W9Lha9 Th TI9 WhwL5 hC 59YLDeki Electronics is like a bonsai Small y - PDF document

1 W9L/ha9 Th TI9 WhwL5 hC 59YLDeki Electro
W9L/ha9 Th TI9 WhwL5 hC 59YLDeki Electronics is like a bonsai. Small yet complete.Complete range of plastic film capacitors with a choice of technologies.Every branch and twig shaped or eliminated until the chosen image is achieved.Clear focus on quality and providing solutions.The image maintained and improved by constant pruning and trimming. Commitment to training and knowledge enhancement. 5eki at a DlanceThree decades & moreEstablished in 1984, in technical collaboration with OkayaElectric

2 Industries, JapanIndia’s largest film
Industries, JapanIndia’s largest film capacitor manufacturer Annual Production Capacity of 1.2 billion pcs/annumOne stop shop Full range of film capacitors, technologies, constructions, encapsulations, pitch size and dielectrics availableServing all segments of the electronics sector Lighting, Consumer Electronics, Telecom, Medical, Industrial, Automotive, IT Hardware, Fan Regulators, Energy meters ...Ambitious prospects Average Annual Growth in Turnover (last 10 years): 25% troduct & troce

3 ss management systems implemented in spi
ss management systems implemented in spirit & approvals received 9wTL / 9b9/ / UL for X2 range / /A/T & /5hTTS 16949:2009/ LSh 9001-2008 / LSh 14001: 2004 / LSh 18001: 2007/ustomer Specific Approvals:Sony / Sanyo / thilips / Sharp / JV/ / Toshiba / tanasonic / hsram, .AD…Iighest quality standardsSingle 5igit tta level for all capacitors, zero defect for automotiveDlobal reach 9xporting to 9urope, Iong Yong, /hina, Thailand, thilippines, aalaysia, South Yorea, aiddle 9ast/ommitted team 600 +

4 member team, low attrition rateA team th
member team, low attrition rateA team that learns together, delivers together, grows together 5eki at a Dlance … Why 5eki ?Design Capability DSIR recognized Technical Centre enables customers to make informed selection from a wide range of film capacitors QualityThree decades of manufacturing experience4 Ms designed, established and enabled to consistently deliver single digit PPM to dynamic customer expectationsCost Global scale at internationally competitive pricesContinual improvement in b

5 usiness processes leading to benchmark y
usiness processes leading to benchmark yieldsDeliveryFlexible delivery, short lead times, “Vendor managed inventory”projectsServicePassionate, customer oriented team that aims at leveraging great service as our competitive edge 5eki: Lndia’s 3rdlargest component manufacturer DEKI T/O TREND USD (Mln)* 1USD = Rs.65/-(INR) 1,601,982,492,903,304,337,398,038,829,9611,6913,4915,4619,1723,97 -5,000,005,0010,0015,0020,0025,00CY 03-04CY 04-05CY 05-06CY 06-07CY 07-08CY 08-09CY 09-10CY 10-11CY 11-12

6 CY 12-13CY 13-14CY 14-15CY 15-16CY 16-17
CY 12-13CY 13-14CY 14-15CY 15-16CY 16-17CY 17-18 CY 03-04 CY 04-05 CY 05-06 CY 06-07 CY 07-08 CY 08-09 CY 09-10 CY 10-11 CY 11-12 CY 12-13 CY 13-14 CY 14-15 CY 15-16 CY 16-17 CY 17-18 59YL b9W twh5U/T (Value, ws. /rore) 3,512,744,893,914,345,218,527,997,709,5613,9415,6716,9616,6123,84 0,005,0010,0015,0020,0025,0030,00CY 01-02CY 02-03CY 03-04CY 04-05CY 05-06CY 06-07CY 07-08CY 08-09CY 09-10CY 10-11CY 11-12CY 12-13CY 13-14CY 14-15CY 15-16 SEGMENT JISE SHARE (%) /9; 1,6%Telecom; 0,2%Auto; 2,8%Lndus

7 trial; 26,7%Lighting; 68,6% Semiconducto
trial; 26,7%Lighting; 68,6% Semiconductors1MMS –Strategy and Business Development DEKI ELECTRONICS Ltd Purpose•Be a company that makes India proud •Be the global benchmark in electronic component manufacturing. Strategic directionBusiness enablersResults (BBS)Year 2016/17 initiativesVisionLeadershipFinancialsTop "must do" actions•Lead the organization to achieveRs. 123cr turnover during 2016/17 & double it by 2019/20•Focus on delivering peace of mindto customers•Ensure safe ,cl

