1. Project : LAKSHYA

2. Project : LAKSHYA
 Productivity improvement at PTP (II) i.e. from 5000 kg to 8000 kg
…… (60 % improvement).
 More focus towards quality consistency and improvement at both plants .
 System introduction and addressing primary issues in thrashing plants.
 Customer Satisfaction and aiming for “Customer Delight”.
 Process facility PTP (I) and PTP (II) at par with each other and should have skill
& system equilibrium.

3. Why to Have excellence in operations ?
 Assures decisions based on long term success of the enterprise
 Aligns manufacturing with business and corporate strategies
 Creates an awareness of competition
 Assures long term product, capability and process differentiation from competitors
 Provides clear communication between management levels
 Focuses improvement activities on long-term success
PROVIDES A BASIS FOR FUTURE SUCCESS

4. Understanding “Excellence in Operations”
Manufacturing
System
Team workLeadership
Empowering employees
Optimizing the existing activities
in the process
Customer satisfaction
Improving
Aim :
OE’s main objective is to reduce operation cost and improve productivity ,
without affecting quality , timely delivery with customer satisfaction
Element 1
Element 3
Element 2

5. What is Manufacturing System Design ?
 Manufacturing system “structure” design
 Manufacturing strategy
 Designing and implementation of KPI
 Operating policy
 Designing and developing various policies
 Partnerships (with customer)
 Initiatives towards building and developing relationship with customer
 Organization structure details
 Clear and visible job description of each individual in organization (Plant)
 Manufacturing system “infrastructure” design
 Buildings, location, capacity
 Continual improvement initiatives
 Process auto Automation / plant modernization / Machine selection / Layout changes
 Systematic approach towards above all
Element 1
We are here

6. What is Manufacturing Strategy?
A “game plan” for the manufacturing organization to keep itself aligned with the
Corporate strategy
It consists of :
 Long term objectives
 Strategies
 Programs
 Initiatives
To help the business build and maintain a competitive advantage
for future success
Product performance, quality & cost
Low risk participation, steady business
Customers
Business
Return of investmentStockholders
Employment stability
Satisfactory salary, working conditions
Promotion opportunities
Employees
Hourly
Management
Primary NeedStakeholder
Element 1

7. Team Work
Element 2
And
Element 3
Leadership
Considering all above three Elements
--- KPI for each in PTP-2 factory are designed as follows
Teamwork holds a highly valuable place in organizations, with teamwork among
employees every bit as important as collaboration among members of a sporting
team..
Leaders have an important role to play in coordinating and integrating the
activities of these individuals and teams, ensuring that they are aware of the
institution's priorities and that they are working towards them.

8. KPI for PTP (2)
Key performance indicators
From 5000 kg
to 8000 kg out
put per Hour
Improved
Productivity
Low overhead
cost
Reduction in
Overhead cost
Best in Class
Quality
improvement
Best Work
practices
System
improvement
Repeated
customer order
through
customer
delight
Customer
Focus
Recognition as
best threshing
facility in
vicinity
Innovation at
Work
All four Managers at PTP(2) has given objective basis of above
Hence forth Performance will be reviewed based on following deliverables.

9. KPI
Improved Productivity
Area
Prasad
Mukhtar
Reddy
Vijaya
1 Phase one – 10% improvement in throughput a
2 Reduction in non-conformity product at shop floor. a
3 Introducing first in first out (FIFO) at all ware houses for better Productivity a
4 Timely reporting of Production Highlight to HO a
5 PPC contact person for factory a
Objectives
Improved
productivity
Customer Focus
Area
Prasad
Mukhtar
Reddy
Vijaya
1
Designing process Audit format and executing first audit.
(Reference- karedu plant audit by customer)
a
2
As a part of consistency in quality - Designing and developing Quality control
manual / judgment standard manual and imparting the training to all concern.
a
3 Better ware house management/ control for addressing Customer compliant. a
4
Monitoring Customer visit to factory through self-designed protocol and
improvement
a
Objectives
Customerfocus

10. KPI
Reduction in over all cost
Area
Prasad
Mukhtar
Reddy
Vijaya
1 Process Yield improvement. a
2 Optimum utilization of Production work strength. No extra manpower a
3
Effective utilization of resources - consumables used for boiler and RO plant
and Power
a
4
Effective Engg. Manpower utilization by more in-house work execution
avoiding vendor cost.
a
5 Reduction in Damage at warehouse due to improper handling a
6 All invoice and work order track record updating on daily basis a
7
Feasibility study and introduction of Time office for effective utilisation of
manpower
a
Objectives
Reductioninoverallcost

