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1 Sustainable Quality Systems 1 Sustainable Quality Systems

1 Sustainable Quality Systems - PowerPoint Presentation

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1 Sustainable Quality Systems - PPT Presentation

in Supply Chain amp After Sales 19 Jan12 Girish Shah Service Head Videocon Industries Ltd 2011 2012 One chassis with D2H 3D LED TV range Real 2D3D conversion IP TV ID: 623836

quality amp system service amp quality service system product process management defect launch innovation smart field improvement thro

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Slide1

1

Sustainable Quality Systems in Supply Chain & After Sales19 Jan’12Girish Shah – Service HeadVideocon Industries LtdSlide2

2011

2012 One chassis with D2H 3D LED TV range Real 2D-3D conversion IP TV , Health TV & Security TV.

Education TV through D2H

Digital Signage Crystal design with new design trends. 3D transmission through D2H OLED introduction. Solar power LED TV 3G compatible LED with Datacom support. Multiple injection molding. Video streaming server. Auto stereoscopic 3D TV Gesture Recognition.Projection through Mobile

CE Technology Progression

2Slide3

FF Ref

Electronic Temp ControlSide by Side & DC Inverter TechnologySide by Sidewith LCD ScreenDC RefFF RefSAWMFAWM - TLFAWM - FLFAWM – FLwith HeaterFAWM – FLDirect DriveFAWM – Tilt DrumDirect Drive

MWO - Solo

MWO - GrillMWOConvectionAuto Cook MenusMWO with LCD Screen2000-20052010-20112009 200820122013-2015Smart Refs with Wi-Fi Connectivity, Remote Access, Interfacing with other Smart Appliances , Various Intelligent & Customised Applications etc. Smart MWO with Smart Apps & Communication Capability, Interface with other smart appliancesMusic/ Voice Activated Ovens/ USB Interface (Stores upto 40 voices) Oven with Separate Bottom GrillMulti Steamer ( with detachable Water tank)External Micom with Interactive LCD/ LED Panel with improved energy efficiency.Smart Washers with Intelligent Wash programs, Wi-Fi Connectivity, Remote Access, Interfacing with other Smart Appliances , Various Intelligent & Customised Applications etc.Home Appliances Technology Progression Community LaundryPortable/ Wall Mount WM

Community Refs

3Slide4

INDUSTRIES SUPPLY CHAIN

PRODUCT DEVELOPMENT CYCLEVENDOR MANAGEMENTPRODUCTION MANAGEMENTLOGISTICS MANAGEMENTAFTER SALES & SERVICE MANAGEMENTCUSTOMER SATISFACTION

4Slide5

WORLD CLASS PRODUCT

System (PLM) /

mySAP

Process Quality system set up (VMES)Field Quality system set up (VQINS)Mould SystemProductivity Improve by LOB and StandardizationInternal Process Quality Control100% Defect free deliveryNew Model Quality PerformanceProduct Innovation My Model Ownership Standardization Product Innovation 3F . Part Reliability Product Performance.System

Setup

Production Quality Assurance

MY PRODUCT MY PRIDE

5Slide6

PRODUCT LAUNCH CYCLE

1 . IDEATION - Market Study / Potential - Understanding of Need & Gaps - Driven through Quantitative research - FGD’s - Workshops - TG Mapping New Product Launch Process 2. CONCEPTLIZATION - Based on ideation concepts taken ahead - Need s & benefits / features - Product design & style - International concepts 3 . MANAGEMENT PLAN

- Feasibility study / Project - Cost & market planning - Production -Pricing -Channel selection & criteria 4 . LAUNCH PROCESS - PRODUCT LAUNCH COMMUNICATION - PRODUCT LAUNCH CHANNEL & PLACEMENT PRODUCT TESTING - PRE LAUNCH PRODUCT TESTING - POST LAUNCH New Product Launch Process 6Slide7

VENDOR MANAGEMENT

Self Q Certification by Vendors (DOL).JIT Supplies. –MILK VAN CONCEPTStrong 4M Management system.Periodic Supplier Assessment Initiative from Vendors for Cost & Q Innovation.Setup Inhouse Reliability Test FacilitiesPerformance Evaluation & Monitoring thro’ SAP version-6.0 or Equivalent.Periodic Review system(Meetings)APPROACHTOWARDS

Q

100PPMWIN – WIN SITUATIONTHE BEST PRACTICES:7Slide8

PRODUCTION MANAGEMENT :

Daily Monitoring Thro’ 6-TOOLSMonthly Auditing system thro’ MI 10 Tools(End-to-End)Mind innovation School for Training all employees. Improvement Projects thro’ SRT/SRP/QIT/PITOnline Monitoring of Field Quality thro’ New VQNIS System PROCESS QUALITY CONTROL TOOLS

8Slide9

What are 6 Tools?