8 ean ,happy and productive workplace.Mea
ean ,happy and productive workplace.Measure and continuously improve•Sales and EBITDA•Free Cash Flow(T-OE-delta Inventory)•Productivity (T/OE) •Growth in Profit (T-OE)•Deliver EBITDA> 18% by focusingon the bottom line and product mix .• Productivity >1.4 by Dec 2016.•Achieve >Rs 123 cr sale in 2016/17Customers•Achieve > 50% mkt share of our existing segment by 2017/18.•Increase exports by >20% y-o-y•Achieve new product t/o >25% in 2016/17 and 2017/18 •To diversify i

9 nto 2 other components and 1 new prod
nto 2 other components and 1 new product by 2017/18 People•Market share lin the Indian market•.Infuse entrepreneurial leadership amongst Key managers •Stimulate improvement in performance by rigorous training •Exploit the unlimited potential of each member of the team by empowerment •Customer Satisfaction Score•Customer ComplaintsValues•Delight customers•Deliver on commitments•Respect each other•Open and transparent workingProcessesStrategy•Become the lowest cost

10 producer of good quality DC Film ca
producer of good quality DC Film capacitors •Focus on exports •Innovate to develop new capacitors for emerging applications•Diversify to manufacture other other electronic components and/or product•Increase productivity by using IOT •Increase RM inventory turns to 20 and FG to 30 turns by Dec 2016. •Use TOC to maximise profits.•Add value to our customers by sharing knowledge thru marketing communications and technical seminars. •Pursue excellence in quality and

11 process by using 6 Sigma..• Practi
process by using 6 Sigma..• Practice sustainable agendaMeasure and continuously improve•Yield by minimising waste •Cpk of Critical Processes•Customer Satisfaction Partnerships & resources•Set clear priorities in investments & resources in line with strategy•Use JV route to extend our capabilities in technology, manufacturing and access to customers.•Build partnerships with machine/RM/ technology suppliers.Processes•Establish Process Stability by using6 Sigma methodology â€

12 ¢Use CSS and ESS to understand the needs
¢Use CSS and ESS to understand the needs of our customers’-both Internal and External.•Digitize key processes for better controlCompetenceMeasure and continuously improve•Manufacturing Excellence Score Card marks•ESS score•Recogniseand protect IP •Training scores at critical processes. •Establish and enable achievement of •career goals for HOD’s Grow sales & market share•Increase share of business withexisting local Lighting and Industrial Customers and tap all new

13 local Lighting and Industrial customer
local Lighting and Industrial customers.•Make entry in Power Electronics by selling DC Link and Snubbercapacitors.•Increase Exports by focusing on EU based customers•Explore Latin American market thru internships..Lower costs•Create a culture of waste elimination •Improve OEE of bottleneck m/csby using IOT•Reduce manpower by lowcost automation and productivityimprovement•Ensure manufacturing yields >97.5% and improve material yield by minimisingwaste•Reduce Cost of Non Qua

14 lity byusing 6 Sigma •Regularly engage
lity byusing 6 Sigma •Regularly engage in PPM meetings withkey customers.•Customer CLIP local & export Deki Electronics Ltd. : One page strategy .Discussed and finalized with HOD’s 13-4-16Version 1.0 -2013Approvals•IS/ISO 10002 by December 2016•IS/ISO 50001 by March 2017Continually improveMission Listen carefully to customersIn depth interaction during regular visits to customers, factory tours by customers, participation in trade fairs, deep dive team analysis of complaints and fee

15 dback, half yearly Customer Satisfaction
dback, half yearly Customer Satisfaction Surveys (Internal/External)Learn from the competitionEmerging technology and applications –Japan, EUCost effective automation for mass manufacturing –Korea, TaiwanHigh productivity, economies of scale, pricing strategy –China Deki Culture Shared vision , a learning organization, an enabled passionate team Effective & Consistent communicationDaily prayer, pledge & national anthem, internal newsletter “Sandharitrika”, suggestions scheme, monthly

16 departmental meetings, annual appraisal
departmental meetings, annual appraisals, Skill mapping, small group activities, cultural celebrations Quarterly newsletter “Charge”, technical paper “Primer”, technical seminars, PPM meetings, regular vendor interactions At the core of our strategy http://www.dekielectronics.com Recognized as an independent research centreby Departmentof Science & Industrial Research, Government of IndiaThe Centre is primarily responsible for:•Design & Development of Capacitors•Documentation Centr

17 e for all Specification•Training Cellâ
e for all Specification•Training Cell•Competitor Analysis•Reliability Testing•Approval Coordination•Technical Seminars Technical /entre at 5eki 5eki /ustomers Customer Satisfaction Survey 85% 5eki /ontinual Lmprovement /ontinual Lmprovement /ontd. /ontinual improvement thru 9mployee tarticipation 9mployee aotivation Survey 331829516399119239209155211105176251163159 020406080100120140160180200220240260280 Year Wise Average Suggestions ter aonth 11514340747569486818261502162613101620226

