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CEAT Limited

AM TRACKER FOR THE MONTH OF: SEPTEMBER'15


Sr.No
Machine
Objective
AM Step III Certified - Fy'14-15 Q2
B/D Hours
Operational Efficiency
1
TTB 02
Quality : held up/Rework
Safety: No of Incidents
B/D Hours
Operational Efficiency
2
TTB 04
Quality : held up/Rework
Safety: No of Incidents
B/D Hours
Operational Efficiency
3
Bead Fillering 12
Quality : held up/Rework
Safety: No of Incidents
B/D Hours
Operational Efficiency
4
Bead Fillering 16
Quality : held up/Rework
Safety: No of Incidents
B/D Hours
Operational Efficiency
5
BBM 12
Quality : held up/Rework
Safety: No of Incidents
B/D Hours
Operational Efficiency
6
NTC 49
Quality : no. of tyres scrap/month
Safety: No of Incidents
B/D Hours
Operational Efficiency
7
NTB 01
Quality : held up/Rework
Safety: No of Incidents
AM Step III Certified - Fy'14-15 Q3
B/D Hours
Operational Efficiency
1
TTC press D0
Quality : Tyre Scrap Nos./Month
Safety: No of Incidents
B/D Hours
Operational Efficiency
2
Bead Flipper 18
Quality : held up/Rework
Safety: No of Incidents
B/D Hours
Operational Efficiency
3
TTB 11
Quality : held up/Rework
Safety: No of Incidents

B/D Hours
Operational Efficiency
4
TTBB 13
Quality : held up/Rework
Safety: No of Incidents
AM Step III Certified - Fy'14-15 Q4
B/D Hours
Operational Efficiency
1
TTC press C1
Quality : Tyre Scrap Nos./Month
Safety: No of Incidents
B/D Hours
Operational Efficiency
2
TTC press C2
Quality : Tyre Scrap Nos./Month
Safety: No of Incidents
B/D Hours
Operational Efficiency
3
Bead Covering 22
Quality : held up/Rework
Safety: No of Incidents
B/D Hours
Operational Efficiency
4
3.5" Extruder
Quality : Scrap/month
Safety: No of Incidents
B/D Hours
Operational Efficiency
5
TTC press C0
Quality : no. of tyres scrap/month
Safety: No of Incidents
B/D Hours
Operational Efficiency
6
TTC press D2
Quality : no. of tyres scrap/month
Safety: No of Incidents
B/D Hours
Operational Efficiency
7
BBM 15
Quality : Fabric scrap/month
Safety: No of Incidents
B/D Hours
Operational Efficiency
8
Bead Covering 21
Quality : Fabric scrap/month
Safety: No of Incidents
B/D Hours
Operational Efficiency
9
Bead Flipper 07
Quality : Fabric scrap/month
Safety: No of Incidents
B/D Hours
Operational Efficiency
10
NTB 02
Quality : Fabric scrap/month
Safety: No of Incidents
AM Step III Certified - Fy'15-16 Q1
B/D Hours
Operational Efficiency
1
TTB no. 21

TTB no. 21

Quality : Fabric scrap/month


Safety: No of Incidents
B/D Hours
Operational Efficiency
NTB no. 03
Quality : Fabric scrap/month
Safety: No of Incidents
B/D Hours
Operational Efficiency
Radial Filler no. 17
Quality : Fabric scrap/month
Safety: No of Incidents
B/D Hours
Operational Efficiency
Bead Flipper no 09
Quality : Fabric scrap/month
Safety: No of Incidents
B/D Hours
Operational Efficiency
NTC 35
Quality : Tyre Scrap Nos./Month
Safety: No of Incidents
B/D Hours
Operational Efficiency
TTC C 9
Quality : Tyre Scrap Nos./Month
Safety: No of Incidents

AM Step III Certified - Fy'15-16 Q2


1

B/D Hours
Operational Efficiency
TTB no. 19
Quality : Fabric scrap/month
Safety: No of Incidents
B/D Hours
Operational Efficiency
Bead Filler 20
Quality : Fabric scrap/month
Safety: No of Incidents
B/D Hours
Operational Efficiency
Bale Cutter no 1
Quality : Fabric scrap/month
Safety: No of Incidents
B/D Hours
Operational Efficiency
Band building 16
Quality : Fabric scrap/month
Safety: No of Incidents
B/D Hours
Operational Efficiency
NTB no. 4
Quality : Fabric scrap/month
Safety: No of Incidents
B/D Hours
Operational Efficiency
NTB no. 13
Quality : Fabric scrap/month
Safety: No of Incidents
B/D Hours
NTC 48A

Trac

10

11

12

Operational Efficiency
Quality : no. of tyres scrap/month
Safety: No of Incidents
B/D Hours
Operational Efficiency
NTC 36
Quality : no. of tyres scrap/month
Safety: No of Incidents
B/D Hours
Operational Efficiency
TTC B8
Quality : no. of tyres scrap/month
Safety: No of Incidents
B/D Hours
Operational Efficiency
Rad. Building 3A
Quality : Fabric scrap/month
Safety: No of Incidents
B/D Hours
Operational Efficiency
1000 CFM
Compressor
Quality : Fabric scrap/month
Safety: No of Incidents
B/D Hours
ODR2000,RHEOME Operational Efficiency
TER
Quality : Fabric scrap/month
Safety: No of Incidents
NTC 48A

Unit
Hours
%
Kg/Day
Nos.
Hours
%
Kg/Day
Nos.
Hours
%
Kg/Day
Nos.
Hours
%
Kg/Day
Nos.
Hours
%
Kg/Day
Nos.
Hours
%
Nos
Nos.
Hours
%
Kg/Day
Nos.
Hours
%
Nos./Month
Nos.
Hours
%
Kg/Day
Nos.
Hours
%
Kg/Day
Nos.

Base Line Target Results


48.6
79.8
0
0
72.64
85.25
0
0
6
94
0
0
6
94
0
0
49.75
76
16.7
0
15.12
85.67
3.5
0
6.83
85.33
0
0

34.2
88.46
0
0
54
88.46
0
0
4.2
95
0
0
4.2
95
0
0
34.83
88.22
11.69
0
12
85
2
0
4
91.05
0
0

40.2
86
0
0
26.25
94
0
0
1.3
98
0
0
2
92
0
0
1.5
92
20
0
9
85.49
2
0
3
93.88
0
0

22.45
16.8
73.703333 86.4675
4
2.8
1.75
0
5.52
3.86
87.28
89.02
0
0
0
0
0.52
0.4
94
95
0
0
0
0

46.13
80.34
3
0
0
100
0
0
3
95.73
0
0

Oct-14

Nov-14

Dec-14

40.20
86.00
0.00
0.00
26.25
94.00
0.00
0.00
1.30
98.00
0.00
0.00
2.00
92.00
0.00
0.00
1.50
92.00
20.00
0.00

37.45
84.00
0.00
0.00
23.55
93.00
0.00
0.00
0.00
96.44
0.00
0.00
1.09
91.98
0.00
0.00
4.62
84.43
20.00
0.00
31.30
85.00
17.00
3.00
0.00
92.54
0.00
0.00

22.95
86.84
0.00
0.00
14.30
95.69
1.00
0.00
0.00
95.01
0.00
0.00
0.00
97.08
0.00
0.00
5.48
88.00
16.40
0.00
5.49
93.37
6.00
1.00
0.00
86.79
0.00
0.00

3.00
93.88
0.00
0.00

Hours
%
Kg/Day
Nos.
Hours
%
Nos./Month
Nos.
Hours
%
Nos./Month
Nos.
Hours
%
Kg/Day
Nos.
Hours
%
Kg
Nos.
Hours
%
Nos.
Nos.
Hours
%
Nos.
Nos.
Hours
%
Kg/Day
Nos.
Hours
%
Kg/Day
Nos.
Hours
%
Kg/Day
Nos.
Hours
%
Kg/Day
Nos.
Hours
%

49.75 34.825
76 88.219
16.7
11.69
0
0

0.73
93
16.2
0

25.34
19
21.09
73.703333 86.4675 86.4675
4
3
2
1.75
0
0
16.75
12.6
10.18
73.703333 86.4675 86.4675
3.75
3
3
1.75
0
0
6.52
5.22
0
86.91
88.64
92.6
0
0
0
0
0
0
22
15
6.5
89
93
93.89
0.13
0.09
0.1
0
0
0
19.08
14.3
11.40
73.1
79.8
82.3
2
2
4
1
0
0
19.25
14.4
32
73.781667 80.3363
74.2
4.33
3
3
1
0
0
4.3
2
2
94.2
95
94
17.1
15
16
0
0
0
6.52
4.57
0
86.91
90.5
92.6
0
0
0
0
0
0
9.16
6.82
2.03
90.7
92
95.75
0
0
0
0
0
0
7.83
5.4
3
86.75
89.75
94
0
0
0
0
0
1.51
84.41

1.4
86.97

Kg/Day
Nos.
Hours
%
Kg/Day
Nos.
Hours
%
Kg/Day
Nos.
Hours
%
Kg/Day
Nos.
Hours
%
Nos/Month
Nos.
Hours
%
Nos/Month
Nos.

