Production & Quality Management

PRESENTATION ON : 

PRESENTATION ON PRODUCT & QUALITY MANAGEMENT

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THEIR GOAL

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INNOVATION

KANSAI NEROLAC PAINTS : 

KANSAI NEROLAC PAINTS DID U KNOW……? 6 out of 10 Cars 8 out of 10 Refrigerator 7 out of 10 Air Conditioners 8 out of 10 Washing Machines 6 out of 10 Two Wheelers …..ARE NEROLAC PAINTED

Origin & Evolution of Nerolac:- : 

Origin & Evolution of Nerolac:- BEGINNING GROWTH 1946, Goodlass Wall (India) Ltd. 1957, Goodlass Nerolac Paints Ltd. & thus on 11th of July, 2006 its is KANSAI NEROLAC PAINTS LTD

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Turn Over Second largest coating company in India Market leaders in Industrial Segments

HIERARCHY OF THE ORAGANIZATION : 

HIERARCHY OF THE ORAGANIZATION Managing Director (MD) (Mr. Bharukha) Vice President General Manager Senior Manager Junior manager Assistant manager Executives

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CATHODIC ELECTRO DEPOSITION COATING

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Advantages Of This Concept: No need to apply any solvent Set up Acrylic CED line Protection from both corrosion resistance and weather/ UV resistance Curtail expenses Takes less time

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Departments: Purchase Quality R & D HR I.PURCHASE / MATERIAL DEPARTMENT: Exists within the organization Takes into consideration Raw materials and finished goods. PURCHASE POLICY: ISO 9000 Compliance to TS 16949 to meet global standards

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PURCHASE PROCEDURE: Vendor reliability management 80-90 points as per production , calibration , cost, supply etc VENDOR DEVELOPMENT: Fixed + New suppliers Cross functional team Customers are TOYOTA, Maruti , Honda etc. INVENTORY CONTROL: On the basis of criticality, availability, volume and cost VED, HML, ABC A - Pigments , solvents B – extender (sand), addictives

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STORES: Raw materials + finished goods STORAGE: Tanks and racks LAYOUT: Follow JIT as many materials require volume They follow FIFO management

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TANKS RACKS RAW MATERIAL STORE MACHINERY PRODUCTION DEPARTMENT NEROLAC PAINT FIFO SYSEM

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HIERARCHY OF STORES:   Plant Head   Production Head     Stores Officer & Manager STOCK VERIFICATION: SAP provides estimates of requirement and Marketing needs. Therefore, Stock is verified on daily basis.

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II. QUALITY CONTROL DEPARTMENT: Process is standardized TESTING OF PRODUCTION: Batch processing ERGONOMICS: Temperature control Ventilation PRODUCTIVITY: Productivity is measured in Liters or Kgs of paint produced It’s a ratio of: Productivity = Volume in liters or kg Man days or Working days

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VALUE ENGINEERING: The value of quality must be based on its ability to contribute to profit. Therefore the quality costs are used by management in its pursuit of quality improvements, customer satisfaction, market shares & profit enhancement. Formulation is fixed CODIFICATION: They have seven digit codes for all there solvents. For e.g. 2000086 – Carbon Black 2000087 – Grade 2 Carbon Black STANDARISATION:- They Follow ISO: 14000 – Environment Control & Safety ISO: 18000 – Employee safety

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CERTIFICATION: First to acquire ISO TS 16949: 2002 by accredited body BVQI ( Bureau Veritas) for Design , Development, Manufacturing of paints and coating materials. In category of consumables for Thermax Ltd in 2005 – 2006 for quality, delivery and cost .

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Nerolac has two Emvies, or media awards for innovative executions

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ENVIRONMENTAL POLICY: Objective is to utilize natural resources in an efficient manner. They Encourage continual and targeted improvements to: Prevent waste generation at source Reduce, recover and recycle wastes Reduce and prevent pollution of air, water and land For this Nerolac won GREENTECH SAFETY award in 2003 -2004

JOB ROTATION : 

JOB ROTATION Job rotation is followed in this organization. E.g. from R & D Sales I T BENEFITS ARE:- Creating a pool of talent in the employee Training time is less Recruitment cost goes down.

VISION FOLLOWS MISSION:- : 

VISION FOLLOWS MISSION:- Every department has to reach the target of achieving the organizational profit KRA- Key Result Area of all departments is given

WORKER PARTICIPATION:- : 

WORKER PARTICIPATION:- Worker participate by giving valuable suggestion & idea

KAIZEN : 

KAIZEN

Slide 31: 

They follow the KAIZENS concept to increasing production efficiency & cost savings. KAIZEN from Chennai Plant wins 8th Kaizen Competition The worker gave the idea to reduce the BALL MILL Maintenance Time.

