npm metrics

ACTIVITY DEPT

Gate 0 : Engagement and Approval

TO BE TRACKED

Plant Facilities

HR

3P Team

PPC

Work Instructions Production

PED/FACILITY PLANNING

Producibility Analysis (Product

and Process Development

Practices)

Engineering & Quality

Personnel Certification

Manufacturing Planning and Scheduling

Pre-Production Planning activities

Production Control

Manufacturing Management

Manufacturing Engineering

Vendor Delivery SCM

QMS

IE

HR

QA

SQA

QA

Software Issues IT

QA

SCM

Material Management

Tooling/Test Equipment

TOOLING, ENGINEERING

& QUALITY

Work Measurement


Schedule Performance

Project Management

Scrap, Rework and Repair (SRR)

Industrial Engineering

Manpower/Training/Labor

Relations

Quality Assurance

Supplier Quality Assurance

Metrology/Variation Reduction

Non-Confirming Materials

Manufacturing Processes and

Control


Manufacturing Stress Screening


Subcontractor Management and

Selection

Manufacturing Technology


Production

IT

IT

Low Rate Initial Production

(LRIP)

Modeling and Simulation

Product Data Management

(PDM)

Gate 0 : Engagement and Approval

METRICS Daily Weekly Monthly Quarterly PMR Annual

Gate 1 : Concept Development

TO BE TRACKED METRICS Daily

• Plant Security• Plant Capacity

•Approvals Regulatory/Statuatory/Legal Bodies• Identify Plant Layout plan

• Identify Critical and scarce materials• Alternates for critical materials or processes identified.

• Cost projections•List of subcontractors required

•Factory layout with Emergency Exit identification• facilities adequacy to support production Additional

requirements if any• facilities shared

• list of schedules established for Plant.

• plant layout optimization

Activities to facility completion (Planned Vs Actual )

Gate 1 : Concept Development

Weekly Monthly Quarterly PMR Annual

Gate 2 : Pre-Production Readiness

TO BE TRACKED

Fabrication & Installation of Tooling (Plan vs Actual)

Technical Data Transfer Status

List of Equipment & spares. List of critical spares, ROI Depvelopment of Equipments, Life cycle estimation of Plant machinery with hours of usage and years.

Number of design, non-design and support tools identified and quantified from customer

Design data transfer from Customer to TASL (Planned Vs Actual)

MBOM Creation Plan vs Actual

AOS / MOS Creation & signoff Plan vs Actual

Configuration Change implementation received vs actual

Parts digitization Plan vs Actual

Production manpower planning

Standard Tools requirements as per work content (% Completion for each AOS/ MOS)

Production Master Scheduling

Document preparation Plan vs Actual

Raw material availability (Plan vs Actual)Vendor Management tracking

NA

Part wise production readiness Plan vs actual

Materials Management (Raw material , Composites, Tooling) PO issue Plan Vs Actual

Expenditure - Budget Vs Actual

Required Approvals (Planned Vs Actuals)

Manpower availability Plan vs actualTraining Plan vs Actual

PMR action items Tracking Plan Vs ActualQuality Certifications (EASA) Plan vs Actual

Kaizen Newspaper SummaryRisk Identification & Mitigation Plan

IT Systems & softwares (ERP, Collaboration Center etc) Identification & Implementation - Plan Vs Actual

IT Architecture (Severs / LAN / Wifi/ Laptops & Desktops/ Printers/ Attendance Recording) Implementation - Plan Vs Actual

MBOM CreationEngineeirng X-Mas tree creation

Process Mapping

Gate 2 : Pre-Production Readiness

METRICS Daily Weekly Monthly


Activities to facility completion (Planned Vs Actual), Breakdown Analysis Reports, Life cycles & ROI Estimation of Machinery

Gate 2 : Pre-Production Readiness Gate 3 : FAI & Production Induction

Quarterly PMR Annual TO BE TRACKED

• list of schedules established

• plant layout optimization • idle time of any euipment •breakdown analysis and time

recorded

MOS Creation & signoff Plan vs Actual

§5S Activities Initiation & Implementation plan

§Crew Load Charts (Plan Vs Actual)