0
2

0
0

6
92
0
0

4.2
94
0
0
5.3
95
0

0
0

35.01
24.51
78.11
83.58
19
13
0
0
14.07
9.849
84.7 88.525
4
2.8
0
0

Tracking will start October onwards.


Hours
%
Kg/Day
Nos.
Hours
%
Kg/Day
Nos.
Hours
%
Kg/Day
Nos.
Hours
%
Kg/Day
Nos.
Hours
%
Kg/Day
Nos.
Hours
%
Kg/Day
Nos.
Hours

%
Nos/Month
Nos.
Hours
%
Nos/Month
Nos.
Hours
%
Nos/Month
Nos.
Hours
%
Kg/Day
Nos.
Hours
%
Kg/Day
Nos.
Hours
%
Kg/Day
Nos.

Jan-15

Feb-15

Mar-15

Apr-15

May-15

Jun-15

Jul-15

21.00
91.06
0.00
0.00
12.75
95.19
0.00
0.00
0.00
91.78
0.00
0.00
0.00
100.00
0.00
0.00
2.26
89.00
16.20
0.00
2.37
92.17
1.00
0.00
1.00
88.49
0.00
0.00

21.00
93.44
0.00
0.00
21.00
95.09
0.00
0.00
0.00
96.23
0.00
0.00
0.00
95.60
0.00
0.00
4.39
90.00
15.80
0.00
19.47
90.11
4.00
0.00
2.00
93.00
0.00
0.00

23.55
95.00
0.00
0.00
24.10
93.00
1.00
0.00
0.00
94.00
0.00
0.00
0.00
91.34
0.00
0.00
4.39
87.00
16.00
0.00
8.52
95.92
1.00
0.00
0.00
92.00
0.00
0.00

20.45
92.00
0.00
0.00
22.35
95.00
0.00
0.00
2.45
94.64
0.00
0.00
1.82
90.28
0.00
0.00
0.97
93.00
16.20
0.00
4.57
95.56
1.00
0.00
0.00
93.00
0.00
0.00

15.61
93.34
0.00
0.00
13.20
96.00
0.00
0.00
1.09
95.64
0.00
3.00
0.00
90.20
0.00
3.00
1.79
93.00
18.00
0.00
9.52
92.29
1.00
0.00
0.00
91.00
0.00
0.00

8.55
92.56
0.00
0.00
21.10
91.13
0.00
0.00
0.00
97.40
0.00
0.00
0.71
95.40
0.00
0.00
0.00
80.00
14.00
0.00
9.71
95.48
3.00
0.00
0.00
90.00
0.00
0.00

12.30
93.11
0.00
0.00
22.10
93.67
0.00
0.00
0.00
97.80
0.00
0.00
0.00
94.00
0.00
0.00
0.00
93.00
13.30
0.00
18.80
95.30
6.00
0.00
0.00
89.00
0.00
1.00

46.13
80.34
3.00
0.00
0.00
100.00
0.00
0.00
3.00
95.73
0.00
0.00

43.28
76.82
5.00
0.00
3.00
97.20
0.00
0.00
0.75
96.25
0.00
0.00

15.11
81.43
0.00
0.00
1.24
98.00
0.00
0.00
0.60
98.00
0.00
0.00

10.60
83.19
4.00
0.00
0.00
99.04
0.00
0.00
0.75
98.00
0.00
0.00

14.22
82.89
5.00
0.00
0.00
89.90
0.00
3.00
0.90
98.83
0.00
0.00

13.01
87.93
2.00
0.00
0.00
93.60
0.00
0.00
2.05
97.59
0.00
0.00

18.18
89.00
11.00
0.00
0.00
98.00
0.00
0.00
1.50
96.34
0.00
0.00

0.73
93.00
16.20
0.00

4.09
93.00
15.80
0.00

1.30
88.00
16.00
0.00

0.00
98.00
16.20
0.00

1.54
86.00
18.00
0.00

0.00
93.00
14.00
0.00

0.00
98.24
0.00
0.00

21.40
85.50
2.00
0.00
33.30
71.30
0.00
0.00
2.82
90.97
0.00
0.00
12.05
92.17
0.10
0.00
11.40
82.30
4.00
0.00
32.00
74.20
3.00
0.00
1.54
95.00
16.20
0.00
2.82
90.97
0.00
0.00
0.00
98.21
0.00
0.00
7.00
87.00
0.00
0.00

15.27
90.37
1.00
0.00
9.81
76.27
23.00
0.00
0.00
90.97
0.00
3.00
9.70
94.58
0.09
0.00
26.79
84.05
5.00
0.00
42.18
80.38
1.00
0.00
0.00
97.00
18.00
0.00
0.00
90.97
0.00
3.00
2.20
92.80
0.00
3.00
9.00
86.00
0.00
0.00

32.72
85.36
0.00
0.00
29.81
81.80
6.00
0.00
1.97
95.50
0.00
0.00
13.30
93.39
0.10
0.00
18.90
80.05
3.00
0.00
14.54
72.72
0.00
0.00
0.00
95.00
14.00
0.00
1.97
95.50
0.00
0.00
0.00
95.59
0.00
0.00
9.00
88.00
0.00
0.00

26.90
89.90
1.00
0.00
18.18
82.05
12.00
0.00
1.20
95.70
0.00
0.00
3.38
95.20
0.06
0.00
16.72
88.30
1.00
0.00
0.00
0.00
0.00
0.00
2.32
83.00
13.30
0.00
1.20
95.70
0.00
0.00
0.00
95.30
0.00
0.00
0.00
87.00
0.00
0.00
23.40
88.80

0.00
0.00
0.00
92.00
0.00
0.00
0.80
97.00
0.00
0.00
0.00
98.10
0.00
0.00
0.29
99.90
1.00
0.00
11.77
88.14
2.00
0.00

Aug-15

Sep-15

15.95
94.78
0.00
0.00
10.25
94.57
0.00
0.00
0.00
97.64
0.00
0.00
0.00
93.38
0.00
0.00
1.30
90.00
15.70
0.00
19.40
96.48
2.00
0.00
8.00
91.00
0.00
0.00

12.30
97.31
0.00
0.00
15.60
93.31
0.00
0.00
0.00
96.70
0.00
0.00
0.00
94.00
0.00
0.00
0.00
96.00
17.80
0.00
18.78
90.94
3.00
0.00
6.00
89.74
0.00
0.00

38.00
83.89
0.00
0.00
0.00
100.00
0.00
0.00
0.30
98.79
0.00
0.00

13.16
83.00
4.00
0.00
0.00
100.00
0.00
0.00
0.30
97.32
0.00
0.00

0.00
100.00
0.00
0.00

0.00
91.00
0.00
0.00

40.00
89.45
3.00
0.00
26.40
90.00
1.00
0.00
0.00
96.78
0.00
0.00
4.70
93.43
0.10
0.00
51.50
85.38
1.00
0.00
0.00
0.00
0.00
0.00
0.00
98.00
15.70
0.00
0.00
100.00
0.00
0.00
0.00
95.25
0.00
0.00
6.00
93.00
0.00
0.00