100 PPM QUALITY PROCESSOS&D*(Over/Shortage/Defect)Sequential InspectionMain Process ControlTime CheckQuality AuditReview Meeting123456

Perfect

CheckSystemCultivatingTeamSkillImplement6TOOL*OS&D : Over, Shortage & Defect9Slide10

Types of SRT/SRP

ProductivityQualityInventoryR &D RMC /VCI New Modela) Increase UPHb) Increase Sets/hra) Decrease FCRb) Customer Delight :3F Inventory Reduction b)Supply ImproveTypes of QIT/PIT

Productivity

QualityVendorPEa) Tact time Reductionb) Improve process Process Defect Reduction Quality Improvement.Bottom upTop DownReduce M/C LossPROJECTS THRO’ - SRT/ SRP/ QIT/ PITSlide11

Audit Area

5S Sorting Systematic Arrangement Sweeping Systems Self-disciplineAudit Factors Right Location Right Q’ty Right Container Communication System Identification Boards Production Control Boards Slogan Mixing in one box Easy to find Floor/conveyor

5S Map/Checklist

Always clean Location Marking Standard Stock Box, trolley Office/Supervisor/ Operator Area/Location Monthly,Daily,Hourly Line/Shop SloganMi-10/ The 10 Pillars for Manufacturing InnovationKeep BasicsEESHSelf ManagementMulti SkillVendor DevelopmentQ A SystemMaterial FlowMaintenanceProductivity Mgt.T5SMi-10 items123456789103R

Visual

M

anagement

11Slide12

R&D

S/W

PE/Prod

QALogisticVMESManufacturing Data Monitoring System Under DevelopmentAll of India Factory AURKASGANBANHYDKOLSHJ

SAP

VQINS

(Sep.2011~)

WEBCMS

Service

M-Graph

IR Trend

Worst Defect

Field Quality Data Analysis System

Master Data Server

Developed

Manufacturing Quality

Field Quality

Quality Management System

Dealer

Call center

Customer

FCR

Repeat Call

Impr. History

Correlation Process

vs

Field

Provision

12Slide13

Benefits :

Field Defect Auto Analysis Reports on real time basis – FCR Trend, IR Trend, Accumulated Rate, Worst Defect, Monthwise Graph(M-Graph), Improvement History & Effectiveness MonitoringF-Cost MonitoringCorrelation Analysis, Field vs Process Detail Analysis - Product wise, Factory wise, Category wise, Segment wise, Worst defect wise, Branch wise, Brand wiseEasy to access from every factory through www.vqins.com , so no man dependencySupport to R&D for defect condition study and improvement plan

VQINS : Videocon Quality Information Network System

13Slide14

Mind Innovation

Basics of Manufacturing What is culture Morale Training What is Mind innovation Attitude , Discipline & Passion Continuous & Continual Improvement Cost Innovation( SRT,SRP,QIT,PIT & LET Projects) Self Analysis Smart Working for Quality Output Positive Attitude Basics of IE (Industrial Eng.) Total 5S (5S,3R, & Visual

Management)

What is Work What is Quality 7 Types of Losses Fool Proofing OEE Training & Practical ExercisesInnovation School Slide15

VG – Logistics in Domestic

15Slide16

16Slide17

Wide, Customized & optimized Network -

- 650 Service Centers across India Speed of Service - 24 Hrs Response > 80% at ASC Locations Parts availability for immediate solution - Regional Hub for immediate supply - MSL at ASCs – 1 month Call Registration - Outbound Calls to Dealers - 7 days Call Centre support ( 8:00 am to 10 pm) 7 Days Service Speed Quality Manpower - Tie up with ITI Evaluation at all levels - Monthly evaluation for Branch/ASI/ASC Trained Manpower - Technical, Soft Skills 2 Mandays/Qtr. Awards & Penalties Exclusive Hi End EngineersService Quality Review Mechanism Strong CRM for Monitoring Meetings , Interaction Market Visit Audits & Evaluation

Competitor Information

Service Marketing Free Service Camps in off season Glow Sign at ASCs Uniform and I Card with Engineers Other Initiatives Acknowledgement of Call within 2 Hrs Reassurance to Customer over SMS Engg Evaluation thru Happy Calls/CRM Service Infra improvement at ASCsService Strength : Differentiated Service Experience17Slide18

Service Network

18Slide19

Service Centre

Front & Glow sign boardReceptionCustomer CharterCE WorkshopHA WorkshopBulletin Board19Slide20

Training Academy

Delhi Training Centre's at Sahajanpur, Aurangabad, Bangalore & Kashipur20Slide21

Service Marketing

Service VanFree Service Camp ( Leaflet )Engineer ToolkitFree Service Camp ( Canopy )Engineer Uniform21Slide22

THANKS

22