MEASURE IN CASE OF ACCIDENT:- : 

MEASURE IN CASE OF ACCIDENT:- Separate department known as EHS i.e. Environment Health & Safety Department. Controlled by EHS manager His aims are:- Creating awareness Safety Norms Precautions to Handle Fire

QUALITY CIRCLES:- : 

QUALITY CIRCLES:- It is the cross functional team i.e. it consists of production officers & also workers.

They follow 5 ‘S’ Principles & they are:- : 

They follow 5 ‘S’ Principles & they are:- S – Seiko i.e. Proper Arrangement S – Seiton i.e. Orderliness S – Seiketso i.e. Personal Cleanliness S – Seiso i.e. Clean up S – Shitsuke i.e. Discipline.

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The Late Shri Nandlal Madhavlal DhootFounder, the Videocon Group (26 February 1932 - 26 April 1993) A man of Ideas, A man of Substance,A man of Vision. Venugopal N DhootChairman

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Today, Videocon is household name across the nation- India's No. 1 brand of Consumer Electronics & Home Appliances, trusted by over 50 million people to improve their quality of life.

Corporate Profile : 

Corporate Profile Today the group operates through 4 key sectors they are:- Consumer Durables

Slide 40: 

Thomson CPT CRT Glass Oil & Gas

Videocon mission: A reflection of continuity & change : 

Videocon mission: A reflection of continuity & change

Hierarchy: : 

Hierarchy: Director Vice President General Manager SR. Manager Manager Executive Officer Assistant

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PURCHASE DEPARTMENT

STORES MANAGEMENT : 

STORES MANAGEMENT

ORGANIZATIONAL HIERARCHY : 

ORGANIZATIONAL HIERARCHY

JUST IN TIME(JIT) : 

JUST IN TIME(JIT)

SUPPLIER DEVELOPMENT : 

SUPPLIER DEVELOPMENT INVENTORY CONTROL

QUALITY CONTROL DEPARTMENT : 

QUALITY CONTROL DEPARTMENT PRODUCTIVITY STEPS TAKEN TO IMPROVE PRODUCTIVITY: KANBAN LEAN SIGMA SMALL QUALITY CIRCLES

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R & D DEPARTMENT

Introduction : 

Introduction Specific Areas In Which R & D Is Carried Out Benefits Derived Future Plans Of Action Standards Adopted

Specific Areas In Which R & D Is Carried : 

Specific Areas In Which R & D Is Carried Home Theatres-High End Models And HTIB Models. Larger Screen Television. True Flat Televisions. Plasma Televisions. Cosmetic Design And New Out Look To The TV’s. Manufacturing Of Components For CTV, Refrigerators and Air conditioners. Efforts to Reduce Power Consumption.

Benefits Derived : 

Benefits Derived Development Of New Design. Can Face Competition. Increase In Productivity. Reduction In Power Consumption.

Future Plans Of Action : 

Future Plans Of Action Manufacturing Of Components. Multimedia TV. Plasma Televisions. Launching Of New Brands. Better Features, Better Quality & Improved Reliability.

LATEST TECNOLOGY : 

LATEST TECNOLOGY Vediocon plasma TV 42”

Standards Adopted : 

Standards Adopted CE Standard-Capillary Electrophoresis. BIS Standard-Bureau Of Indian Standard. IEC Standard-International Electro Technical Commision.

HR Department : 

HR Department Salary/Incentives. Team Targets. Job Performance. Job Safety Design. Job Evaluation. Ergonomics. Quality Circles.

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Salary Incentives:- Monthly attendance incentives. Quarterly attendance incentives. Half Yearly attendance incentives. Yearly attendance incentives.

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Team Targets:- Diwali Or Festival Gifts. Cash Rewards. Job Performance:- Internal Training. Brain Storming session. Workshops.

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Job Rotation:- Motivation Without Monetary Increase. Skill Development. Innovative Ideas. Job Safety Design:- Safety is given atmost importance in videcon.

WORKSHOPS : 

WORKSHOPS

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Job Evaluation:- Productivity. Discipline. Consistency. Dependability. Ergonomics:- Individual Cabin. Every dept is provided with a/c’s. Every dept Has Exhaust Fans. Storage Space For Documentation.

Quality Circles:- : 

Quality Circles:- Component Falling From PCB. Damage Of Component Due To Overlapping PCB Running Production line.

Slide 63: 

Kaizen Concept:- Continuous Interaction with down the line. Production and productivity importance awareness training. Some Motivation Rewards.

COMPARISON BETWEEN VIDEOCON & NEROLAC PAINTS : 

COMPARISON BETWEEN VIDEOCON & NEROLAC PAINTS

THANK YOU : 

THANK YOU