35.30
90.13
2.00
0.00
2.90
91.80
2.00
0.00
0.00
95.04
0.00
0.00
7.40
93.16
0.09
0.00
9.70
94.03
4.00
0.00
0.00
0.00
0.00
0.00
9.98
97.00
17.80
0.00
0.00
100.00
0.00
0.00
0.00
97.70
0.00
0.00
6.00
86.94
0.00
0.00

40.05
88.41

38.70
92.78

0.00
0.00
7.20
94.00
0.00
0.00
0.00
97.46
0.00
0.00
0.00
98.00
0.00
0.00
14.00
65.30
30.00
0.00
18.06
89.60
4.00
0.00

0.00
0.00
12.20
82.82
0.00
0.00
0.00
93.70
0.00
0.00
0.00
95.00
0.00
0.00
45.70
56.80
115.00
0.00
3.50
91.07
1.00
0.00

Guidelines for Colour Coding


SN

QIP : Specific Problem

High Laceration Accidents/Month (Knifeless)

High rush of people in HR for queries

High usage of knife for flash cutting operation


(developing specialized tool)

High usage of knife Batch-off unit of Ban.no.5 ( for


sample cutting operation )

High usage of hot knife for ply cutting in NTB

High flash cure in tractor tyres

Radial tyre scrap due to No PCI

Elimination of naptha based outer paint in all radial sizes

Manual cutting operation of Belt edge cushion of


7.00R15 Milaze at 2A radial first stage building machine.

10

The manual process takes long time and workflow plans


& documents are paper-intensive.

11

No tread weight data analysis in excel also


No report generated through SAP

12 High light side wall defect in 6.00-16 Ayushman size

13

High Radial tyre scrap due to bladder over bead (BOB)


defect

14 HIgh Mica defect in rear tractor tyres.

15 Tread rejection due to side crack at 8*10 Extruder

15 Tread rejection due to side crack at 8*10 Extruder

16 Deteriotion of fabric booking liners

17

% Improvement in export lot size warehousing

InProcess QIP Tracker alongwith T


% adherence to planned time lines
KPI
Accidents/month

Actual
Leader
Prasad Sarode

PLAN
Plan

Step I

Actual
Nos./month

Anand Rahatekar

Plan

Step I

Actual
Task Achievement

Rajiv Joshi

Plan

Step I
May W3

Actual
Task Achievement

Mahendra Sawardekar

Plan

Step I

Actual
Task Achievement

B J Choudhari

Plan

Step I

Actual
%age

Nandakishor Khade

Plan

Step I
May W4

Actual
Percentage scrap of No PCI in
all radial sizes of total
production
Task achievement

Vinayak pote

Plan

Step I

Actual
K Sudarshan

Plan

Step I

Actual
Task achievement
(Process reduction with
automation)
Adherence to timeline.

Vaibhav Gadgil

Plan

Step I

Actual
Sampayan Kar

Plan

Step I

Actual
Task Achievement

Vaibhav Shewale

Plan

Step I
July W2

Actual
% light side wall defect in 6.0016 Ayushman
Percentage scrap due BOB in all
radial sizes of total production
Mica defect in rear tractor
tyres.

Anil Pansare

Plan

Step I

Actual
Dinesh Gharate

Plan

Step I
June W1

Actual
Rajesh K. Pandulkar

Plan
Actual
Plan

Abhijeet Jadhav

Step I
July W2
Step I

Abhijeet Jadhav
Actual
Nos

Bhushan Joshi

Plan

Step I
June W4

Actual
%

Sanjay Kumar

Plan
Actual

Step I
Aug W4

er alongwith TIMELINE
Pending With Respect to the
Timeline

PLAN

DO

Step II

Step III

Step IV

Step II

Step III

Step IV

Step II
May W4

Step III
June W2

Step IV
June W3

Step II

Step III

Step IV

Step II

Step III

Step IV

Step II
June W1

Step III
June W3

Step IV
July W1

Step II

Step III

Step IV

Step II

Step III

Step IV

Step II

Step III

Step IV

Step II

Step III

Step IV

Step II
JulyW4

Step III
Aug W3

Step IV
Aug W4

Step II

Step III

Step IV

Step II
June W2

Step III
July W1

Step IV
July W4

Step II
July W3

Step III
Aug W1

Step IV
Aug W3

Step II

Step III

Step IV

Step II
July W1

Step III
July W3

Step IV
July W4

Step II

Step III

Step IV

Aug W4

Sept W3

Oct W3

CHECK

ACT

Step V

Step VI

Step VII

Step V

Step VI

Step VII

Step V
July W1

Step VI
July W4

Step VII
Aug W2

Step V

Step VI

Step VII

Step V

Step VI

Step VII

Step V
Aug W1

Step VI
Aug W2

Step VII
Aug W3

Step V

Step VI

Step VII

Step V

Step VI

Step VII

Step V

Step VI

Step VII

Step V

Step VI

Step VII

Step V
Sept W2

Step VI
Sept W3

Step VII
Sept W4

Step V

Step VI

Step VII

Step V
Monitoring

Step VI
for nxt

Step VII
3 months

Step V
Aug W4

Step VI
Aug W4

Step VII
Sept W1

Step V

Step VI

Step VII

Step V
Aug W1

Step VI
Aug W4

Step VII
Sept W3

Step V

Step VI

Step VII

Oct W4

Nov W2

Nov W3

CEAT

QIP TRACKER FOR THE


SN
QIP : Specific Problem
List of downgraded QIPs of Fy'13-14
Reduction in premature failure of bladders due to degradation of
1
bladders
2
Reduction in bead scrap
3

Reducing the production loss in radial due to GT trolley shortage

List of downgraded QIPs of Fy'13-14


1
Reduction of accidents in bead
Completed QIP Quarter I FY 14-15 : Nasik
2
3
4

Asset identification in production areas - Curing Assets


Step off variation
Employee database updation in SAP

Completed QIP Quarter II FY 14-15 : Nasik


1
Reduction of Mica defect in Non Truck tyres
2
Reduction of tyre scrap due to split cord in radial tyres
3
Reduction of RMS delay in mixing
4
Reduction of flow crack in tractor
5
Reduction Of Tread shoulder seperation in Truck

Elimination of missing cord in CANYLO

Reduction of shoulder separation defect in 7.00R15 milaze lt

8
9

Reduction in employee complaints


OE Yield Improvement in LCV & Radial sizes

10

Reduction in Band Loss due to trolley shortage

Completed QIP Quarter III FY 14-15 : Nasik


1

Reduction of Soap Solution consumption

Tyre stiffness improvement in 7.50-16 double bead sizes for


indonesian market

Re-engineering of 195R15 LT Steelplus in Nashik due to tyre


claim

Squegee blister reduction in all radial sizes

Reduction in Mix Carbon Scrap

Uniformity yield improvement in 185R14 LT Milaze

Reduction of squeegee blister in 195R15 Steelplus

Reduce utility power consumption

Reduction of customer complaint tread joint open in size 80018Aayusmaan

Elimination of Toe Flash in 59 J (While excess Sidewall stitching)


10
Completed QIP Quarter IV FY 14-15 : Nasik
1

Elimination of customer complaint No serial

Manufacturing Lead time reduction

scrap reduction in 8x6 Lt cold feed extruder

Reduction in FM defect in tractor sizes from 7.8% to 6.24%

Reduction of Premature by reducing turn up separation in 100020H CL HL sizes

Reduction of Customer complaint of groove crack in size 120024HT SUPER

To reduce the bead failure in premature & claim tires in 1020


Mile XL /HCL /HL

Productivity improvement in Non truck sizes.

Improve the Resolution of Bol Bindass Complaints


( Admin & Engineering related)
Asset identification
& tagging
in production
Completed
QIP Quarter
I FY 15-16
: Nasik. areas Band building, Extruder, Calendering/Bias cutter/Balancing
1
Machine,PCI units, Utility, Drums, Inspection m/c, vehicles &
machines
2 other
High set
up time in NTC
9

Improvement of cut tyre rating in all radial sizes to A & B rating


from C

High canteen cost

High trimming damage defect in eleveta sizes (NTC)

High Loss of production Due to unmix batch generation at Ban02

High premature claims due to breaker stretch

High Ply width variation on High table bias cutter at radial dept.

Low Productivity in banbury 02

Completed QIP Quarter II FY 15-16 : Nasik.