11. KPI
Quality improvement
Area
Prasad
Mukhtar
Reddy
Vijaya
1 Spillage control and improvement at production hall a
2 More QA focus - Daily QA report preparation and circulating to concern. a
3
Weekly quality report meeting and monthly Report system to bring Quality
awareness in lime light.
a
4 Infestation monitoring and control at ware houses a
5
Display of Weekly performance chart of quality achievement to bring more
quality awareness and further improvement in plant.
a
Objectives
Qualityimprovement

12. Area
Prasad
Mukhtar
Reddy
Vijaya
1 Operation diary introduction to each key process eqpt. a
2 Introduction of SOP / Do’s and don’ts at shop floor a
3 Root Cause analysis of breakdown a
4
Introduction of online – offline check sheet (Implementation of Karedu plant
check sheet with little modification)
a
5 MIS / Barcode effective utilization a
6 Key writer role in Daily Factory meeting. Updating and circulating a
Objectives
System
imporovement
KPI
System improvement

13. Area
Prasad
Mukhtar
Reddy
Vijaya
1 Re dryer automation – in-house or through vendor a
2 Introduction of 5 min 5's at production hall a
3 Establishing communication system at plant. a
4 Ph Boosted drinking water for plant people. a
5 Better visual 5S at all ware houses a
6 Training need identification in consultation with concern and execution of a
7 Head the safety related movement in plant. a
Innovationatwork
Objectives
KPI
System improvement

14. Responsibility chart and Further line of Actions:
 Individual MANAGER :
 After finalizing the objective with respective KPI with each Manager , they have to form a team of
their subordinates
 Each objective will be further divided in to sub objective depending up on the skill set they have.
 They will own up entire responsibility till control phase.
 Factory Team
 Periodic review mechanism will be introduce for present status and support in there action
implementation.
 Monthly report generation on each KPI will be monitored by Concern
 Designing and developing various policies and framing Initiatives towards building and developing
relationship with customer
 Drafting entire blue print for infrastructure / Layout ,Process auto Automation / Plant
modernization / Machine selection / Layout changes
Core
Teams
formation
Review of
Current status to
finalizing the
Base Level
(From where to
improve upon)
Brainstorming
and Sub team
formation
Implementation
of Action plan 1
Review of
actions and
Implementation
of Action plan 2
Control and
Closer
Oct 2013
Oct 2013 Nov 2013 Nov - Dec
2013
Jan 2014
March 2014

15.  Individual Team
 Prasad
 Spillage Control
 Yield Improvement
 Mukhtiar
 QA Mannual
 Reddy
 Warehouse FIFO
 Vijaya
 PPC
 Factory team
 For KPI review
 MK / PBS / BVS
 Support – BVS sir/ Ratanam sir / Raja sir/ Raghu sir/MK / U Rao / PBS
 Designing and developing various policies and framing Initiatives towards building and developing relationship
with customer
 Drafting entire blue print for infrastructure / Layout ,Process auto Automation / Plant modernization /
Machine selection / Layout changes
 For Audit
 MK / UMR / PBS And Down the line Mngrs
Core
Teams
formation
Oct 2013
Leader
1 Reductioninnon-conformityproductatshopfloor. Murli Suresh Subba Rao
2
Asapartof consistencyinquality- DesigninganddevelopingQualitycontrol manual /judgment
standardmanual andimpartingthe trainingtoall concern. Raju
K R Raju Sudhakar
3 Effective utilization of resources- consumablesusedforboilerandROplant Vijay Prasad Shakila
4 Effective Engg.Manpowerutilizationbymore in-house workexecutionavoidingvendorcost. Salim Rashid MV Rao
5 More QA focus- DailyQA reportpreparationandcirculatingtoconcern. Murli Sasikala
6 WeeklyqualityreportmeetingandmonthlyReportsystemtobringQualityawarenessinlime light. Sasikala
7 RootCause analysisof breakdown Rajeshwar Sudhakr
8
Introductionof online –offline checksheet(Implementationof Kareduplantchecksheetwithlittle
modification) Vijay Raju
9 Establishingcommunicationsystematplant. Sasikala
10 PhBoosteddrinkingwaterforplantpeople. Vijay PrasadMukhtarAhmd.
Teammember
Sample
SUB TEAM FOR MUKHTIAR
TEAM

16. Review of
Current status to
finalizing the
Base Level (From
where to
improve upon)
Oct 2013
 DATA COLLECTION IS IN PROGRESS :

