QUALITY AND ENVIRONMENT MANAGEMENT SYSTEM

Krishna Maruti Ltd. Seat Division

Performance Improvement by implementing TQM

TERM PAPER PRESENTATION Submitted by: Pryank Malik 2009 SMF 6613

SML - 715

Company Introduction
Krishna Marutis share of business in Indian Market
34%
66% Krishna Maruti Others

Product: Established in:

Automotive Seating System 1994

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TQM Values Adopted

Customer First

Kaizen

Total Employee Involvement

A Strong Winning Team

Respect for Individual

Standardization

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Approach

Product Quality Improvement and Cost Reduction Improvement in relationship of trust

With Customers With Vendors
JIT and eNagare Guidance, training and involvement of vendors

Cordial Relationship with the Society

Product Innovations and development
Patents applied for new concepts
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Approach

Product Quality Improvement and Cost Reduction Improvement in relationship of trust

Cordial Relationship with the Society Product Innovations and development

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Product Quality Improvement

The focus shifted towards TQM Journey The objective was to achieve First Time Right Customers First

Operator skill enhancement POKA YOKE - jig design, spot welding sensor, et al.

QUALITY
Strict adherence to SOP (standard operating procedure) Quality Improvement through Quality Circle activities
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Cost Reduction
Seat Cost Breakup
Manufacturing Cost

Overhead Material Cost

Material Cost Reduction (Vendor End) Manufacturing Cost Reduction

Yield improvement for metals & PVC/Fabric Development of alternate material for PU used for seat pads Technology up-gradation

Implementation of lean manufacturing principle Focus on cost reduction of energy, manpower through increased productivity, et al. Process technology up-gradation Attack on cost due to poor quality Introduction of Employee Suggestion Scheme
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For 13/11/2010

employee motivation, special Cost Saving Award given to the suggestor

Approach

Product Quality Improvement and Cost Reduction Improvement in relationship of trust

Cordial Relationship with the Society Product Innovations and development

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Improvement in Relationship of Trust

Use of IT & eNagare b/w customer, KML & vendors through indigenously developed Extranet

Vendors
Extranet is also used to communicate important matters regarding Quality, late deliveries, cost, etc. with vendors

Customers

KML
Vendor Upgradation Process Flow Cluster Approach

Vendor cluster formation

Inaugural meeting with CEO/COO

Monthly meeting at one of the vendor end followed by plant visit

Quarterly review of vendors with CMD 13/11/2010

Monthly follow up visits & performance monitoring

Implementation of planned activity 9

Total Employee Involvement

Improvements Decentralized Decision making
Suggestion Committee

Cultural Activities
Annual Day celebration

Social Activities
Employees and their families involvement in rural development

Suggestions

Quality Circles

Price Negotiation Committee

Annual trips

CMD address to KML team for monthly performance

5S Committee

Get togethers

Initiation of TPM activities

Safety Committee

Religious trips

Festival celebrations 13/11/2010 10

Approach

Product Quality Improvement and Cost Reduction Improvement in relationship of trust

Cordial Relationship with the Society Product Innovations and development

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Relationship with the Society

Corporates are created by society and they must, therefore, serve it and not merely profit from it. -Ashok Kapur, Chairman KML

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Approach

Product Quality Improvement and Cost Reduction Improvement in relationship of trust

Cordial Relationship with the Society Product Innovations and development

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Product Innovation
Easy Seat
To make a seat for those who face difficulty while entering and coming out of the car. Currently in the Indian market no such automotive seating is available.

Patent Applied

Received Design Excellence Award from National Institute of Design

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New Product to be developed for Indian market

Brain storming sessions held to find the new innovative product for Indian market Out of the 4 ideas generated, seat for handicap people was selected for further development Characteristics of the seat should be
The seat should rotate, come out or near to the gate of the vehicle for easy entry and exit of the disabled people

First prototype was made using office chair Feedback from the Orthopedic doctor was taken KML arrange for Market Survey with Orthopedic doctors, actual users, Engineers, etc.
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New Product to be developed for Indian market

Following highlights were come out from survey

1. Speed of rotation to be fast 2. Seat operation should be automatic 3. Seat cost, et al.

3rd prototype was made using QFD (quality function deployment) Detailed designing of seat mechanisms, assemblies and sub-assemblies to qualify for the safety regulations is done
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Advanced R&D
New R&D facility
A strong centralized R & D Center (first of its kind in country) has been established with an investment of $ 1.5 Million
This center is the best in the country and is recognized by the Department of Scientific & Industrial Research, Ministry of Science & Technology, Govt. of India This center is capable of not only testing as per International Standards but can also issue Test Certificates to other Seat manufacturers This test center can also perform test for non - Automotive components for Endurance & Repeatability

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Policy Management
Daily Work Management
Initially DWM was started in production, QA and maintenance
This showed an improvement in shop floor activities such as achieving production targets, increase in productivity, reduced reqork, etc. This was largely due to employees involvement in morning meetings, PDCA approach. Then, each HOD practiced DWM Monthly, Quarterly and Annual PDCA Cycle to review progress

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Policy Management

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Cross Functional Management

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Problem Solving

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Deep Analysis

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Overall Results of TQM

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Overall Results of TQM

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Overall Results of TQM

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Overall Results of TQM

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Overall Results of TQM

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Overall Results of TQM

Intangible Effects
Enhanced Customer Satisfaction
Improved Product Quality Motivated Employees A strong winning team Knowledge based organization

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Summation of the Concept

KML achieved all this in short span of time. They call it as 6F principle
Focused: Focus towards customer delight, engineering infrastructure, cost consciousness and continuous improvements through '5-S', 'Kaizen', Quality Circle Meetings and Suggestion Meetings Fast: Fast system & technological up - gradation and implementation

Flexible: Flexible towards customer requirements

Friendly: Creating friendly environment among customer, employees & vendors

Firm: Firmly adhering to laid down policies & procedures

Fun: Achieving the targets in stipulated time

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Key Success Factors for TQM Implementation

Top Management Commitment

Total Vendors Involvement

Total Employee Involvement

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References
Mr. Sanjeev Saxena, IT Department, Krishna Maruti Ltd. Mr. Krishnamurthi Ayyar, Production Department, SKH Auto Mr. Sanjay Malik, HoD, Design Department, Krishna Maruti Ltd. Literature of Quality Policy and TQM Initiative provided by Krishna Maruti Ltd. Companys website - www.krishnamaruti.com

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