1

Reduction of breakdown hours due to drop door rubber jamming


phenomina

Elimination of Frequent side wall jam up in Separating conveyor


at 8x6 Booking area

3
4
5

Elimination of 7.5 MVA Transformer


Improvement of Fumes Extraction System at Banbury
Reduction of 4.00-8 tyre scrap due to Arm Damage

CEAT Limited
QIP TRACKER FOR THE MONTH OF: SEPTEMBER'15
KPI

Name of leader

Base Line

Tyres/Bladder

Parameshwaran

130.00

%age Scrap
No. of tyre loss due to trolley
shortage/month

Sanjeev Sharma

0.075

Shyam sunder

434.00

No. of Accidents

Sanjeev Sharma

2.23

Task Achievement
Non-compliance in %
Task Achievement

Uday Kansara
Shrikant Ghadge
Sampayan Kar

Task
36.67
Task

%age
%age scrap in total scrap
%age Loss
Customer Complaints PPM
Premature Claims PPM

Pratap Patil
Sonal Nerkar
Sharad Khairnar
NE Khade
Parameshwaran

1.5800
16.40%
0.24
207
1084

Kalaivendhan

78

Sudarshan
Anand Rahatekar
Sunil Malagi

2.34
60
67.12

Jeevan Tambat

6.59

Pratap Patil

0.0011

Kiran Shankar

44

Kg

%age
No. per Month
%age
%age

Kg/Kg
Tyre defection (mm)

Task Achievement (ND PPM)


%age defect
%age Scrap
%age yield
%age Scrap
KWH
Customer Complaints for tread
joint open
%

No serial Customer complaint

Sudarshan

0.15

Sudarshan

0.32

Nitin Kolhe

0.112

Sudarshan

70

Sudarshan

9.6

Avinash Pradhan

34000

NE Khade

N Parameshwaran

70

NE Khade

R Kedia

11.91

Dablu Kumar

10.77

Shifts.
%age Tread rejection for Light
Truck Sizes
% Defect in tractor sizes

Anil Pansare

Premature claims due to Turn up


separation in 1000-20H CL HL
sizes (PPM)
N Khade

8.1

886

Customer complaint (nos.)


PPM
%age Productivity

N E Khade

Shrikant Ghadge

224

Kiran Sankar

Resolution %age

Anand Rahatekar

Task Achievement

Uday Mekhe

Task

Pravin Patil

244

Ankit Rana

77

Mins/Changeover
Monthly Cut tyre rating (%)

90

Rs. (Lacs)
Anand Rahatekar
%age trimming damage defect
Avg Min/month

Anil Pansare

3.40%

T Kalaivendhan

152

%age Non Compliance

Shrikant Ghadge

Process capability, Cp of bias


cutter

K Sudarshan

%age

Brk down Hrs/Month


Brk down Occurences
Cost in Lakhs
Muri Reduction
Tyre scrap in No's

60.35%
0.28

T Kalaivendhan

Pradeep Subedarpage

37

Prashant Kage

14

Sanjay Pagare

24

Pradeep Subedarpage

Vinayak Pote

23

Res/Tgt
150.00
0.049
94.00

0.00

Achieved
10.00
Achieved

1.4000
12%
0.12
154
867

Jul-15

Aug-15

Sep-15

143.00
0.063

146.00
0.060

153.00
0.055

30.00

23.00

168.00

1.00

0.00

0.00

0.90
8.87%
0.06
0.00
749.00

1.04
12.60%
0.09
0.00
234.00

One Time
One Time

1.17
3.04%
0.07
0.00
1489.00

QIP tracking completed


for 12 months
39

38.00

38.00

1.5
20
88.07

0.22
6.00
89.50

0.41
6.00
91.81

0.76
6.00
91.00

1.48

2.72

0.91

0.00098

0.00100

0.00097

4.41

0.0009

42

Size not Run in the Size not Run in the


Month of July'15
Month of Aug'15

Size not Run in the


Month of Sept'15

0.07

0.07

0.07

0.06

0.16

0.01

0.04

0.02

0.03

0.0015

0.0010

0.0000

77.00

87.00

90.00

0.47

0.90

0.43

30219

30904

30139

10

18

15

9.90

9.96

9.45

7.32%

6.3

9.07

5.20

4.35

5.00

882.00

364.00

0.00

15%

15%

15%

74

89

119.86

One Time

One Time

One Time

209

232

211

200.19

100

100.00

100.00

83.33

80
1.92
30000
0
56

9.92
8
6.48

708

0
124
10%
95
Achieved

Till Aug '15 Saving


one more month
is 1.5
Till Sept '15 saving is
for assesment lakhs/month(Appro Approx 3 Lakhs/month.
ximate )
0.50%

0.00

0.00

0.00

45.00

72.00

0.00

36.21

15%

11.96%

21.57

1.33

1.33

2.55

3.00

5.59% (Task
Achievement)

5.59% (Task
Achievement)

5.59% (Task
Achievement)

5.40

5.30

76

14
0
0
2
0

Tracking will start


Oct'15 onwards

Tracking done for 12 months.

CEAT Limited
AM TRACKER FOR THE MONTH OF: SEPTEMBER'15
Sr.No
Machine
Objective
AM Step III Certified - Fy'13-14 Q3
B/D Hours
Operational Efficiency
1
PTBM 23
Quality : held up/Rework
Safety: No of Incidents
B/D Hours
Operational Efficiency
2
TTB 59J 06
Quality : held up/Rework
Safety: No of Incidents
B/D Hours
Operational Efficiency
3
TTB 59J 23
Quality : held up/Rework
Safety: No of Incidents
B/D Hours
Operational Efficiency
4
BBM 11
Fabric Scrap
Safety: No of Incidents
B/D Hours
Operational Efficiency
5
Bead Fillering 02
Quality : held up/Rework
Safety: No of Incidents
B/D Hours
Operational Efficiency
6
Bead Fillering 08
Quality : held up/Rework
Safety: No of Incidents
B/D Hours
Operational Efficiency
7
Bead Winding 02
Quality : held up/Rework
Safety: No of Incidents
B/D Hours per month
Operational Efficiency
8
Radial Curing 50
Quality : no. of tyres scrap/month
Safety: No of Incidents
B/D Hours per month
Operational Efficiency
9
NTC 46
Quality : no. of tyres scrap/month
Safety: No of Incidents
B/D Hours per month
Operational Efficiency
10
Radial Building 2B
Quality : held up/Rework
Safety: No of Incidents
B/D Hours / month
11

NTBC 02

Operational Efficiency
11

NTBC 02

12

TTC A5

13

TTC C3

Quality : held up/Rework (fabric scrap kg/day)


Safety: No of Incidents
B/D Hours per month
Operational Efficiency
Quality : no. of tyres scrap/month
Safety: No of Incidents
B/D Hours per month
Operational Efficiency
Quality : no. of tyres scrap/month
Safety: No of Incidents

AM Step III Certified - Fy'13-14 Q4

B/D Hours
Operational Efficiency
BBM 4
Quality : held up/Rework
Safety: No of Incidents
B/D Hours
Operational Efficiency
BBM 10
Quality : held up/Rework
Safety: No of Incidents
B/D Hours
Operational Efficiency
BBM 14
Quality : held up/Rework
Safety: No of Incidents
B/D Hours
Operational Efficiency
Bead Fillering 5
Quality : held up/Rework
Safety: No of Incidents
B/D Hours
Operational Efficiency
Bead Fillering 10
Quality : held up/Rework
Safety: No of Incidents
B/D Hours
Operational Efficiency
Bead Winding 03
Quality : held up/Rework
Safety: No of Incidents
B/D Hours / month
Operational Efficiency
Ban 05
Quality : Comp Scrap
Safety: No of Incidents
B/D Hours
Operational Efficiency
PTBM 28
Quality : held up/Rework
Safety: No of Incidents
B/D Hours
TTB 15

