastes
9. Improve packaging:-- To minimize waste through improvement in packaging and recycle
packaging material
10
Training Program
Duratio
n (Hr.)
No of
participant
s
Training
Man-hrs.
2014
23
69
Antoine
2014
18
Uday Apte
2014
32
Amit Chakraborty
2014
40
2014
32
Jeet Trapasiya
2014
32
96
Faculty
Conducted
in year
Sameer Parab
SAP KANBAN
Kaizen Awareness
Keyur Angadiya
2014
24
48
Laxman Aglawe
2013
1.5
91
136.5
2013
16
32
2013
2.5
19
47.5
2013
16
48
BFW Pune
2013
24
24
2013
96
96
Rajesh Pandey
2013
21
42
10
11
12
13
14
Quality Parameters
11
CONVENTIONAL
MODEL
LEAN MODEL
Status
Outsourcing
Cost-based
Strategic
Implemented
Relationship focus
Transaction-focused
Mutually-beneficial
Implemented
Selection length
Lowest price
Implemented
Contract length
Short-term
Long-term
Implemented
Pricing practices
Competitive bids
Target costing
implemented
Price changes
Upward
Downward
Implemented
Quality
Inspection-intensive
Designed-in
Partially
Implemented
Delivery
Large quantities
Smaller quantities
(KANBAN LOT)
Implemented
Inventory buffers
Large
Minimized,
eliminated
Implemented
No Initiation
Initiation started
Under process
Communication
Limited; task-related
Extensive; multi-level
Implemented
Production flexibility
Low
High
Implemented
Technology sharing
Very limited;
nonexistent
Extensive
Implemented
12
Parameter
Cost of quality
Unit
F 12-13
F 1314
% of sale
1.84
7.24
PPM
4760
1679
PPM
16400
7408
% of GRN
First pass
O.K.
99.08%
99.08%
13
14
15
Description
01543130
Total
Previous Present Reduction Reductio
Qty
Cost
Wt.Saved
Wt./ Kg. Wt./Kg. In Wt./Kg.
n%
Procured
Saved/Mn
in Kg.
0.654
0.067
0.587
89.76%
3857
2264.1
0.12
16
Description
Previous
Wt./ Kg.
Present
Wt./Kg.
1.075
0.375
Total
Reduction Reduction
Qty
Wt.Saved
In Wt./Kg.
%
Procured
in Kg.
0.700
65.12%
11478
Cost
Saved/Mn
8034.6
0.44
17
Description
Previous
Wt./ Kg.
Present
Wt./Kg.
0.850
0.320
Total
Reduction Reduction
Qty
Wt.Saved
In Wt./Kg.
%
Procured
in Kg.
0.530
62.35 %
2020
Cost
Saved/Mn
1070.6
0.03
18
Description
Total
Previous Present Reduction Reductio
Qty
Cost
Wt.Save
Wt./ Kg. Wt./Kg. In Wt./Kg.
n%
Procured
Saved/Mn
d in Kg.
1.125
0.924
0.201
17.87%
9576
1.416
1.120
0.296
20.90%
4968
1.248
1.107
0.141
11.30%
9792
1924.77
6
1470.52
8
1380.67
2
Benefits :
Increase Pump efficiency.
Power Consumption reduce
Reduce product weight and transport cost and Co2 emission
This is a proprietary document of Kirloskar Brothers Limited
19
0.43
0.30
0.41
Description
Total
Previous Present Reduction Reductio
Qty
Cost
Wt.Save
Wt./ Kg. Wt./Kg. In Wt./Kg.
n%
Procured
Saved/Mn
d in Kg.
1.352
1.25
0.102
7.54 %
4920
501.84
0.19
2.400
2.193
0.207
8.62 %
315
65.21
0.02
Benefits :
Increase Pump efficiency.
Power Consumption reduce
Reduce product weight and transport cost and Co2
emission
This is a proprietary document of Kirloskar Brothers Limited
20
61009121
Description
Previous
Wt./ Kg.
