Initial Control 1 Total slides : 16 Total time : 10 min.

Contents Aim DM Organization Structure Summery of Component Development Activity Involved in clutch component Development Summery of Major Action taken on lead time reduction Future Plan

Aim To reduce Development Lead Time by systematic monitoring and control Development Activities

Mr. T.N.Kandakure CEO Mr. Farooq Shaikh DM Pillar Chairman Mr. Shinde M.A TPM Coordinator Mr. Sudhir Kumar CNC Mr. Gorakh Gande Wire Cut Mr. Pawra Tool Room Mr. Potdar QA Mr. R.B. Bhusare Die Designe DM Structure

Summary of component development Sr. No. Name of the component Pertaining to which ETL Plant Developmen t start date Developmen t end date Total Lead time in no of Days 1 Plate Clutch Piaggio HTTS26/08/200927/10/ Formed Plate Clutch Piaggio HTTS26/08/200901/11/ Formed Core Plate Clutch M&M HTTS04/08/201002/09/ Clutch outerHTTS09/09/201001/11/ Moving pulleyHTTS02/09/201019/10/ Fixed pulleyHTTS02/09/201019/10/ Holder clutch 3w4s HTTS29/10/201106/11/

Summary of component development 2012 Sr. No. Name of the component Pertaining to which ETL Plant Developmen t start date Development end date Total Lead time in no of Days 1 U Type Bracket Assly. ETPL E-9206/06/201223/06/ Piston rod PlatedETPL E-9201/03/201225/04/ Shoe Web Bracket Disc Break division12/12/201125/03/ Core plate HeroHTTS15/06/201216/08/ Driving plate reduce HTTS10/06/201228/06/

Activity involved in clutch component development Sr. No Activity involved Earlier lead time in days Current Lead time in days % reduction of Lead time 1 Ensure availability of the Raw Material Design & order for required tools Study of required inspection facility Order for required gauges Design of process flow with Work Instructions & Control plan Sample Submission4250 7PPAP submission4250 Total ( Days)8437 More than 50% 7

Summary of major actions taken on lead time reduction Sr. No. Actions Taken Lead time reduction in no of days 1Tool room shifted from Pune to Aurangabad Shendra plant.5 2Added rotary grinding M/C in in-house tool room5 3 Added one more imported submerged wire cut M/C in in-house tool room 2 4Established own engineering facility for tools & fixtures design2 5Developed local source for raw material, gauges etc2 6Deputed expert team for first time right sample3 7 Added one Digital Height measuring instrument (Trimos) for critical parameters inspection at in house. 2 8Added one more surface grinder with high accuracy4 9 Added one more source for Heat treatment (Automated Heat treatment at Shantdeep Metals) 3 10Added one more Jig Boring M/C4 11Added one more High accuracy DRO M/C4 12 Added One dedicated 150T Hydraulic Press for Trial in the tool room 2 8

Summary of major actions on lead time reduction Sr. No. Actions Taken Lead time reduction in no of days 13 Started to use Standardize Pillar Sets, Bottom Plate, top plate, Pillar Bush with ball cage & striper plates in the tooling 3 14Started to use standard Nitrogen Gas springs in the tooling's2 15 Started to use 3D Catia Software for design to avoid trial error method of time consuming 1 16Developed local source for heat treatment at Waluj' area3 17 Added One more imported Sodick Make CNC wire cut M/C in in- house tool room 5 18Added Two SPM welding & sizing process for shoe web component65 19Added One more pneumatic 160 T press M/C in in-house tool room2 20 Added One High accuracy 300 T Fine Blanking M/C in in-house tool room 7 21Added Two dedicated 25 T Hydraulic Press for Trial in the tool room3 22Added Two more pneumatic 10 T press M/C in in-house tool room2 23Added two 50 KVA spot welding M/C5

Lead Time Reduction Improvement Sheet Zone name/no :- Tool Room 10 Added One more pneumatic 160 T press M/C in in-house tool room

Lead Time Reduction Improvement Sheet Zone name/no :- Tool Room 11 Added One SPM Auto welding process for shoe web component

Lead Time Reduction Improvement Sheet Zone name/no :- Tool Room 12 Added SPM Auto Sizing (Radius Type)process for shoe web component

Lead Time Reduction Improvement Sheet Zone name/no :- Tool Room 13 Added One High accuracy 300 T Fine Blanking M/C in in-house tool room

Lead Time Reduction Improvement Sheet Zone name/no :- Tool Room 14 Added Two dedicated 25 T Hydraulic Press for Trial in the tool room

Future Plan Sr. No Plan Target Date Status 01 To procure one new Imported CNC Wire cut Machine of Sodick Make Mar-2012 Come To Make separate shop floor for tool room to avoid vibration impact on CNC machines May-2012 Come To Add one VMC Machine for In house tools machining U/M 04 To procure new profile Projector & CMM U/M 05 To add one 250 T Pneumatic press M/C at tool roomJuly - 12Come. 06 To Develop nickel corm plating process in house at Our DAP plant waluj. July - 12Come.

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