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Chennai Plant Metrics Performance-2014

Responsible
Person

Function
Owner

CAR Cost Ratio


Chennai Plant
(%)

V B.
Venkatachalam/
Jeeva

Chennai
Plant

External Defect
Chennai Plant
PPM

Jeeva

Item in Metrics Report

Total
Cost of Poor Scrap
Quality (CoPQ)
(KUSD)
Obsolescence

V B.
Venkatachalam/
Jeeva

CAR Cost
Product Audit
Razor
(%)
First Pass Yield
Razor
(%)
Supplier DPPM
Incoming Inspection Accuracy(%)
On Time Incoming Insepction Rate(%)

Jeeva
Jeeva
Jeeva
Jeeva

Chennai
Plant
Chennai
Plant
Chennai
Plant
Chennai
Plant
Chennai
Plant
Chennai
Plant
Chennai
Plant
Chennai
Plant
Chennai
Plant

2015 Goal

2014

2015
YTD

Jan

Feb

Mar

Apr

May

Jun

Jul

Aug

Sep

Oct

Nov

Dec

#DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0!

#DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0!

#DIV/0!

#DIV/0! #DIV/0! #DIV/0!

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#DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0!

#DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0!

#DIV/0!

#DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0!

#DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0!

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Plant or Group Name


2009 BUSINESS PLAN DEPLOYMENT

Category

Updated at the monthly review determined by reviewing the


entire BPD status.

Goal:

Overall Status:
Schedule & Control Point

#
1.0

OBJECTIVE & METHODS


OBJECTIVE:

TARGET

What you are trying to achieve by a particular course


of action. Objectives directly support goals and are
agreed to by all levels of the organization. They are
more specific than goals and they are followed up
and reviewed monthly. It is best to limit the number
of objectives per goal so that the team can remain
focused on top priority items. All objectives require a
target.

METHODS:

2.0

RESPONSIBLE

Jan Feb Mar

Apr May Jun

This area is used to track the


monthly status of the
objective and methods of the
BPD. Status is shown using
the rating system below.

METHODS:

3.0

OBJECTIVE:
METHODS:

4.0

Aug Sep Oct Nov Dec Status

Example time line

OBJECTIVE:

Comprised of one or more activities which are planned to


meet the objective. Methods should have a target to track
progress and signal whether we are meeting our methods.
They are the "how" of the annual plan. They should be
specific, timed and scheduled, assigned to individuals
responsible for carrying them out, and supported by
detailed action plans.

Jul

The names of the individual(s) who


are responsible for carrying out the
specific methods designed to meet the
objective.

The target is meant as a means by which to track


progress. Targets provide us with a tool to evaluate
the success of our plan. Targets must be achievable,
challenging, based on reliable statistics, and tracked
regularly. Targets must also be SMART (Specific,
Measured, Accurate, Realistic, Timed).

OBJECTIVE:
METHODS:

5.0

OBJECTIVE:
METHODS:

Symbols to be used on the BPD


timing schedule.

Time-Line Legend
Time line
Control point
Planned start/end time

Form 6001, Rev 01/28/10,

Rating system for monthly status on


objectives and methods. Colors or symbols
may be used independently to represent the
same rating system.

STATUS LEGEND
Meets or exceeds target
Improvements needed

Fill in when performed


Actual start/end time

Ref. SOP 21.10

Printed on: 02/19/2015

Quality

Plant or Group Name:

Quality

2014 BUSINESS PLAN DEPLOYMENT


Goal: Achieve Quality Measures for FPR, PPM, Scrap, First Pass Yield, Product Audits

Overall Status:
Schedule & Control Point

#
1.0

OBJECTIVE & METHODS

RESPONSIBLE

TARGET

Jan

Feb Mar

Apr May Jun

Jul

Aug Sep

Oct

100%

OBJECTIVE: CAR Order Cost Ratio


METHODS:

2.0

100%

OBJECTIVE: External Defect PPM


METHODS:

3.0

100%

OBJECTIVE: Cost of Poor Quality


METHODS:

4.0

100%

OBJECTIVE: Product Audit


METHODS:

5.0

100%

OBJECTIVE: First Pass Yield


METHODS:

6.0

100%

OBJECTIVE: Supplier DPPM


METHODS:

Time-Line Legend
Time line
Control point
Planned start/end time

Fill in when performed


Actual start/end time

STATUS LEGEND
Meets or exceeds target
Improvements needed

Nov Dec Status

CAR Order Cost Ratio


0.4

CAR0.3Order Cost Ratio (%)


0.3
0.2
0.2
0.1
0.1
0.0

2014

2015 YTD

Jan

Month

2014

Goal

0.32

Actual

0.06

CAR Order Cost (KUSD)

3.7

Feb

2015
YTD

Mar

Jan

#DIV/0! #DIV/0!
0.0

0.0

Apr

May

Feb

Mar

Apr

###

#DIV/0!