Operational Efficiency
Quality : held up/Rework
Safety: No of Incidents
B/D Hours
Operational Efficiency
10
TTB 25
Quality : held up/Rework
Safety: No of Incidents
B/D Hours
Operational Efficiency
11
TTB 17
Quality : held up/Rework
Safety: No of Incidents
B/D Hours per month
Operational Efficiency
12
NTC 28A
Quality : no. of tyres scrap/month
Safety: No of Incidents
B/D Hours per month
Operational Efficiency
13
NTC 39
Quality : no. of tyres scrap/month
Safety: No of Incidents
AM Step III Certified - Fy'14-15 Q1
9

TTB 15

Bead Flipper 01

Bead Flipper 04

PTBM 05

TTB 13

BBM 02

NTC 48

S22 Strip Out

B/D Hours
Operational Efficiency
Quality : held up/Rework
Safety: No of Incidents
B/D Hours
Operational Efficiency
Quality : held up/Rework
Safety: No of Incidents
B/D Hours
Operational Efficiency
Quality : held up/Rework
Safety: No of Incidents
B/D Hours
Operational Efficiency
Quality : held up/Rework
Safety: No of Incidents
B/D Hours
Operational Efficiency
Quality : held up/Rework
Safety: No of Incidents
B/D Hours per month
Operational Efficiency
Quality : no. of tyres scrap/month
Safety: No of Incidents
B/D Hours
Operational Efficiency
Quality : Scrap/month

S22 Strip Out

Safety: No of Incidents
AM Step III Certified - Fy'14-15 Q1
B/D Hours per month
Operational Efficiency
1
Rad 52
Quality : no. of tyres scrap/month
Safety: No of Incidents
AM Step III Certified - Fy'14-15 Q3
B/D Hours
Operational Efficiency
1
TTC press D0
Quality : Tyre Scrap Nos./Month
Safety: No of Incidents
B/D Hours
Operational Efficiency
2
Bead Flipper 18
Quality : held up/Rework
Safety: No of Incidents
B/D Hours
Operational Efficiency
3
TTB 11
Quality : held up/Rework
Safety: No of Incidents
B/D Hours
Operational Efficiency
4
TTBB 13
Quality : held up/Rework
Safety: No of Incidents
AM Step III Certified - Fy'14-15 Q4
B/D Hours
Operational Efficiency
1
TTC press C1
Quality : Tyre Scrap Nos./Month
Safety: No of Incidents
B/D Hours
Operational Efficiency
2
TTC press C2
Quality : Tyre Scrap Nos./Month
Safety: No of Incidents
B/D Hours
Operational Efficiency
3
Bead Covering 22
Quality : held up/Rework
Safety: No of Incidents
B/D Hours
Operational Efficiency
4
3.5" Extruder
Quality : Scrap/month
Safety: No of Incidents
B/D Hours
Operational Efficiency
5
TTC press C0
Quality : no. of tyres scrap/month
Safety: No of Incidents
B/D Hours
Operational Efficiency
6
TTC press D2
Quality : no. of tyres scrap/month
Safety: No of Incidents

B/D Hours
Operational Efficiency
7
BBM 15
Quality : Fabric scrap/month
Safety: No of Incidents
B/D Hours
Operational Efficiency
8
Bead Covering 21
Quality : Fabric scrap/month
Safety: No of Incidents
B/D Hours
Operational Efficiency
9
Bead Flipper 07
Quality : Fabric scrap/month
Safety: No of Incidents
B/D Hours
Operational Efficiency
10
NTB 02
Quality : Fabric scrap/month
Safety: No of Incidents
B/D Hours
Operational Efficiency
Quality : Fabric scrap/month
Safety: No of Incidents
AM Step III Certified - Fy'15-16 Q1
B/D Hours
Operational Efficiency
1
TTB no. 21
Quality : Fabric scrap/month
Safety: No of Incidents
B/D Hours
Operational Efficiency
2
NTB no. 03
Quality : Fabric scrap/month
Safety: No of Incidents
B/D Hours
Operational Efficiency
3
Radial Filler no. 17
Quality : Fabric scrap/month
Safety: No of Incidents
B/D Hours
Operational Efficiency
4
Bead Flipper no 09
Quality : Fabric scrap/month
Safety: No of Incidents
B/D Hours
Operational Efficiency
5
NTC 35
Quality : Tyre Scrap Nos./Month
Safety: No of Incidents
B/D Hours
Operational Efficiency
6
TTC C 9
Quality : Tyre Scrap Nos./Month
Safety: No of Incidents
B/D Hours
Operational Efficiency
7
Quality : Fabric scrap/month

Safety: No of Incidents
B/D Hours
Operational Efficiency
Quality : Fabric scrap/month
Safety: No of Incidents

AM Step III Certified - Fy'15-16 Q2


1

10

11

B/D Hours
Operational Efficiency
TTB no. 19
Quality : Fabric scrap/month
Safety: No of Incidents
B/D Hours
Operational Efficiency
Bead Filler 20
Quality : Fabric scrap/month
Safety: No of Incidents
B/D Hours
Operational Efficiency
Bale Cutter no 1
Quality : Fabric scrap/month
Safety: No of Incidents
B/D Hours
Operational Efficiency
Band building 16
Quality : Fabric scrap/month
Safety: No of Incidents
B/D Hours
Operational Efficiency
NTB no. 4
Quality : Fabric scrap/month
Safety: No of Incidents
B/D Hours
Operational Efficiency
NTB no. 13
Quality : Fabric scrap/month
Safety: No of Incidents
B/D Hours
Operational Efficiency
NTC 48A
Quality : no. of tyres scrap/month
Safety: No of Incidents
B/D Hours
Operational Efficiency
NTC 36
Quality : no. of tyres scrap/month
Safety: No of Incidents
B/D Hours
Operational Efficiency
TTC B8
Quality : no. of tyres scrap/month
Safety: No of Incidents
B/D Hours
Operational Efficiency
Rad. Building 3A
Quality : Fabric scrap/month
Safety: No of Incidents
B/D Hours
Operational Efficiency
1000 CFM
Compressor

Trac

11

12

1000 CFM
Compressor

Quality : Fabric scrap/month


Safety: No of Incidents
B/D Hours
ODR2000,RHEOME Operational Efficiency
TER
Quality : Fabric scrap/month
Safety: No of Incidents

Unit
Hours
%
Kg/Day
Nos.
Hours
%
Kg/Day
Nos.
Hours
%
Kg/Day
Nos.
Hours
%
Kg/Day
Nos.
Hours
%
Kg/Day
Nos.
Hours
%
Kg/Day
Nos.
Hours
%
Kg/Day
Nos.
Hours
%
Nos
Nos.
Hours
%
Nos
Nos.
Hours
%
%
Nos.
Hours

Base Line Target Results


4.66
78.75
0.00
0.00
70.80
85.25
0.00
0.00
51.00
78.75
0.00
0.00
20.00
87.00
22.00
0.00
5.50
93.00
0.00
0.00
6.00
95.00
0.00
0.00
34.50
93.94
38.90
0.00
38.80
75.93
24.40
0.00
54.00
87.13
9.50
0.00
19.01
79.00
0.02
0.83
31.11

3.26
91.05
0.00
0.00
49.56
88.46
0.00
0.00
35.70
88.46
0.00
0.00
14.00
88.22
15.40
0.00
3.85
95.00
0.00
0.00
4.20
95.00
0.00
0.00
24.15
95.00
27.23
0.00
27.16
80.29
17.08
0.00
37.80
87.26
6.65
0.00
13.31
83.73
0.02
0.00
21.78

1.00
86.00
0.00
0.00
33.60
81.75
0.00
0.00
22.50
87.66
0.00
0.00
17.40
92.00
17.50
0.00
4.00
94.00
0.00
0.00
0.00
96.00
0.00
0.00
8.00
94.00
22.00
0.00
25.07
80.19
18.00
2.00
22.67
90.84
8.00
2.00
11.40
80.00
0.01
1.00
24.17

Jan-15

Feb-15

Mar-15

40.21
70.93
45.00
0.00

21.74
88.79
61.00
0.00

29.90
76.55
50.00
0.00

80.29

88.86

81.01

Kg/Day

67.54

47.28

43.22

Nos.
Hours
%
Nos
Nos.
Hours
%
Nos
Nos.

