QUALITY CIRCLE FORUM OF INDIA VADODARA CHAPTER Telephone: 0265-2976242 E-mail: [email protected], [email protected] Changing Business Environment Challenges for GSFC Marketing Team CHANGE IMPACT OF SOFTWARE Aeroponics is a way of growing plants without soil and with very little water. Plants are put into special horizontal boards in such a way that the top of the plant, the crown and the roots are suspended in the air. Cultured meat production claim that from 10 muscle cells of posk or beef they can produce 50,000 tons of corresponding meat. Raising livestock takes huge toll on the environment, including water and feed that animals consume, the methane and waste they emit. Modern meadow is a 3 year old biotech start up working to develop meat by growing animal cells and not the whole animal. THE GSFC STORY GSFC Turnover details of last 5 years Financials of GSFC (Rs. in Crores) S.No. Particulars 2015-16 2014-15 2013-14 2012-13 2011-12 1 Net Sales 6163.33 5324.57 5412.49 6253.3 5301.83 2 Other Income 64.21 101.93 157.05 138.09 162.08 3 Total Revenue 6227.54 5426.5 5569.54 6391.39 5463.91 4 Less : Operating 5548.49 4733.92 4883.66 5455.37 4167.19 Expenses 5 Operating Profit 679.05 692.58 685.88 936.02 1296.72 6 Profit before taxes 548.12 573.91 495.42 767.72 1113.35 7 Profit after taxes 379.85 400.51 342.17 518.1 757.57 Last 5 years turnover of some major companies (in Rs Crs.) 12000 Turnover 10000 8000 2011-12 6000 2012-13 Axis Title 2013-14 4000 2014-15 2015-16 2000 0 Tata Chemicals RCF Kribhco GSFC Deepak GNFC GACL CHANGES OVER THE YEARS. 1. New Companies 2. Importers 3. Information era. 4. Government Policy THE GSFC ADVANTAGES ACHIEVEMENTS OF GSFC: •First company to adopt the steam Naphtha Reforming process for manufacture of Ammonia. •GSFC has set up the first DAP fertiliser complex in India, at Sikka, Jamnagar Gujarat. •GSFC is the first company in India to establish a Caprolactum plant. This was in the year 1974. This led to manufacture of downstream products like Nylon yarn, tyre cords etc. •GSFC is the first company to recover ARGON gas from purge gas in 1981. •GSFC also has to its credit setting up India’s first Melamine plant. •GSFC has a market presence of 55 years and carved an impeccable image in the Indian Marketing scene. •GSFC has excelled in integration of technologies, brilliant innovative research, having created a product mix ranging from more than 24 brands of fertilisers to petrochemicals, chemicals, the industrial gases, plastics, fifers and other products. • Strong Company with high reputation Expansion Plans. Huge Goodwill • Product acceptability Awareness and Interest. MARKETING TEAM • Advantage to be part of GSFC team. • GSFC selects Cream of talent. • Qualification, Aptitude and Attitude. • High level of training Proactive, Modern, practical and effective. • Marketing : process of planning and executing the conception, pricing, promotion, and distribution of ideas, goods, and services to create exchanges that satisfy individual and organizational goals. It is indeed a matter of pride for the employee’s to be an integral part of GSFC, and working in the GSFC family, contributing to the Corporate growth and National growth. They should as a member of GSFC family to pursue the path of excellence, to deliver according to the new challenges and Market scenario. Every member of GSFC family has to raise the performance bar and make a positive and tangible difference to make the organisation to achieve the goals. CASE STUDIES . Scientifically designed . Related to daily work zone . Related to your knowledge experience and insight . Simple format . Research, compile responses . Opportunity to be creative acknowledged and add to the growth of the company. Welspun Group ABOUT QCFI WELSPUN INDIA LIMITED FACTORY: VILLAGE: MORAI, VAPI, GUJARAT – 396 191 HEAD OFFICE: WELSPUN HOUSE, 6TH FLOOR, SENAPATI BAPAT MARG, LOWER PAREL, MUMBAI – 400 013. Welspun India Ltd (Overview) . Inception its journey in 1985 with a small textile unit . Located at - Vapi and Anjar, Gujarat . Global leadership position in Line Pipe and Home Textiles . Largest Home Textiles Player in the World – HTT . Largest Bath Towels Supplier . 2nd Largest Bedding Supplier . 