Present
Wt./Kg.
0.834
0.365
Reduction Reduction
Qty
In Wt./Kg.
%
Procured
0.469
56.24%
1146
Benefits :
Weight of the component reduced by 56.24 %
Increase Pump efficiency.
Power Consumption reduce
Reduce product weight and transport cost and Co2 emission
This is a proprietary document of Kirloskar Brothers Limited
21
Total
Wt.Saved
in Kg.
537.474
Description
Previous
Wt./ Kg.
Present
Wt./Kg.
Reduction In Reduction
Wt./Kg.
%
Qty
Procured
Total
Wt.Saved
in Kg.
13010112S
13010112
4.57
3.95
0.62
13.57%
12544
7777.28
14080241S
7.62
7.4
0.22
2.89%
1414
311.08
14090221S
5.2
4.8
0.4
7.69%
13865
5546
14090512S
6.45
6.35
0.1
1.55%
5982
598.2
22
Project
Objective
Team
JD,MKP, RP
DR,PPJ,CHD
MKP,DR,RC
JD, MKP,RM
DR,RC,MSS
RM,JC,MKP
DR,MKP,CHD
23
FY 2012-13
S. No
Chemicals
FY 2013-14
FY 2014-15
till July
Type
Total
Consumpti
ons
No.Of
Pump
Kg.Per
Pumps
Total
Consumpti
ons
No.Of
Pump
Kg.Per
Pumps
Total
Consumpti
ons
No.Of
Pump
Kg.Per
Pumps
199.12
16820
0.012
388
55376
0.007
131
32357
0.004
Pigment Paste
(Kg)
Liquid
Emulsion Resin
(Kg)
Liquid
Kleenol (Kg)
Liquid
151.5
16820
0.009
182
55376
0.003
73
32357
0.002
Duridine (Kg)
Liquid
185.2
16820
0.011
426
55376
0.008
148.6
32357
0.005
Liquid
15696.5
16820
0.933
16735
55376
0.302
6625
32357
0.205
Flow
Additive( Lit)
Liquid
151.5
16820
0.009
182
55376
0.003
29
32357
0.001
Ph
Stabliser( Lit)
Liquid
185.2
16820
0.011
426
55376
0.008
32357
0.000
6
7
Trend
Better
1253.5
16820
0.075
2107.5
55376
0.038
675
32357
0.021
24
Year
Total packed
Stator and Rotor
receipt
% Recycled
Material
2012-13
20673
10489
50.74%
2013-14
22231
10270
46.20%
2014-15
7910
6052
76.51%
Total
50814
26811
57.82%
25
Slide 25
Afte
r
26
This is a proprietary document of Kirloskar Brothers Limited
26
Descrption
06080990
Total
Reduction Reduction
Purchase qty Wt.Saved in
In Wt./Kg.
%
Kg.
Previous
Wt./ Kg.
Present
Wt./Kg.
2.53
1.752
0.778
30.75%
750
583.50
2.97
2.008
0.962
32.39%
550
529.10
3.47
2.272
1.198
34.52%
1110
1329.78
3.81
2.492
1.318
34.59%
950
1252.10
4.25
4.91
2.405
2.925
1.845
1.985
8.086
43.41%
40.43%
1462
271
5093
2697.39
537.94
6929.81
KS4 640
KS4 760
KS4 855
KS4 940
36.02%
Particulars
Details Of Saving
Material Code
Description
8.086
Purchased Qty
5093
Purchase in Kgs.
6929.81
54
128
27
This is a proprietary document of Kirloskar Brothers Limited
27
Description
Previous
Wt./ Kg.
(2Pc)
Before
useTotal
2 Cap in 1 Twine Packing Tube 1.08
Present
Total
Reduction Reduction
Wt./Kg.
Purchase qty Wt.Saved in
In Wt./Kg.
%
(4 Pc)
Kg.