0.00
31.36
84.89
2.75
2.00
31.36
84.89
3.00
2.00

0.00
21.95
86.47
2
0.00
21.95
86.47
1.00
0.00

0.00
14.20
87.80
2.00
2.00
21.80
81.60
3.00
2.00

Hours

30
21
84
88.22
16.7
11.69
0
0
58.75
41.13
82
88.22
16.7
11.69
0
0
49.75
34.83
76
85
16.7
11.69
0
0
6.5
4.55
92.25
95
0
0
1
0
5
3.5
94
95
0
0
1
0
35.5
24.85
91.33
95
35.88 25.116
0
0
45
31.5
84.95
90.59
149.6 104.72
1
0
5.42
3.79
89.55
91.05
0
0
0
0
68.1
47.67

7.5
90
16.5
0
15
92
16.5
0
21
92
16.5
0
0
100
0
0
1
99
0
0
4
97
15
0
24
90.8
97
0
0
97
0
0
30

%
Kg/Day
Nos.
Hours
%
Kg/Day
Nos.
Hours
%
Kg/Day
Nos.
Hours
%
Kg/Day
Nos.
Hours
%
Kg/Day
Nos.
Hours
%
Kg/Day
Nos.
Hours
%
Kg/Day
Nos.
Hours
%
Kg/Day
Nos.
Hours

1.30

4.74

4.25

96.00
16.20
0.00
0.00
93.00
16.20
0.00
6.59
89.00
16.20
0.00
1.37
88.78
0.00
0.00
0.00
100.00
0.00
0.00
17.31
90.49
14.65
0.00
32.60
93.54
47.00
0.00
0.00
98.87
0.00
0.00
0.00

97.00
15.80
0.00
6.11
93.00
15.80
0.00
4.14
94.00
15.80
0.00
0.00
97.49
0.00
0.00
0.00
100.00
0.00
0.00
17.00
91.03
18.14
0.00
31.70
91.99
42.00
0.00
0.00
97.00
0.00
0.00

92.00
16.00
0.00
1.42
90.00
16.00
0.00
0.00
93.00
16.00
0.00
2.62
95.05
0.00
0.00
0.00
100.00
0.00
0.00
15.01
93.90
21.80
0.00
22.50
91.97
100.00
1.00
0.00
97.00
0.00
0.00
0.00

%
Kg/Day
Nos.
Hours
%
Kg/Day
Nos.
Hours
%
Kg/Day
Nos.
Hours
%
Nos
Nos.
Hours
%
Nos
Nos.

87.3
0
0
90.6
84
0
0
89.4
84
0
0
28.84
81.88
11.00
1.00
19.45
83.88
7.00
1.00

88.46
0
0
63.42
88.46
0
0
62.58
88.46
0
0
20.19
87.26
7.70
0.00
13.62
87.26
4.90
0.00

93
0
0
48
93
0
0
29
100
0
0
16.00
83.00
9.00
0.00
16.78
85.00
6.00
0.00

93.42
0.00
0.00
5.55
93.35
0.00
0.00
1.80
96.62
0.00
0.00
6.18
89.90
8.00
0.00
9.70
86.46
0.00
0.00

1.95
100.00
0.00
0.00
1.05
97.04
0.00
0.00
20.63
90.45
7.00
0.00
22.35
95.19
3.00
0.00

95.00
0.00
0.00
0.00
100.00
0.00
0.00
0.00
99.00
0.00
0.00
14.31
90.03
9.00
0.00
23.35
93.26
1.00
0.00

Hours
%
Kg/Day
Nos.
Hours
%
Kg/Day
Nos.
Hours
%
Kg/Day
Nos.
Hours
%
Kg/Day
Nos.
Hours
%
Kg/Day
Nos.
Hours
%
Nos
Nos.
Hours
%
Kg/Day

7.7
5.39
92.48
95
0
0
0
0
7.57
5.3
94.15
95
0
0
0
0
5
3.5
85.33
91.05
0
0
1
0
43.2
30.24
95.43
88.46
0
0
0
0
3.24
2.27
91.22 88.219
10
7
1
0
18
12.6
80.33
87.26
3
2.1
1
0
3.57
2.5
76.15
81.32
0.13
0.09

0
95.48
0
0
1.77
96.83
0
0
7
91.98
0
0
0
100
0
0
2.99
88
17
0
13.23
90
2
0
1.5
81.5
0.053

1.18
96.09
0.00
0.00
2.70
95.63
0.00
0.00
6.00
89.79
0.00
0.00
0.00
98.30
0.00
0.00
0.00
96.00
16.20
0.00
17.58
93.07
4.00
0.00
0.00
87.36
0.06

2.00
96.12
0.00
0.00
0.00
97.23
0.00
0.00
1.00
93.00
0.00
0.00
2.70
92.59
0.00
0.00
0.00
97.00
15.80
0.00
9.33
94.44
1.00
0.00
10.00
85.00
0.06

0.00
97.00
0.00
0.00
1.06
96.50
0.00
0.00
0.00
93.00
0.00
0.00
1.65
98.00
0.00
0.00
5.38
92.00
16.00
0.00
21.04
90.52
4.00
0.00
2.00
82.70
0.10

Nos.

28.91
80.9
24
1

20.24
80.29
16.8
0

Hours
%
Nos./Month
Nos.
Hours
%
Kg/Day
Nos.
Hours
%
Kg/Day
Nos.
Hours
%
Kg/Day
Nos.

22.45
16.8
73.703333 86.4675
4
2.8
1.75
0
5.52
3.86
87.28
89.02
0
0
0
0
0.52
0.4
94
95
0
0
0
0
49.75 34.825
76 88.219
16.7
11.69
0
0

Hours
%
Nos./Month
Nos.
Hours
%
Nos./Month
Nos.
Hours
%
Kg/Day
Nos.
Hours
%
Kg
Nos.
Hours
%
Nos.
Nos.
Hours
%
Nos.
Nos.

25.34
19
21.09
73.703333 86.4675 86.4675
4
3
2
1.75
0
0
16.75
12.6
10.18
73.703333 86.4675 86.4675
3.75
3
3
1.75
0
0
6.52
5.22
0
86.91
88.64
92.6
0
0
0
0
0
0
22
15
6.5
89
93
93.89
0.13
0.09
0.1
0
0
0
19.08
14.3
11.40
73.1
79.8
82.3
2
2
4
1
0
0
19.25
14.4
32
73.781667 80.3363
74.2
4.33
3
3
1
0
0

Hours
%
Nos
Nos.

0.00

0.00

0.00

19.32
83.9
19
0

11.63
92.11
6.00
0.00

18.73
91.33
22.00
0.00

14.54
92.70
26.00
0.00

46.13
80.34
3
0
0
100
0
0
3
95.73
0
0
0.73
93
16.2
0

46.13
80.34
3.00
0.00
0.00
100.00
0.00
0.00
3.00
95.73
0.00
0.00
0.73
93.00
16.20
0.00

43.28
76.82
5.00
0.00
3.00
97.20
0.00
0.00
0.75
96.25
0.00
0.00
4.09
93.00
15.80
0.00

15.11
81.43
0.00
0.00
1.24
98.00
0.00
0.00
0.60
98.00
0.00
0.00
1.30
88.00
16.00
0.00

Hours
%
Kg/Day
Nos.
Hours
%
Kg/Day
Nos.
Hours
%
Kg/Day
Nos.
Hours
%
Kg/Day
Nos.
Hours
%
Kg/Day
Nos.

4.3
94.2
17.1
0
6.52
86.91
0
0
9.16
90.7
0
0
7.83
86.75
0
0

2
95
15
0
4.57
90.5
0
0
6.82
92
0
0
5.4
89.75
0

2
94
16
0
0
92.6
0
0
2.03
95.75
0
0
3
94
0
0

Hours
%
Kg/Day
Nos.
Hours
%
Kg/Day
Nos.
Hours
%
Kg/Day
Nos.
Hours
%
Kg/Day
Nos.
Hours
%
Nos/Month
Nos.
Hours
%
Nos/Month
Nos.
Hours
%
Kg/Day

1.51
84.41
0
2

1.4
86.97
0
0

0
0

6
92
0
0

4.2
94
0
0
5.3
95
0

35.01
24.51
78.11
83.58
19
13
0
0
14.07
9.849
84.7 88.525
4
2.8
0
0

Nos.
Hours
%
Kg/Day
Nos.