###

0.0

0.0

0.0

Jun

May

Jul

Jun

Aug

Jul

Aug

Sep

Sep

Oct

Oct

#DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0!


0.0

0.0

0.0

0.0

0.0

0.0

Nov

Dec

Nov

Dec

#DIV/0!

#DIV/0!

0.0

0.0

CAR Order Cost Pareto


12.000

10.000

Monthly Top 3 CAR Order Pareto


8.000

6.000

4.000

2.000

0.000

External DPPM Pareto


5.00

Monthly
4.00Top 3 External Defect Qty Pareto

3.00

2.00

1.00

0.00

CoPQ Pareto
12

10
Monthly Top 3 CoPQ Pareto
8

Product Audit(%)-Razor
100.0

98.0

96.0

94.0
Product
Audit (%)
92.0

90.0

88.0

86.0

84.0

82.0

80.0

2014

2015 YTD

Jan

Feb

Mar

Apr

May

Jun

Jul

Aug

Sep

Oct

Nov

Dec

92.0

90.0

88.0

86.0

84.0

82.0

80.0

2014

2015 YTD

Jan

Feb

Mar

Apr

May

Jun

Jul

Aug

Sep

Oct

Nov

Dec

udit(%)-Razor

May

Jun

Jul

Aug

Sep

Oct

Nov

Dec

May

Jun

Jul

Aug

Sep

Oct

Nov

Dec

First Pass Yield - Razor


100
99
98
97 Yield %
First Pass
96
95
94
93
92
91
90

2013

2014

2015 YTD

Jan

Feb

Mar

Apr

May

Jun

Jul

Aug

Sep

Oct

Nov

Dec

Corporate
Corporate
Engineering Engineering
Corporate
Corporate
Production Production
Corporate
Corporate
Supplier
Supplier
Corporate
Corporate
System
System

Corporate
Engineering
Corporate
Production
Corporate
Supplier
Corporate
System

#DIV/0!

#DIV/0!

#DIV/0!

#DIV/0!

#DIV/0!

#DIV/0!

Price book
+Product
design
+BOM+
Special
design

Marketing

Marketing

#DIV/0!

#DIV/0!

#DIV/0!

Process
Design

Sustaining
Engineering

Sustaining
Engineering

#DIV/0!

#DIV/0!

#DIV/0!

Production

Production

Production

#DIV/0!

#DIV/0!

#DIV/0!

Planning
Plant
Distribution

Planning

Planning

#DIV/0!

#DIV/0!

#DIV/0!

Distribution

Distribution

#DIV/0!

#DIV/0!

#DIV/0!

#DIV/0!

#DIV/0!

#DIV/0!

OEM Supplier
OEM + PQE
in CHN

#DIV/0!

#DIV/0!

#DIV/0!

OEM
OEM
OEM
Engineering
Engineering in
Engineering
in OAP
OAP

OEM
OEM
OEM
Engineering
Engineering in
Engineering
in CHN
CHN
OEM
Supplier in
CHN

OEM
Supplier in
OAP
Warranty
Others

OEM + PQE
Warranty

#DIV/0!

#DIV/0!

#DIV/0!

OEM Supplier
in OAP

#DIV/0!

#DIV/0!

#DIV/0!

Warranty
Others
Total:

#DIV/0!
#DIV/0!

#DIV/0!
#DIV/0!

#DIV/0!
#DIV/0!
#DIV/0!

CAR Cost Ratio


Function Goal

Sales

Sales

SQE +
Supplier
Sourcing
Corporate
Corporate
Engineering Engineering
Corporate
Corporate
Production Production
Corporate
Corporate
Supplier
Supplier
Corporate
Corporate
System
System
Price book
Marketing

TP $

GCNA
SEA
India
AustraliaNZ
ME

Jul-15
FPR Cost Shipment Extra Cost Total CAR Total CAR
$
Cost $
$
Cost $ Cost Ratio
#DIV/0!

Supplier
Corporate
Engineering
Corporate
Production
Corporate
Supplier
Corporate
System
Marketing

TP $

Aug-15
FPR Cost Shipment Extra Cost Total CAR Total CAR
$
Cost $
$
Cost $ Cost Ratio
0.00
#DIV/0!
0.00
#DIV/0!
0.00
#DIV/0!
0.00
#DIV/0!
0.00
#DIV/0!