0.072
0.108
60.00%
750
81
0.072
0.108
60.00%
550
59.4
0.072
0.108
60.00%
1110
119.88
0.072
0.108
60.00%
950
102.6
0.072
0.072
0.432
0.108
60.00%
0.108
60.00%
0.648 After
60.00%
use 4
1462
271
Cap5093
in 1
Sq.
157.896
29.268
550.044
Box
Packing
tube
28
This is a proprietary document of Kirloskar Brothers Limited
28
Before
Changes incorporated :
Change in design to prevent transit damage.
Packing Box size reduced .
Stacking improve
Space utilizations improved
After
Weight reduction 13259 Kgs.
Supplier Box
Finish Product
29
This is a proprietary document of Kirloskar Brothers Limited
29
Description
Previous
Wt./ Kg.
Present
Wt./Kg.
2.53
0.581
Total
Reduction Reduction
Purchase qty Wt.Saved in
In Wt./Kg.
%
Kg.
1.949
77.04%
Particulars
Details Of Saving
Material Code
06089490
Description
1.949
Purchased Qty
6803
Purchase in Kgs.
13259.05
54
246
30
This is a proprietary document of Kirloskar Brothers Limited
6803
13259.05
30
Code
Description
Previous
Wt./ Kg.
(2Pc)
0.00
0.18
100.00%
Purchase
qty
Total
Wt.Saved in
Kg.
6803
1224.54
Plas
tic C
ap E
limi
nat
ed
0.18
Pl
ic
t
as
p
a
C
31
This is a proprietary document of Kirloskar Brothers Limited
ed
t
a
in
lim
31
1. Average cost
Engineering
reduction
66
through
Value
3.
4.
a.
b.
c.
d.
Changes incorporated :
Packing Box size reduced .
Stacking improve
Space utilizations improved
After
Weight reduction 19709.06 Kgs.
Supplier Box
Finish Product
32
This is a proprietary document of Kirloskar Brothers Limited
32
Descrption
CORRUGATED BOX
735x180x102MM
CORRUGATED BOX
06085320
660x180x102MM
CORRUGATED BOX
06085340
810x180x102MM
06085330
Present
Wt./Kg.
1.53
0.59
0.94
61.45%
5387
5066.54
1.53
0.55
0.98
64.06%
422
413.78
1.53
0.62
0.91
59.49%
1065
969.70
4.781
65.51%
6874
19709.06
Total
Reduction Reduction
Purchase qty Wt.Saved in
In Wt./Kg.
%
Kg.
Previous
Wt./ Kg.
Particulars
Details Of Saving
Material Code
Description
4.781
Purchased Qty
12612
Purchase in Kgs.
18739.00
54
347
33
This is a proprietary document of Kirloskar Brothers Limited
33
Before
- 0.00 Kg/Pc
for
After
34
This is a proprietary document of Kirloskar Brothers Limited
34
Description
Previous Wt./
Kg.
Present
Wt./Kg.
Reduction In
Wt./Kg.
Reduction
%
Purchase
qty
Total
Wt.Saved
in Kg.
0.86
0.86
100.00%
12629
10860.94
Particulars
Details Of Saving
Material Code
Description
St_Rt Tube
0.86
Purchased Qty
12629
Purchase in Kgs.
10860.94
54
201
35
This is a proprietary document of Kirloskar Brothers Limited
35
through
Value
- 0.00 Kg/Pc
36
This is a proprietary document of Kirloskar Brothers Limited
36
All of our packaging products are 100% recyclable/reusable - The list of material
used in our packaging products are 100% recyclable/reusable. The details of one of
the product sample is given below.
Sr.
No.
Material Used
Material
Material
Recyclable in % Reusable in %
Corrugated boxes/sheets
100%
100%
MS strip
100%
100%
BOPP tape
100%
100%
Plywood Boxes/sheets
Polypropylene strip
100%
M.S Nail
100%
Polythine 40 micron
100%
Wooden Boxes
100%
100%
37
38
THANK YOU
This is a proprietary document of Kirloskar Brothers Limited
39