Tracking will start October onwards.


Hours
%
Kg/Day
Nos.
Hours
%
Kg/Day
Nos.
Hours
%
Kg/Day
Nos.
Hours
%
Kg/Day
Nos.
Hours
%
Kg/Day
Nos.
Hours
%
Kg/Day
Nos.
Hours
%
Nos/Month
Nos.
Hours
%
Nos/Month
Nos.
Hours
%
Nos/Month
Nos.
Hours
%
Kg/Day
Nos.
Hours
%

Kg/Day
Nos.
Hours
%
Kg/Day
Nos.

Apr-15

May-15

Jun-15

Jul-15

Aug-15

Sep-15

66.60
81.10
46.00
0.00

24.23
92.09
28.00
0.00

30.18
89.89
23.00
0.00

16.11
87.66
30.00
0.00

17.60
93.60
33.00
0.00

25.00
88.80
19.00
0.00

18.25
94.49
18.50
0.00

7.67
95.00
20.00
3.00

6.30
96.30
23.40
0.00

6.40
97.00
24.00
0.00

3.79
96.00
22.00
0.00

11.20
96.60
23.24
0.00

3.00
95.08
0.00
0.00
2.25

96.24
0.00
0.00
0.00
0.00
0.00
0.00
0.00
99.11
0.00
0.00
22.90
58.90
101.00
0.00
17.20
88.40
6.00
0.00

0.00
94.95
0.00
0.00
0.00
98.34
0.00
0.00
2.00
92.00
0.00
0.00
0.00
96.00
0.00
0.00
7.17
95.00
16.20
0.00
5.81
89.01
1.00
0.00
1.00
87.25
0.10

0.00
99.00
0.00
3.00
0.00
98.00
0.00
3.00
0.00
94.00
0.00
0.00
0.60
97.50
0.00
0.00
0.00
93.00
18.00
0.00
4.90
94.50
4.00
0.00
1.00
88.12
0.08

0.00
98.30
0.00
0.00
0.00
98.19
0.00
0.00
0.00
91.00
0.00
0.00
0.00
98.03
0.00
0.00
0.00
96.00
14.00
0.00
16.15
94.00
3.00
0.00
1.00
87.25
0.10

0
99
0
0
0
98
0
0
2
87.02
0
0
0
100
0
0
3.52
96
17.8
1
20.57
88.35
5
0
0.00
89.57
0.08

0.00

0.00

0.00

0.00

10.24
87.70
27.00
0.00

18.96
88.85
33.00
0.00

36.78
89.48
34.00
0.00

17.18
88.23
14.00
0.00

42.78
86.20
30.00
0.00

10.60
83.19
4.00
0.00
0.00
99.04
0.00
0.00
0.75
98.00
0.00
0.00
0.00
98.00
16.20
0.00

14.22
82.89
5.00
0.00
0.00
89.90
0.00
3.00
0.90
98.83
0.00
0.00
1.54
86.00
18.00
0.00

13.01
87.93
2.00
0.00
0.00
93.60
0.00
0.00
2.05
97.59
0.00
0.00
0.00
93.00
14.00
0.00

18.18
89.00
11.00
0.00
0.00
98.00
0.00
0.00
1.50
96.34
0.00
0.00
0.00
98.24
0.00
0.00

38.00
83.89
0.00
0.00
0.00
100.00
0.00
0.00
0.30
98.79
0.00
0.00
0.00
100.00
0.00
0.00

13.16
83.00
4.00
0.00
0.00
100.00
0.00
0.00
0.30
97.32
0.00
0.00
0.00
91.00
0.00
0.00

21.40
85.50
2.00
0.00
33.30
71.30
0.00
0.00
2.82
90.97
0.00
0.00
12.05
92.17
0.10
0.00
11.40
82.30
4.00
0.00
32.00
74.20
3.00
0.00

15.27
90.37
1.00
0.00
9.81
76.27
23.00
0.00
0.00
90.97
0.00
3.00
9.70
94.58
0.09
0.00
26.79
84.05
5.00
0.00
42.18
80.38
1.00
0.00

32.72
85.36
0.00
0.00
29.81
81.80
6.00
0.00
1.97
95.50
0.00
0.00
13.30
93.39
0.10
0.00
18.90
80.05
3.00
0.00
14.54
72.72
0.00
0.00

26.90
89.90
1.00
0.00
18.18
82.05
12.00
0.00
1.20
95.70
0.00
0.00
3.38
95.20
0.06
0.00
16.72
88.30
1.00
0.00
0.00
0.00
0.00
0.00

40.00
89.45
3.00
0.00
26.40
90.00
1.00
0.00
0.00
96.78
0.00
0.00
4.70
93.43
0.10
0.00
51.50
85.38
1.00
0.00
0.00
0.00
0.00
0.00

35.30
90.13
2.00
0.00
2.90
91.80
2.00
0.00
0.00
95.04
0.00
0.00
7.40
93.16
0.09
0.00
9.70
94.03
4.00
0.00
0.00
0.00
0.00
0.00

1.54
95.00
16.20
0.00
2.82
90.97
0.00
0.00
0.00
98.21
0.00
0.00
7.00
87.00
0.00
0.00

0.00
97.00
18.00
0.00
0.00
90.97
0.00
3.00
2.20
92.80
0.00
3.00
9.00
86.00
0.00
0.00

0.00
95.00
14.00
0.00
1.97
95.50
0.00
0.00
0.00
95.59
0.00
0.00
9.00
88.00
0.00
0.00

2.32
83.00
13.30
0.00
1.20
95.70
0.00
0.00
0.00
95.30
0.00
0.00
0.00
87.00
0.00
0.00

0.00
98.00
15.70
0.00
0.00
100.00
0.00
0.00
0.00
95.25
0.00
0.00
6.00
93.00
0.00
0.00

9.98
97.00
17.80
0.00
0.00
100.00
0.00
0.00
0.00
97.70
0.00
0.00
6.00
86.94
0.00
0.00

23.40
88.80
0.00
0.00
0.00
92.00
0.00
0.00
0.80
97.00
0.00
0.00
0.00
98.10
0.00
0.00
0.29
99.90
1.00
0.00
11.77
88.14
2.00
0.00

40.05
88.41
0.00
0.00
7.20
94.00
0.00
0.00
0.00
97.46
0.00
0.00
0.00
98.00
0.00
0.00
14.00
65.30
30.00
0.00
18.06
89.60
4.00
0.00

38.70
92.78
0.00
0.00
12.20
82.82
0.00
0.00
0.00
93.70
0.00
0.00
0.00
95.00
0.00
0.00
45.70
56.80
115.00
0.00
3.50
91.07
1.00
0.00

m/c off shedule

SN

QIP : Specific Problem

Completed QIP Quarter II FY 14-15 : Nasik


1
Reduction of Mica defect in Non Truck tyres
2
Reduction of tyre scrap due to split cord in radial tyres
3
Reduction of RMS delay in mixing
4
Reduction of flow crack in tractor
5
Reduction Of Tread shoulder seperation in Truck

Elimination of missing cord in CANYLO

Reduction of shoulder separation defect in 7.00R15 milaze lt

8
9

Reduction in employee complaints


OE Yield Improvement in LCV & Radial sizes

10

Reduction in Band Loss due to trolley shortage

Completed QIP Quarter III FY 14-15 : Nasik


1

Reduction of Soap Solution consumption

Tyre stiffness improvement in 7.50-16 double bead sizes for


indonesian market

Re-engineering of 195R15 LT Steelplus in Nashik due to tyre


claim

Squegee blister reduction in all radial sizes

Reduction in Mix Carbon Scrap

Uniformity yield improvement in 185R14 LT Milaze

Reduction of squeegee blister in 195R15 Steelplus

Reduce utility power consumption

Reduction of customer complaint tread joint open in size 80018Aayusmaan

10

Elimination of Toe Flash in 59 J (While excess Sidewall stitching)

Completed QIP Quarter IV FY 14-15 : Nasik


1 Elimination of customer complaint No serial
2

Manufacturing Lead time reduction

scrap reduction in 8x6 Lt cold feed extruder

Reduction in FM defect in tractor sizes from 7.8% to 6.24%

Reduction of Premature by reducing turn up separation in 100020H CL HL sizes

Reduction of Customer complaint of groove crack in size 120024HT SUPER

To reduce the bead failure in premature & claim tires in 1020


Mile XL /HCL /HL

Productivity improvement in Non truck sizes.

