town hall factory may 12

TOWN HALL MEET– 2nd May 2012 1

1.Plant & Production Performance

2.News from the Product Desk Washing Machines /Commercial Washers / Kitchen Appliances

3. News from Operations R n D/SCM/QC/Benchmarking/Training

4. Cell Improvements – Corlim Cell

5. Questions & Answers

2

3

Volume Details – Vanaja Rane

4

WM– Apr12 V/s Apr 11 Comparison

2012 2011

PRODUCTION 15,828 11139

DISPATCH 16031 10791

0 2,000 4,000 6,000 8,000

10,000 12,000 14,000 16,000 18,000

Production v/s Despatch

CD Apr 12 V/s Apr 11 Comparison

5

2012 2011

PRODUCTION 32 330

DISPATCH 259 152

0

50

100

150

200

250

300

350

Production v/s Despatch

6

Plant Performance - Kartik

Particulars 2011-12 (Mar)

Budget Actual Actual

Net Sales

22.53 Cr

19.50 Cr

13.93 Cr

RM

% to Net Sales 69.32 % 79.23 % 77.84 %

PBDIT

% to Net Sales 15.87 % 2.92 % 10.04 %

Business Performance Factory – Mar12

2010 –11 (Mar)

7

Particulars

YTD 2011-12 Mar

Budget Actual Actual

Net Sales 313.79Cr 294.32 Cr 234.50 Cr

RM

% to Net Sales 70.22 % 74.72 % 72.22 %

PBDIT

% to Net Sales 16.62 % 11.83 % 11.96 %

YTD Business Performance Factory -Mar

2010 –11

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News from Product Desk ~Washing Machines by Venkatesh & Mandar

WASHING MACHINE Sales Performance FTM Apr 12

PRODUCT BUDGET

(VOL)

ACTUAL

(VOL)

%ACH %GOLY

FRONT

LOADERS

14,280

15,995

112%

39%

TOP

LOADERS

4,284

1,628

38%

-52%

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AQUA SPA WASH – A UNIQUE FEATURE IN NEW TOP LOADER

WASHING MACHINES

1. 3D Water fall 2. Tornado Wash 4. Scrub board Wash

6. Dirt Sway away 7. High Speed revolution

3. Centre punch

5. Air Bubble Wash 11

Commercial Washers by Kartikayein

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Commercial Machines – Performance

All India Budget Achieved Backlog LY GOLY% Budget Achieved Backlog LY GOLY%

IDW 69 54 -15 34 59% 138 126 -12 80 58%

ILE 33 27 -6 17 59% 66 82 0 33 150%

Total 102 81 -21 51 59% 204 208 0 113 85%

Quantity Value

FTM/YTD

Esteemed Client Addition

Infosys, Gurgoan

Chung Wah

Dr. Reddy’s

The Bake House Inn

Royal Goan Beach Club

Apollo Hospitals

HSBC

Repeat Orders

SAP labs

Goa Shipyard Ltd.

Lupin Ltd.

Bangalore Club

Qualcomm

ABB

Nala Hotels

• All India trainers training – Trainers trained on the commercial machines.

– Franchisee are provided training to take up the part of commercial

machines service.

• Laundry Chemicals- Testing started, to be launched

in mid of June – AIO Detergent- Premium, medium and economic.

– OXY and Chlorine Bleaches

– Emulsifiers

– Neutralizers

– Softeners

– Spotting Chemicals

• Cross Selling is being done with great focus. – Modular kitchens at Royal Goan Beach Resorts.

– Microwave oven billed to one of the IDW customer. Now going for

Dishwashers

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Kitchen Appliances by Rajan Chandna

15

Chimney Built in Hob Built In oven Built in

MWO Built In DW Total

221 58 33 3 10 325

Kitchen Appliances – April 2012

TY LY GOLY

48.69 42.17 15.46 %

Volume

Value - Lacs

Why We require a Chimney

BAD VENTILATION...