3th Largest Bath Rugs Supplier . Exports more than 35 countries . Exports contribute 94% of the revenue . Integrated facility from raw cotton to finished product. Products - Terry Towel, Rugs & Carpet, Bathrobe & Bed Linen Welspun Corporate Overview Welspun India Welspun Corp Welspun Syntex Ltd. Ltd. Ltd. Welspun Power Welspun Plate Welspun Retail & Steel Ltd. & Coil Mills Ltd. Welspun Welspun Natural Welspun Max Tubular LLC Resources Ltd. steel Ltd. Welspun Global Welspun Welspun Brands Ltd. Investment Ltd. Infratech Ltd. Welspun Energy Ltd. Our Different Products… 9 Core Values Adaptability Collaboration Dare to Risk Customer Innovation Integrity Centricity Inclusive Technology Speed Growth OurTop Customers Worldwide REVMAN TQM is defined as a continuous effort by the management as well as employees of a particular organization to ensure long term customer loyalty and customer satisfaction It is a strategy for continuously improving performance at every level Effective utilization of time, inventory, space, people and money Steps for Continuous improvement… Cost Saving • Name of Dept.: m/c tufting • Name of Project: Reduction in downgrade due to mending • Name of Project Owner: Mr Kundan kumar/Arvind pandey and team • Description of project: To minimise mending defective p/c • Benefits of Project internal / External: cost saving COST ACTUAL ACTUAL TARGET TARGET PROJECT BP Target SAVING (IN (PC) (%) (PC) (%) NAME INR) DURING 511 0.12 158410 CURRENT DOWNGRA PROJECT DE DUE TO 1288 0.14 0.1 POST MENDING 237770 767 0.1 PROJECT ESTIMATIO N PLAN 1. Define the Problem 2.Collect Data 3.Ascertain root cause Improper Improper finishing mending mending after mending PROBLEM IMPACT 1. Effect in Cost 2. Order pending 3. Extra planning for shortfall 4. Delay in Shipment 5. Effect in Quality 6. Decrease Customer Satisfaction 7. Effect on Inclusive Growth Reason Pcs Percentage Lining due to mix up of shade lots 21 0.00 back stitch 236 0.05 Missing Tuft/ Mending 484 0.10 Design Cut / Short size ( Width less) 16 0.00 loop problem 4 0.00 M/C Tufting Total Target - 0.1% 741 0.16 Series 1 600 500 484 400 300 200 263 100 0 21 16 4 Series 1 HEAT SETTING & CABLING YARN GO-DOWN PP CANVAS GO-DOWN COATING MACHINE TUFTING MC TUFTING PREPAROTORY CUTTING & STITCHING GREY WARE DYEING PACKING & DISPATCH Department Flow Diagram Single Yarn/ Yarn preparation Tufting preparatory Tufting Defect Mending and Roll Checking finishing Roll preparation Chenille Length Cutting/roll Roll doffing checking Roll transport to Cut & sew Dyeing coating MAN MACHINE Stop motion senor not Untrained Manpower working/ Yarn tight end Operator negligence sensor Improper material Mending machine not Downgrade due to handling proper tufting department No defined SOP for Mixed yarn First piece checking Knots in Yarn No precautionary Method for bottom run out Damaged tubes METHOD MATERIAL Actual Vs Target Finding the root cause 0.20 0.10 Percentage 0.00 Total Mending Percentage 0.2 Aim 0.15 0.1 0.05 Percentage 0 Actual Target Do 1. Development of Solution 2.Implimentation of Solution “Reduce down grade and make awareness in associates regarding the problem facing & its effects” 600 100 99 100 95 97 500 484 80 400 60 61 300 263 40 200 20 100 21 16 4 0 0 Missing Tuft/ back stitch Lining due to mix up Design Cut / Short loop mending of shade lots size ( Width less) problem/mending %age Problems DEVELOPMENT SOLUTION Root cause 1:- Back stitch due to Improper mending New mending gun introduced Rework after mending Mending gun implemented required in all the machines x √ Development of Solution •Awareness to mender and quality checkup while rolling •Proper stitching of products for withstanding the dying process forces. •Handling the products carefully to avoid peeling of coating. •Placement of coated products in appropriate manner to avoid marks. Implementation of Solution MINIMISING DOWN GRADE PC. BY PROCESS IMPROVEMENT •Awareness to operator & mender by training about quality requirement •Improved mending quality and consistency by introducing mending gun •Procured mending gun(manual mending & automatic mending M/C) parts & improve mending performance. •Made sop to check first pc. swatches. To reduce chances of mix yarn ACTION PLAN FOR IMPLEMENTATION THE SOLUTION Sr. No. Description Responsibility 1 Operator training Mr. Kundan kumar 2 Develop the SOP & Training Modules Mr. Arvind Pandey 3 Procure new mending machine Purchase 4 Implement mending machine All team Check 1. Compare Before and after data Comparing the data Percentage 18% 16% 14% 12% 10% 8% percentage 6% 4% 2% 0% Sep - dec Jan - apr may - aug Act 1. Documenting the result 2. Standardizing the process Documenting UTM TOTAL PC. MONTH 16- DEFECTIVE AVG PC PER DAY TILL DATE % CHECKED PC. 15-Sep 761600 1066.2 36 0.14% 15-Oct 843174 1602 53 0.19% Before 15-Nov 680283 1768.7 59 0.26% 15-Dec 696784 696.78 23 0.10% AVG. 745460.3 1283.4 43 0.17% 16-Jan 680421 996 33 0.15% 16-Feb 643644 708 24 0.11% During project 16-Mar 654842 700 47 0.11% 16-Apr 675686 706 32 0.10% AVG. 663648.3 777.5 34 0.12% 16-May 949950 584 19 0.06% 16-Jun 978503 1301 43 0.13% After 16-Jul 1288858 1090 35 0.08% 16-Aug 1166340 632 22 0.05% AVG. 1095912 901.75 29.74 0.08% Checksheet Checked by :- Check sheet for M/C Tufting Shift incharge Date: A Shift B Shift C Shift Check point S.No.