Improve the Resolution of Bol Bindass Complaints


( Admin & Engineering related)
Asset identification
& tagging
in production
Completed
QIP Quarter
I FY 15-16
: Nasik. areas Band building, Extruder, Calendering/Bias cutter/Balancing
1
Machine,PCI units, Utility, Drums, Inspection m/c, vehicles &
machines
2 other
High set
up time in NTC
9

Improvement of cut tyre rating in all radial sizes to A & B rating


from C

High canteen cost

High trimming damage defect in eleveta sizes (NTC)

High Loss of production Due to unmix batch generation at Ban02

High premature claims due to breaker stretch

High Ply width variation on High table bias cutter at radial dept.

Low Productivity in banbury 02

Completed QIP Quarter II FY 15-16 : Nasik.


1

TRACKING WILL START OCT'15 ONWARDS

Reduction of breakdown hours due to drop door rubber jamming


phenomina

2
3
4
5
6
7
8
9
10
11
12
13
14
15

Elimination of Frequent side wall jam up in Separating conveyor


at 8x6 Booking area
Elimination of 7.5 MVA Transformer
Improvement of Fumes Extraction System at Banbury #1&2
Reduction of 4.00-8 tyre scrap due to Arm Damage
Radial tread Recutting

High time consumption during cut tyre analysis &


rating
Wrong die usage at 8*10 Extruder
Knifeless operation at banbury dump mill
Sq. Gauge variation at Truck 3 Roll calender
Deteriotion of fabric booking liners
High Water consumption
Over-size of tyres in Radial sizes
High Grease consumption in A Div
High oil consumption due to leakages

CEAT

QIP TRACKER FOR THE


KPI

%age
%age scrap in total scrap
%age Loss
Customer Complaints PPM
Premature Claims PPM

Name of leader

Base Line

Pratap Patil
Sonal Nerkar
Sharad Khairnar
NE Khade
Parameshwaran

1.5800
16.40%
0.24
207
1084

Kalaivendhan

78

Sudarshan
Anand Rahatekar
Sunil Malagi

2.34
60
67.12

Jeevan Tambat

6.59

Pratap Patil

0.0011

Kiran Shankar

44

Sudarshan

0.15

Sudarshan

0.32

Nitin Kolhe

0.112

Sudarshan

70

Sudarshan

9.6

Avinash Pradhan

34000

Kg

%age
No. per Month
%age
%age

Kg/Kg
Tyre defection (mm)
Task Achievement (ND PPM)
%age defect
%age Scrap
%age yield
%age Scrap
KWH

Customer Complaints for tread joint open NE Khade


%

N Parameshwaran

5
70

No serial Customer complaint

NE Khade

R Kedia

11.91

Dablu Kumar

10.77

Shifts.
%age Tread rejection for Light Truck Sizes
% Defect in tractor sizes
Premature claims due to Turn up
separation in 1000-20H CL HL sizes
(PPM)

Anil Pansare

8.1

N Khade

886

N E Khade

Shrikant Ghadge

224

Customer complaint (nos.)


PPM
%age Productivity

Kiran Sankar

Resolution %age

Anand Rahatekar

Task Achievement

Uday Mekhe

Task

Pravin Patil

244

Ankit Rana

77

Mins/Changeover
Monthly Cut tyre rating (%)

90

Rs. (Lacs)
Anand Rahatekar
%age trimming damage defect
Avg Min/month

Anil Pansare

3.40%

T Kalaivendhan

152

%age Non Compliance

Shrikant Ghadge

Process capability, Cp of bias cutter

K Sudarshan

%age

60.35%
0.28

T Kalaivendhan

G WILL START OCT'15 ONWARDS


Brk down Hrs/Month

Pradeep Subedarpage

37

Brk down Occurences


Cost in Lakhs
Muri Reduction
Tyre scrap in No's
Quality
Time in Mins/Section
Technology
No of accident
Gauge in MM
Nos
Kg/Kg
Customer Complaints in No's
Grease consumption (Kg)
Oil consumption in liters per month

Prashant Kage

14

Sanjay Pagare

24

Pradeep Subedarpage

Vinayak Pote

23

K Apparao
Shrikant Ghadge
Dablu Kumar
Raj Parvatikar
Abhijeet Dushing
Bhushan Joshi
Mukul Karande
Ankit Rana
Raj Parvatikar
Pradeep Subedarpage

Task Achievement

CEAT Limited

ACKER FOR THE MONTH OF: SEPTEMBER'15


Res/Tgt

1.4000
12%
0.12
154
867

39
1.5
20
88.07
4.41

0.0009

Sep-14

Oct-14

Nov-14

Dec-14

Jan-15

1.30
9.77%
0.00
686.00

1.40
7.10%
0.08
0.00
164.52

1.30
9.10%
0.06
0.00
434.05

1.20
21.00%
0.08
0.00
338.00

1.10
14.47%
0.04
0.00
295.00

29.00

34

35

30

36

1.48
21.00
86.00

1.31
20.00
86.00

1.10
15.00
87.77

0.83
14.00
86.46

3.53

0.86

0.89

0.85

0.0009

42
0.07

0.05

0.16

0.05

0.03

0.001

80

69.00

1.92
30000
0
56

0.52
30649
0
12.0

9.92
8
6.48

708

0
124
10%
95
Achieved
209
100

0.50%
76
36.21
1.33

14

0
0
2
0

Task Achievement

Feb-15

Mar-15

Apr-15

May-15

Jun-15

1.70
34.34%
0.11
0.00
796.00

1.10
19.18%
0.28
0.00
910.00

1.46
4.54%
0.11
0.00
940.00

1.10
4.50%
0.09
0.00
877.00

0.02
0.00
1994.00

1.17
3.04%
0.07
0.00
1489.00

65

38.00

16.00

38.00

10.00

38.00

0.49
15.00
87.45

0.20
5.00
82.77

0.39
13.00
90.50

0.35
3.00
89.72

0.86
6.00
89.25

0.22
6.00
89.50

0.77

1.65

1.83

3.23

2.80

1.48

0.0009

0.0009

0.0009

0.0009

0.0009

0.00098

0.80

Jul-15

Size not Run in the


Month of July'15
0.06

0.07

0.07

0.07

0.07

0.07

0.02

0.13

0.11

0.00

0.01

0.01

0.0010

0.0036

0.0040

0.0030

0.0020

0.0015

72.00

69.00

92.00

89.00

87.00

77.00

0.18

0.18

1.35

0.06

0.33

0.47

30122

28959

28527

28662

30196

30219

14.0

13.5

19

15

16

10

9.5

9.6

9.7

9.4

9.75

9.90

8.00

9.20

10.58

10.35

7.32%

5.71

4.71

616.00

285.00

546.00

882.00

15%

15%

15%

15%

95%

87%

115

74

One Time

One Time

One Time

One Time

5.20

232
100.00
one more month
for assesment
0.00
45.00
15%
1.33
5.59% (Task
Achievement)

Aug-15

Sep-15

0.90
8.87%
0.06
0.00
749.00

1.04
12.60%
0.09
0.00
234.00
QIP tracking completed
for 12 months

38.00

Tracking done for 12 months.

0.41
6.00
91.81

0.76
6.00
91.00

2.72

0.91

0.00100

0.00097

Size not Run in the


Month of Aug'15

Size not Run in the


Month of Sept'15

0.07

0.06

0.04

0.02

0.0010

0.0000

87.00

90.00

0.90

0.43

30904

30139

18

15

9.96

9.45

6.3

9.07

4.35

5.00

364.00

0.00

15%

15%

89

119.86

One Time

One Time

211

200.19

100.00

83.33

Till Aug '15 Saving


is 1.5
Till Sept '15 saving is
lakhs/month(Appro Approx 3 Lakhs/month.
ximate )
0.00

0.00

72.00

0.00

11.96%

21.57

2.55

3.00

5.59% (Task
Achievement)

5.59% (Task
Achievement)

5.40

5.30

Tracking will start


Oct'15 onwards