• Bad ventilation is when there is no proper channel to exhaust all the contaminated air generated during the cooking process and due to the burning of the fossil fuel .i.e. LPG and CNG, in the KITCHEN.

Effects of bad ventilation:

• Besides spoiling the aesthetic look of the kitchen it also causes various health problems like asthma, head aches, nausea, allergy, cancer, birth defect etc.

GL-10PL Size: 60/90 cm

Type: Wall Mounting

Suction: 1050 M³/h

Finish: Glass /SS

Motor: 250 watt- Centre Mounted

Rotor: Metal -2 Rotor

Outlet: 150/120

Filter: AL. Cassette-Outer layer SS -2/3

Control: Electronic – Touch

Speed: 3

Light: 2 LED - 2 watt each

Maximum Power – 254 Watt

*Smart Feature – Auto – by activating the function Chimney will

switch on by it’s own if certain amount of smoke

is accumulated is under the chimney

Timer – Chimney can be programme for 60

Minute

Remote Sencer– optional - will be available from

March

SIZE SAP Code Offer MRP

60 8903287002267 14990 20990

90 8903287002311 16990 22990

*Feature deactivate in case of power failure

C-1- PL- 60/90cm

Clean Air – Every hour Chimney will switch for 10 Minute

at low speed to remove the stale air

Filter block Indicator – will remind customer it’s time to

clean the filter by way of blinking the light.

Delay Timer – ideally chimney must be kept on for 10-15

minute even after the cooking to remove the cooking

contaminate which are generated due to burning of fossil

fuel ( LPG & CNG) beside smoke, smell which generated

during the cooking process

Booster speed – chimney is programmed with inbuilt

prefixed time for high speed for initially air flow than

automatically come to preset speed.

Size: 60/90 cm

Type: Centre Island

Suction: 960 M³/h

Finish: SS

Motor: 250 Watt

Rotor: Plastic -I Nos

Outlet: 120/150

Filter: AL. Cassette- 3

Control: Electric Push Button

Speed: 3

Light: 2*20 halogen

Maximum Power – 290 Watt

*Feature deactivate in case of power failure

SIZE SAP Code offer MRP

60 8903287002243 14990 22990

90 8903287002250 16990 25990

Size 590 X 520

Burner -3 Nos- Flat Burner One - LR – 3.8 Kw One TR- 2.50 KW One Auxiliary 1.00 KW

Grid –Sheet Enameled

Cutting Demission L*W*D

MM 555 X 485X60

Finish - check Glass

532S- MLR- CG

Code TP MRP

8903287004131 8800 14990

RnD Dept by Oscar

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Wind chill PDM Link

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Product View

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Supply Chain Management by

Manerkar

OBJECTIVE PRESENT PRACTICE FUTURE PRACTICE

PLANNING *MANUAL SCHEDULE THRU

E –MAIL AND TELEPHONE.

* THRU PORTAL BY END

JUN

COMMUNICATION *SCHEDULES

*SOB

*IFB DAY WISE PLAN

* THRU PORTAL BY END

JUN

RESPONSIBILITY OF

VENDORS

* DELIVERY EX WORKS FOR

OUTSIDE GOA SUPPLIERS

•DELIVERY F.O.R VERNA

FOR ALL BY END JUN

BUFFER MANAGEMENT *AT IFB AND ALL CARGO •AT SUPPLIER PLACE ALSO

END MAY

CAPACITY

EVALUATION &

BUILDING

THEORITICAL ESTIMATIONS

AND

DECLARATION BY SUPPLIER

DURING PPAP

THEORITICAL ESTIMATION

FOLLOWED ACTUAL

VERIFICATION AT SUPPLIER

-ON CONTINUOUS BASIS

Supply chain management procurement cell TODAY & TOMORROW

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OBJECTIVE PRESENT PRACTICE FUTURE PRACTICE

DELIVERY AND

QUALITY RESPONSE

•AFTER 24 TO 72 HRS OF

INCIDENCE

*SUPPLIERS

REPRESENTATIVE

AT IFB FOR TAKING

ACTIONS ON THE SPOT.

