Copyright, Confidential, Tata Motors Ltd

Slide 1

FSOK LINE-1
87

Line 1 FSOK
86

BETTER

86

85 85

84 84

83 83

82 82

81

80 Sep'13 Oct'13 Nov'13

Copyright, Confidential, Tata Motors Ltd

Dec'13

Jan'14
Slide 2 Line 1 FSOK

MODELWISE MAJOR CONTRIBUTORS

140

120

100

80

Sep'13

Oct'13 60 Nov'13 Dec'13 40 Jan'14

20

Copyright, Confidential, Tata Motors Ltd

Slide 3

MODELWISE MAJOR CONTRIBUTORS SEP13

80 70 60
50

TS/PPC/NPI/ADD/ERC TCL Plant-III Material Handling

40 30 20 10 0 LPT 2518 LPT 1613 LPT 3118 SK 1613 LP 1512 LPT LP SE 1613 SE LPT 3118TC 1512TC 1613TC 2518TC Copyright, Confidential, Tata Motors Ltd SK 1613TC

Material Defect HVAL Frame Shop Engine Deficiency Assembly Line-1

Slide 4

MODELWISE MAJOR CONTRIBUTORS OCT13

100

90

80 TS/PPC/NPI/ADD/ERC 70
TCL

Plant-III 60 Material Handling

Material Deficieny

50

Material defect HVTL

40

HVAL

Frame Shop 30 Engine

Assembly Line-1

20

10

0 SK 1613 LPT 1613 LPT 2518 LPT 3118 SE 1613 LP 1512 LPT 1512 LPT 2518TC Copyright, Confidential, Tata Motors Ltd LPT 3118TC SK 1613TC
Slide 5

MODELWISE MAJOR CONTRIBUTORS NOV13

140

120

100

TS/PPC/NPI/ADD/ERC

TCL
Plant-III 80

Material Handling
Material defect

HVAL 60 Frame Shop

Engine

Deficiency
Assembly Line-1

40

20

LPT 1613

SK 1613

SE 1613

LPT 2518

LPT 3118 Confidential, LP 1512 Tata LPT 3118TC Ltd SK 1613 TC Copyright, Motors

LPT 1613 TC

Slide 6

MODELWISE MAJOR CONTRIBUTORS DEC13

30

25

20

TS/PPC/NPI/ADD/ERC
TCL

Plant-III 15
Material Handling

Material defect
HVTL

HVAL
10 Engine

Deficiency
Assembly Line-1 5

Copyright, Confidential, Tata Motors Ltd

Slide 7

MODELWISE MAJOR CONTRIBUTORS JAN14

120

100

TS/PPC/NPI/ADD/ERC
80

TCL
Plant-III

Material Handling
60

Material Defect

HVTL HVAL
Frame Shop
40

Engine Assembly Line-1

20

SK 1613

LPT 3118 LPT 1613

SE 1613

LP 1512

LP1512 LPT1613 LPT3118 TC TC Copyright, Confidential, Tata Motors Ltd TC

LPT 2518 LPK 2518

Slide 8

TOP 5 MODELWISE CONTRIBUTORS

120

100

80 Assembly Line-1 Engine Frame Shop HVAL HVTL Material Defect Material Deficieny Material Handling Plant-III TCL TS/PPC/NPI/ADD/ERC