18 525804234440736033795 -800-4000400800120
525804234440736033795 -800-40004008001200160020002400280032003600400044004800 Year Wise Average Training Iours ter aonth Je started a Six Sigma Initiative in each Deptof the company in Oct 2009 to solve chronic issues.The problems are solved through DMAIC Methodology. There is an involvement of 45% operators in these projects and the reason for success is basic discipline of project meetings and commitment of Project leaders. Till Dec 2015 we have completed 63 projects successfully and prese

19 ntly 9projects are running. Six Sigma In
ntly 9projects are running. Six Sigma Initiative 5eki –bew troductMPET-Dip & BoxMPP-Dip & BoxX2 CapacitorCDI CapacitorPP CapacitorMPP/MPP & PP/MPPMiniature -BoxMiniature -DipLow ProfileMiniature Dip 5.0mm pitch 2003 1996 2004 2005 2006MPP Fan Regulator CapacitorPES Capacitor for Lighting ApplicationInductive capacitor with self healing propertyStarter Capacitor for Royal Philips Optima for Fan Regulator 2008 2009 2010 2011 High stability Cap for Energy Meter 2012MMKP CapacitorUltima range for

20 Fan Regulators 2007MPP AC Miniature for
Fan Regulators 2007MPP AC Miniature for lighting 2013Fuse cap, PP/MPP and MPP/MPPDC Link & Miniature MPP 2014 2015 Deki New Product development Application –SuntanningcapacitorCustomer –Philips, TerneuzenJe were approached by Philips as they have found significant failuresin existing design of capacitor supplied by competition.Je found that there is high stress across this capacitor during working.Je had a solution however it was big in size and more expensive. Sincesize was a constraint f

21 or this application Philips R&D team req
or this application Philips R&D team requestedDeki R&D to look for innovative solution.Both the team decided to work together in Deki for meeting the aboverequirement. Nosof trials were planned to find out the most optimumsolution. After one week of rigorous working suntanningcapacitor wasdeveloped.Today we are the sole supplier for this capacitor /ase Study -1 Application –Lighting (CFL)Customer –Osram, ItalyIn2000,whenweapproachedOsram,Italy.JefoundthattheywereusingMKP&MKTNoninductiveexpe

22 nsivedesigns.Jehadadetaileddiscussionwit
nsivedesigns.JehadadetaileddiscussionwiththeirR&Dteam&finallytheyagreedtotesttheOptimumSolutionsofferedbyDeki.AsaresultoftheaboveValueEngineeringwewereabletocutdownthecostoftheirBOMby40%.SincethanweareexportingtoOsramonaregularbasisandtodaythelevelis6mlnpcs/mth. /ase Study -2 Application –Lighting (CFL)Product –PEP Capacitor (mix dielectric)Electronic Ballast is the heart of any CFL. Striking capacitor in it plays a vitalrole in the performance of CFL. Manufacturing of CFL was started with

23 lowwattage ie8J, 11J,14J etc& Plain Poly
lowwattage ie8J, 11J,14J etc& Plain Polypropylene was the ideal solution forthis application.Later all the players started increasing the wattages of CFL ie18J, 20J,23J, 26J etc. The higher wattages resulted in increase in temperature withinthe capsule( > 100 ).Though Polypropylene is the ideal design but it can withstand up to 100 C only. Hence Striking capacitor started failing when the temperature rose>100C.Jhen we Realized this we developed PEP capacitor. Jhich is nothing but thecombinatio

24 n of Plain Polyester & Plain Polypropyle
n of Plain Polyester & Plain Polypropylene. PEP capacitor offershigh stability in capacitance value up to 110 C temperature. PEP capacitor issupplied to all leading CFL manufacturer including Osram, Italy . Deki won ELCINA R&D award for this development. /ase Study -3 Application –Industrial (Electronic Fan Regulator)Product –Ultima Fan Regulator CapacitorElectronic Fan regulator is a combination of rotary switch, Resistors &Capacitors. Film Capacitors plays a vital role in it. The exist

25 ing technology ofFilm Capacitors are pro
ing technology ofFilm Capacitors are prone to catching fire. In case of high spike in voltage thecapacitor can catch fire .In some cases this has resulted as major fire accident in the premises where thefan regulator device is used.Technical Centre at Deki developed a break through technology with Ultimarange of Fan Regulators. Ultima range provides superior safety for Socket & switch type fan regulator capacitors. Instead of catching fire at high spike, theUltima Fan regulator capacitors fail

26 safely. /ase Study -4 Application –Tel
safely. /ase Study -4 Application –Telecom (EPBTs)All leading manufacturers of Electronic Push Button Telephones inIndia have been using expensive MKT Non inductive designs.The findings by Technical Centre suggests that Expensive NonInductive MKT type is not required for EPBT application.Deki proposed Plain Polyester Inductive design to the industry, whichhas been very well accepted by all leading players. This has resulted incost down to customers as high as 30% to 40% of BOM cost. /ase Stud