TP $

Sep-15
FPR Cost Shipment Extra Cost
$
Cost $
$

YTD
Total CAR
Cost $
0.00
0.00
0.00
0.00
0.00

Total CAR
Cost Ratio
#DIV/0!

TP $
-

#DIV/0!
#DIV/0!
#DIV/0!

#DIV/0!

0.00

#DIV/0!

0.00

#DIV/0!

#DIV/0!

0.00

#DIV/0!

0.00

#DIV/0!

0.00

#DIV/0!

0.00

0.00

#DIV/0!

0.00

0.00

#DIV/0!

0.00

#DIV/0!

0.00

#DIV/0!

0.00

#DIV/0!

Sustaining
Engineering

#DIV/0!

0.00

#DIV/0!

0.00

#DIV/0!

Production
Planning

Production
Planning

#DIV/0!
#DIV/0!

0.00
0.00

#DIV/0!
#DIV/0!

0.00
0.00

#DIV/0!
#DIV/0!

Distribution

Distribution

#DIV/0!

0.00

#DIV/0!

0.00

#DIV/0!

#DIV/0!

0.00

#DIV/0!

0.00

#DIV/0!

OEM Supplier
in CHN

#DIV/0!

0.00

#DIV/0!

0.00

#DIV/0!

OEM
OEM
OEM
Engineering
Engineering in
Engineering
in OAP
OAP

Process
Design+Pro
duct design Sustaining
+BOM+
Engineering
Special
design
Production
Planning
Plant
Distribution

OEM
OEM
OEM
Engineering
Engineering in
Engineering
in CHN
CHN
OEM
Supplier in
CHN

OEM
Supplier in
OAP
Warranty
Others

OEM + PQE

OEM + PQE
Warranty

#DIV/0!

0.00

#DIV/0!

0.00

#DIV/0!

OEM Supplier
in OAP

#DIV/0!

0.00

#DIV/0!

0.00

#DIV/0!

Warranty
Others
Total:

#DIV/0!
#DIV/0!

0.00
0.00
0.00

#DIV/0!
#DIV/0!
#DIV/0!

0.00
0.00
0.00

#DIV/0!
#DIV/0!

Total CAR
Cost $
-

Total CAR
Cost Ratio
#DIV/0!
#DIV/0!

CAR Cost Ratio


Function Goal
GCNA
SEA
Sales

Sales

TP $

Oct-15
FPR Cost Shipment Extra Cost Total CAR Total CAR
$
Cost $
$
Cost $ Cost Ratio
0.00
#DIV/0!
0.00

TP $

Nov-15
FPR Cost Shipment Extra Cost Total CAR Total CAR
$
Cost $
$
Cost $ Cost Ratio
0.00
#DIV/0!
0.00

TP $

Dec-15
FPR Cost Shipment Extra Cost
$
Cost $
$

YTD
TP $
-

Supplier DPPM
6000

5000

4000

Supplier DPPM
3000

2000

1000

Note:

Major issue:

Supplier DPPM Pareto


12

10
Monthly Top 3 Supplier Defect Qty Pareto
8

Incoming Inspection Accuracy


100

100

Incoming Inspection Accuracy (%)


99

99

98

98

97

Month

Incoming Inspection Pareto


1200.0%

1000.0%

Monthly Top 3 Incoming Inspection Pareto

800.0%

600.0%

400.0%

200.0%

0.0%

On Time Incoming Inspection Pareto


1200%

1000%

Monthly Top 3 Incoming Inspection Pareto

800%

600%

400%

200%

0%

Chart Title

to

On Time Incoming Inspection Rate


100
90

On Time Incoming Insepction Rate (%)


80
70
60
50
40
30
20
10
0

Month

Date Created:

Team:

W3I

Jotiram Jadhav,Dineshbabu

What, Who, When, Impact


Item #

What

1
2
3

Date
Identified

Issue/Opportunity

Action Item/Countermeasure

Description:

Who

When

Impact (Measure)

Item
Owner

Completion
Date

Quality, Cost, Safety,


Culture, Environment,
Schedule

Quality
Status

Date Created:

Closed W3I Items

Team:

What, Who, When, Impact

Item #

What

1
2
3
4
5

6
7

Date
Identified

Issue/Opportunity

Action Item/Countermeasure

Who

When

Item
Owner

Date
Completed

Team:

Description:

Quality
Impact (Measure)
Quality, Cost, Safety,
Culture, Environment,
Schedule

Closed Items
Comments

Plan
Do
Check
Action

Plan

Do
Check
Action

Action

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