-BY END JUN

QUALITY *COMPONENT APPROVAL

FOLLOWED BY PPAP FOR

CONSISTENCY

•COMPONENT APPROVAL

FOLLOWED BY PPAP FOR

CONSISTENCY AND TILL

MAKING THEM D.O.L.

-BY END SEP

PACKAGING *PACKAGING STANDARD AS PER

SUPPLIER’S CHOICE.

•PACKAGING FOR D.O.L. IN

THE FORM SUITABLE FOR

ASSEMBLY.

-BY END SEP

PAYMENT FOR

SMOOTH SUPPLIES

*OVERDUES OF 1-2 MONTHS *PAYMENT AS PER CREDIT

PERIOD FROM Q2

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Benchmarking by Mitesh Gajjar

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1.Certification Requirement for Export to Europe – Model - Elite Sx and Senator Sx

Test Remark Status

LVD

2006/95/EC

Low voltage directive -Included

in CB (Safety Certification)

directive

Completed

EMC

2004/108/EC

Electromagnetic Compatibility

Testing

Will be completed in-house

With the help of TUV

ErP 1015/2010&

Energy report

(1061/2010)

Energy related product Testing

To be tested in VDE

ROHS

2002/95/EC

Restriction of hazardous

substances

In-progress

REACH

1906/2006

Registration, Evaluation,

Authorization and Restriction

of Chemical substances

To be tested in INTERTEK

Package

2005/20/EC or

94/62/EC

Heavy metal detection in

packaging materials

Will be tested in TUV,

Material already sent.

Noise Report NOISE level measurement of

machine

Noise testing is completed in-

house and certificate has to be

received from TUV

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STATUS : NABL implementation will be done with help of ALPHA & OMEGA Consultancy and expected to be completed by NOV-2012.

NABL accreditation for Test Lab

Level 2 user Documentation

System deployment

GAP Analysis

Internal Audits

NABL Manuals and procedures

Deployment actions based on the requirements identified

by NABL assessors.

Apr May Jun Jul Aug Sep Oct Nov Dec

Phase 1

Phase 2

Phase 3

Phase 4

Phase 5

Phase6

Phase-1

Phase-2

Phase-4

Phase-5

Phase-6

Phase-3 2012

2.NABL ACCREDITATION

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3. TESTING AND VALIDATION To Test and validate Senator SX 8Kg 1400rpm Model.

SENATOR SX 8Kg 1400rpm

3.Display flickering • Action: Problem reported to Topband

4. Pressostat /Bubble pump tube cut

• Action: Spring collar orientation is changed and foam ring will be provided.

1. Al bracket cracked and shaft loosened.

• Action: Drum shaft is Improved and is Under Test

2.WireHarness Cut at Motor Connector.

• Action: Taping length is increased

5. Controller capacitance switch Resistor failure • Action: This is due to manual soldering process will be

resolved in production batch.

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SAP & IT by Mr Sanjeev Saxena

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Material Receipt

Process

Optimization

at Security

Gate for Stores

33

Previous Process at IFB Verna

Vendor park the

vehicle at Gate

Bring the Documents

to store for validation

of schedules lines

After confirmation of

schedule line, vendor

make the gate entry in

the register

Get the stamp at

Security

Vehicle move to

allotted way

Material Unload and

Gate entry - 103 made

at Store

Material placed at

counting scale

While weighing,

system print the tag for

fixing on box/carton

Counted Qty – with

tag forwarded to store

for GRN

Bottleneck 2 – 3

hrs waiting time of

vendor and

processing time of

document

Manual Record

keeping at Security

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Revised Process at IFB Verna