Cell wise tracking

Crew Load Charts

Recovery Plans (If any)


§Weekly Reviewing & Reporting of Master Schedule (Planned vs Actual)


Shipset wise manhours Vs target based on learning curve

FAI Document Preparation (Plan vs Actual)

NC & DR volumeDR Ageing & Closure Tracking

Raw material availability (Plan vs Actual)

Manhours planned Vs ActualCycle Time Planned Vs ActualMetrics on On-Time-Delivery

Production Status at each work station AOS burn (Planned Vs Actual)

SQAR trend at each work stationEnergy Consumption

Attendance


Plan Vs Actual AOS / MOS completion at each work center

Variance Vs the Master Schedule & Recovery Plan if applicable

Process Compliances

Expenditure - Budget Vs ActualShipset wise profitability


Skill Matrix

EH & S ScorecardSafety score

Consumables consumption/Extra hardware consumption

Gate 3 : FAI & Production Induction

METRICS Daily Weekly Monthly Quarterly PMR Annual

Activities to facility completion (Planned Vs

Actual ) No of Breakdowns

Gate 4 : Production Ramp Up & Stable State

TO BE TRACKED METRICS Daily

Preventive Maintainance Plan vs Actual `

Improvement initiatives (Plan Vs Actual)


§Efficiency & Productivity Report; Improvement Initiatives

§Monitoring Learning Curve

§Value Stream Mapping Implementation ( Plan Vs Actual)

§Reporting benefits of Improvement initiatives

§5S Activities Initiation & Implementation plan Audit Compliance

§Productivity, Efficiency Reporting

§Skill Mapping & Gap Identification

§Time Study (VA & NVA), MOST & Method Study for Manpower requirement


Crab Trand

DR Trend

NC & DR volumeDR Ageing

Material Shortage (N+5 shipets / 2 months SS)

Risk assessment score for 5 Shipsets minimum (Detail parts)Open/Pending PRs & PR to PO ageing

% Procurement under LTALogistics Cost per SS

Material Consumption – AOP vs. ActualsInventory tracking (RM/FG/ Inprocess) (Dead / Slow moving)

Inventory Turns @ no of MonthsVendor Ratings

Supplier Rationalization Payment Terms

Cutting plan to m/c shop Plan vs actual


Fast Track Career Program


Gate 4 : Production Ramp Up & Stable State Gate 5: LESSONS LEARNT & CLOSURE

Weekly Monthly Quarterly PMR Annual METRICS Daily

Preventive Maintainance Plan vs Actual

TO BE TRACKED

Gate 5: LESSONS LEARNT & CLOSURE

Weekly Monthly Quarterly PMR Annual

List of Events§First revisiting of Man-hours estimation based on inputs from ME/Business Case & master schedule requirements

IMS Preparation3P & Facility Footprint FinalizationValue Stream Map (Depicting Uni-directional flow)Make and Buy Analysis EH& S requirements identification3P1 Event conducted during week of October 10Detailed facility layout developedEquipment list validatedData transfer completedJV site approach road clearing and leveling work completeJV hiring and talent development initiatedMOS development initiated, tooling and raw material RFQs issuedJV closing date TBDIndustrial license approval pendingINTEGRATED MASTER SCHEDULE

§First revisiting of Man-hours estimation based on inputs from ME/Business Case & master schedule requirements

Detail Part ManufacturingGate 2 : Pre-Production Readiness

Facility & Maintenance

Tooling


MBOM Creation Plan vs ActualMOS Creation & signoff Plan vs Actual


IE


Quality Document preparation Plan vs Actual

SCM


Number of design, non-design and support tools identified and quantified from customerFabrication & Installation of Tooling (Plan vs Actual)

ME & Configuration / Engineering Design data transfer from Customer to

TASL (Planned Vs Actual)Standard Tools requirements as per work content (% Completion for each AOS/ MOS)