60

40

20

LPT 1613

LPT 2518

LPT 3118

SE 1613

SK 1613
Slide 9

Copyright, Confidential, Tata Motors Ltd

PARETO ANALYIS- SK 1613

140 117 89 83 79 68 60 52 51 40 40 31 21
20

120

120

93

96

98

99

100

100 100

100 70

80

80

60

15

20 11 7 6
2

1 0

Occurance
Copyright, Confidential, Tata Motors Ltd

Cum. Percentage
Slide 10

MAJOR CAB & COWL DEFECTS- SK 1613

20
20

18

16
16

14

12

10

9
8
8

2
2

2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

Occurance

Copyright, Confidential, Tata Motors Ltd

Slide 11

MAJOR MATERIAL DEFECTS- SK 1613

18

18 16 14
14 12

10 8 6

9
7

4
4 2

4 3 2 2 2 2 2 1 1 1 1 1 1 1 1 1 1

Copyright, Confidential, Tata Motors Ltd

Occurance

Slide 12

MAJOR INPROCESS DEFECTS- SK 1613

18

17

16
14

13

12 10
8

6 6
4

2 2
0

2 1 1 1 1 1 1 1 1 1 1 1 1 1

Copyright, Confidential, Tata Motors Ltd

Occurance
Slide 13

MAJOR HANDLING DEFECTS- SK 1613

35

33

30

25

20

14
15

10

3 1
Dent/ Damage due to handling Paint scratch Broken Dirty

0 Occurance
Slide 14

Copyright, Confidential, Tata Motors Ltd

PARETO ANALYIS- LPT 1613

120 106
100 91 94

120

97

98

99

99

100

100 100

80

76

80 68

80

60 56 41
40

60

38

37

40

33 20 9 0 9 3 3 2
1 1

20

Copyright, Confidential, Tata Motors Ltd

Occurance

Cum. Percentage Slide 15

MAJOR MATERIAL DEFECTS- LPT 1613

18 17

16

15

14

12

11

11

10

7 6

5 4

2 2
1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

Occurance
Copyright, Confidential, Tata Motors Ltd
Slide 16

MAJOR CAB & COWL DEFECTS- LPT 1613

16 15

14

12

10

8 7 6 6 4
4

4 3 3 3
2 2 2 2 2 2 1 1 1 1 1 1 1 1 1 1 1 1 1

Occurance

Copyright, Confidential, Tata Motors Ltd

Slide 17

MAJOR HANDLING DEFECTS- LPT 1618

20
20 18 16 14 12
10

13

8
6

4
2

1
Bolt broken

1
Leakage

1
Puncture
Occurance Slide 18

Dent/Damage during handling

Scratch

Defective

Paint scratch

Copyright, Confidential, Tata Motors Ltd

PARETO ANALYIS- LPT 3118

80 70 70 60 85 80 50 40
30 69 93 96

120

98

99

100

100 100

90

72 57 37 33 40 60

20 10
0

29 12 8 7 3 3
2 20

1
0

Occurance
Copyright, Confidential, Tata Motors Ltd

Cum. Percentage
Slide 19

MAJOR MATERIAL DEFECTS- LPT 3118

14 14 12 10 8
8 7 7

6
4 4

4
2

3 2 2 2
1 1 1 1 1 1 1 1 1 1 1

Occurance
Copyright, Confidential, Tata Motors Ltd
Slide 20

MAJOR INPROCESS DEFECTS- LPT 3118

8
8

7
7

6 6

5 5

4 4

Occurance

Copyright, Confidential, Tata Motors Ltd

Slide 21

MAJOR CAB & COWL DEFECTS- LPT 3118

7 7

5 4
4

3
3

2 2 1 1 1 1 1 1 1 1 1

Copyright, Confidential, Tata Motors Ltd

Occurance
Slide 22

MAJOR HANDLING DEFECTS- LPT 3118

16

15

14

12

10

3 2 2 1 1 1 1

0 Dent/ damage during handling Scratch Broken Lug Broken Paint scratch Defective Orientation wrong Pipe missing Switch missing
Occurance

Copyright, Confidential, Tata Motors Ltd

Slide 23

PARETO ANALYIS- LPT 2518

80
70

120 69 61 93 77 40
97

98

99

100

100

60 50 40 30

80

59

34

60

40 20
10 31

9 3 2 2

20

Copyright, Confidential, Tata Motors Ltd

Occurance

Cum. Percentage Slide 24

MAJOR INPROCESS DEFECTS- LPT 2518

12
11

10

8
8

4 4

3 2 2 2 2 2 2 2 2
1 1 1 1 1 1 1 1 1 1 1 1 1

Copyright, Confidential, Tata Motors Ltd

Occurance Slide 25

MAJOR MATERIAL DEFECTS- LPT 2518

9 9 8
8

7 6 6
5 4 4 4

4 3 3 2
2

2 1 1 1 1 1 1 1 1 1 1

1 0

Occurance
Copyright, Confidential, Tata Motors Ltd
Slide 26

MAJOR CAB & COWL DEFECTS- LPT 2518

9 9

8 8 7 6
6

5 4 3 3 2 2
1 1 1 1 1 1 1 1 1 1 1 1 1

Occurance
Copyright, Confidential, Tata Motors Ltd
Slide 27

PARETO ANALYIS- SE 1613

60 120

50

48 89 93 95

97

98

99

99

100 100

40

83 37 76

80

30

57

28

60

20
32

40

10 10

20 5 3 3
2

1 0

Occurance
Copyright, Confidential, Tata Motors Ltd

Cum. Percentage
Slide 28

MAJOR CAB & COWL DEFECTS- SE 1613

8

8 7
6

6
5

4 4
3 3 3

3 2 2
1 1 1 1 1 1 1 1 1 1 1

1
0

Occurance
Copyright, Confidential, Tata Motors Ltd
Slide 29

MAJOR MATERIAL DEFECTS- SE 1613

8

8 7
6

6
5

5 4 4 3 2 2 1 1
0

2 1 1 1 1 1

Copyright, Confidential, Tata Motors Ltd

Occurance

Slide 30

MAJOR INPROCESS DEFECTS- SE 1613

3 3

2.5
2 2 2 2 2 2

1.5
1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

0.5

Copyright, Confidential, Tata Motors Ltd

Occurance

Slide 31

MULTI LAYERED PARETO SUMMARY LINE 2

Model

Agency

SK 1613

Plant-3

Material defect

Assembly line-1

Material Handling

Deficiency

LPT 1613

Material defect

Plant-3

Material Handling

Deficiency

Assembly line-1

LPT 3118

Material defect

Assembly line-1

Plant-3

Material Handling

TCL

LPT 2518

Assembly line-1

Material defect

Plant-3

Material Handling

TCL

SE 1613

Plant-3

Material defect

Assembly line-1

Engine

Material Handling

Copyright, Confidential, Tata Motors Ltd

Slide 32