17. What is Manufacturing System Design ?
 Manufacturing system “structure” design
 Manufacturing strategy
 Designing and implementation of KPI
 Operating policy
 Designing and developing various policies
 Partnerships (with customer)
 Initiatives towards building and developing relationship with customer
 Organization structure details
 Clear and visible job description of each individual in organization (Plant)
 Manufacturing system “infrastructure” design
 Buildings, location, capacity
 Continual improvement initiatives
 Process auto Automation / plant modernization / Machine selection / Layout
changes
 Systematic approach towards above all
Element 1
We are here
Draft
Draft
Draft
Designed
Target
2014-15
Followed for
forthcoming
Planned
maintenance
Draft
Followed for
forthcoming
Planned
maintenance

18. First draft of policy :

19. Area Description Base level Target Comment
Mechanical efficency improvement - 10% improved up on base line 90.31% 92%
Current efficiency is 90.31% . So improved
efficiency of plant will be 91.5%
Reduction in electrical downtime - 10% reduction 0.55% 0.50%
Refering the base data current electrical
breakdown rate is 0.55% . So by improving
10% we can achieve 0.50%
Reduction in Grade change time loss 2.30% 2%
Base data shows that current time loss
percentage is 2.30% time loss, By
improving the sysytem we can achieve the
10% additional time and new time loss in
grade change will restrict to 2.05%
Introduction of Customer complaint addressel system Nil
100%
implementation
Design and develop the new system after
benchmarking the others - best in
industries
Introduction of three monthly customer feedback sysytem and subsequent
improvement Nil
100%
implementation
Design and develop the new system after
benchmarking the others - best in
industries
PTP II - Targets for 2014-15
ImprovedproductivityCustomerfocus

20. Yield improvement - Grade wise
High Grade
Medium Grade
Low Grade
Resource optimum utilisation
10% Reduction in APESB consumption 31% 28%
its current contribution to the total
thrushing cost is 31 % . Target to achieve 28
% as an contribution
Electrical unit per KG reduction by 10 % 0.22 unit per Kg0.20 unit per Kg
Process optimisation to reduce the per kg
contribution of electrical unit
Reduction is Boiler consumable - Coal and F wood aiming for 5% reduction
16% coal
18% F wood
15% coal
17% F wood
its current contribution to the total
thrushing cost is 16 % coal and 18% F
wood.By initiating effeciency
improvement of boiler we can aim for
reduction by min 5% each
sustating the Thrushing cost per kg 5.30 /- 5.30/- and lower
Refering all above initiative we can
susutain the target and same time can able
to reduce the cost also
Reduction in floor spillage
Aiming for Zero
spillahe on
Ground
Arresting the spillage points and providing
the collecton try or necessary design
hardware solution to achieve the target of
zero spillage on floor
Infestation - control and and monitoring
Designing and
developing the
hygien sysytem
Making entire new blue print for total traps
and revisiting exisiting system of
monitoring the same. Also preventive
messure to be arranges in more systematic
way with audit mechanisum
Reduction in count of Weevile per trap
5% improvement
to existing level
Current base data has to be reviewed in
line with this
PTP II - Targets for 2014-15ReductioninoverallcostQualityimprovement

21. Improvent in process through process audit . 20% improvement in current index no (RPN no)Yet to decide 20% improvement
Introduction of Process audit and
calculation of current RPN no. Karedu plant
has gone thrugh the same and Follwing the
same Customer audit format for PTP 2we
can arrive upon current level
Introduction of Operation diary at Key process equipment nil to be decided
Considering the criticality of each process
and alied equipment we can introduce the
operation diary
Introduction of Online / offline / lubrication check Nil
100%
implementation
Following the karedu check sheet we can
start the same at earliest and improve up
on the current sysytem
Introduction of 5min 5's at plant and further inter- area best mantain dept
competition Nil
100%
implementation
Very basic concept to bring the 5's as an
culture to each and every member of plant
with out devoting only 5min per day all at
same time
Introduction of rewards and recognition for in innovation at work Nil
100%
implementation
Base on kaizen and Suggestion scheme
customise new sysytem can be introduce
for our plant
More use of IT at most possible extent . Ie for data base , communication and
ease in day to day operation Nil ongoing
It is a need of hour to go for IT as reduction
in labour and further ease in operation.
Helps PTP to stand ahead in competition
PTP II - Targets for 2014-15SystemimporovementInnovationatwork

22. Arial View: PTP 2

23. Thanks
 Lakshya
Productivity improvement at PTP (II) i.e. from 5000 kg to 8000 kg
…… (60 % improvement).
 Lakshya
System introduction and addressing primary issues in thrashing plants.
 Lakshya
Customer Satisfaction and aiming for “Customer Delight”.
 Lakshya
Process facility PTP (I) and PTP (II) at par with each other and should have skill & system
equilibrium.
 Lakshya
More focus towards quality consistency and improvement at both plants