Vendor Management tracking

PPC NA

Production

Finance Expenditure - Budget Vs Actual

Legal & Compliance

HR Manpower availability Plan vs actualTraining Plan vs Actual


Part wise production readiness Plan vs actual


IT

EH & S

Admin

Program

Kaizen Newspaper SummaryRisk Identification & Mitigation Plan

MBOM CreationEngineeirng X-Mas tree creationProcess Mapping


IT Architecture (Severs / LAN / Wifi/ Laptops & Desktops/ Printers/ Attendance Recording) Implementation - Plan Vs Actual

TOP / Continuous Improvement

PMR action items Tracking Plan Vs Actual

Quality Certifications (EASA) Plan vs Actual

Assembly Daily Weekly Monthly Quarterly PMR AnnualGate 2 : Pre-Production Readiness

Y


MBOM Creation Plan vs ActualAOS Creation & signoff Plan vs Actual



Document preparation Plan vs Actual


Number of design, non-design and support tools identified and quantified from customerFabrication & Installation of Tooling (Plan vs Actual)

Standard Tools requirements as per work content (% Completion for each AOS/ MOS)





Manpower availability Plan vs actualTraining Plan vs Actual

Cell / Jig wise production readiness Plan vs actual


Kaizen Newspaper Summary


IT Infrastructure (Severs / LAN / Wifi/ Laptops & Desktops/ Printers/ Attendance Recording) Implementation - Plan Vs Actual

Quality Certifications (EASA) Plan vs Actual

Detail Part Manufacturing Assembly Daily WeeklyGate 3 : FAI

MOS Creation & signoff Plan vs Actual AOS Creation & signoff Plan vs Actual

§Crew Load Charts (Plan Vs Actual)

Cell wise tracking

Crew Load ChartsRecovery Plans (If any)

NC & DR volume NC & DR volumeDR Ageing & Closure Tracking DR Ageing & Closure Tracking


Activities to facility completion (Planned Vs Actual )Preventive Maintainance Plan vs

ActualPreventive Maintainance Plan vs Actual







Production Master Scheduling Production Master Scheduling

§5S Activities Initiation & Implementation plan

Shipset wise manhours Vs target based on learning curve





Detail parts availability (Plan vs Actual)

Manhours planned Vs Actual

Cycle Time Planned Vs ActualMetrics on On-Time-Delivery

Production Status at each work station

AOS burn (Planned Vs Actual)

SQAR trend at each work stationEnergy ConsumptionAttendance

Process Compliances

Expenditure - Budget Vs Actual Expenditure - Budget Vs ActualShipset wise profitability

Skill Matrix


Plan Vs Actual AOS / MOS completion at each work center

Variance Vs the Master Schedule & Recovery Plan if applicable

Consumables consumption/Extra hardware consumption



EH & S Scorecard EH & S ScorecardSafety score

Monthly Quarterly PMR Annual Detail Part ManufacturingGate 4 : Ramp Up & Stable State

§Monitoring Learning Curve

§Productivity, Efficiency Reporting§Skill Mapping & Gap Identification

Crab Trand

DR TrendNC & DR volumeDR Ageing




§Efficiency & Productivity Report; Improvement Initiatives

§Time Study (VA & NVA), MOST & Method Study for Manpower requirement

§Value Stream Mapping Implementation ( Plan Vs Actual)

§Reporting benefits of Improvement initiatives

§5S Activities Initiation & Implementation plan Audit Compliance


Material Shortage (N+5 shipets / 2 months SS)

Open/Pending PRs & PR to PO ageing

% Procurement under LTALogistics Cost per SS

Inventory Turns @ no of MonthsVendor RatingsSupplier Rationalization Payment Terms

Cutting plan to m/c shop Plan vs actual


Risk assessment score for 5 Shipsets minimum (Detail parts)

Material Consumption – AOP vs. Actuals

Inventory tracking (RM/FG/ Inprocess) (Dead / Slow moving)

Assembly Daily Weekly Monthly Quarterly PMR AnnualGate 4 : Ramp Up & Stable State

Crab Trand

DR TrendNC & DR volumeDR Ageing




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