Vendor park the

vehicle at Gate

Document process at

Gate by Security in

Bartech System

Security stamped

paper with System

Gate Entry Number

Vehicle move to

allotted way

Material Unload &

placed at counting

scale

While weighing,

system print the tag for

fixing on box/carton

Counted Qty

document forwarded

to store for GRN

Result

Reduction in

waiting time of

vendor and

processing time of

document

No Manual record keeping at

security

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Training by Krishan

Online Test

Sl. No. Participants Name

Product Feature

General

Awareness

Total Score

out of 40

1 Sudhakar Raut 17 85% 16 80% 33

2 Mitesh Gajjar 16 80% 14 70% 30

3 Ramkrishna Bale 16 80% 12 60% 28

4 Petcy Monteiro 17 85% 10 50% 27

5 Senthil Murugesan 11 55% 14 70% 25

Out of 174 employee, 45 employees only appeared for on line test and out of them

29 employees appeared for online test on Product Features. And 38 employees

appeared for online test on General Awareness and only 20 employees has

written both online test.

Test dates – 18th & 19th of every month

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Service Centre – Rohit Gaad

Goa Service Center

• Objective of the Goa service center is to drive closure of

pending calls greater then 48 hours by co-ordinating with

the Franchisee and Branches and to improve customer

satisfaction.

• Currently operating the Goa Service center from Digisol

premises in Verna Industrial Estate.

• Total 15 agents were recruited and trained on product

/process and CRM.

• Currently we are running two outbound processes from the

service center i. e Welcome Calls to new customers who

have bought our products post installation and driving

pending calls greater then 48 hours from CRM.

The two processes have been initiated for customer’s from

Goa, West and North.

Welcome Calling Snapshot

• Total Customers Dialed – 4064

• Total Customers Spoken -2672

• Customers Satisfied with Product -2120

• Customers Di-satisfied with Product -48

• Customer Satisfied with Service and Installation -2003

• Customers Dis-satisfied with Service and Installation -130

• First Time IFB Buyer -1602

Goa Service Center

Voice of Customer

• Tap adaptor should be provided with the machine.

• Recipe Book should be provided with all MWO.

• Only experienced Technicians should be sent for demo.

• Dealer should inform customer about trolley at the point of sale.

Goa Service Center

Pentair Cup – Siddesh

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Pentair Cup was organized by Pentair for all the IDC organizations in Verna .

IFB cleared 3 rounds and we reached the quarter finals for the second

consecutive year .We also gifted the player of the tournament award with a

20PM1S MWO

Sanjay /Yeshwant /Sudan/Desai /Siddhesh /Kapil/Samir

Shishir /Vinay / Rohan / Sanket /Sunil – Team IFB

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New Employee Introduction

Mr Manish Thakur

Worked in

Sumi Motherson for 13 yrs &

Samsung Mobiles for 3.5 yrs

Speciality in

Plastic injection Moulding

DOB : 4th Feb

DOJ : 16th Apr 2012

Home town : Noida

Language : Hindi /English

Corlim Plant Cell by Dattaram

45

Productivity increase of dryer

• Before shifting of dryer assly line to

corlim plant, production out put per

day was 40no’s of dryer

• Which was increased at corlim plant

by 20no’s,

• Output production per day now

60no’s

Improvement for the month

• During painting of Front panels Insulation

tape was provided on four studs , which was

replaced by 6mm pipe resulting in better

productivity.

Before

After


• Paint shop hangers were modified for better

painting of single piece cabinet.

Before modification


After modification

One person was reduced during loading


• Conveyer length was increases to accommodate five no’s of dryer after electrical testing

Before After


52

Goa Branch by Nilotpal & Joyce

SALES PERFORMANCE

Sr. No. PRODUCT APRIL- VOLUME

BUDGET ACHIEVED LY GOLY

1 FL 272 275 187 47%

2 TL 128 60 60 16%

3 MWO 441 375 404 -7%

4 DDW 19 28 14 100%

5 CD 17 29 21 38%

6 IDW 3 4 1 300%

7 ILE 4 1 1 -

8 B. in O. 2 2 2 -

9 Hob 19 6 10 -40%

10 Hood 18 3 9 -66%

11 MK - 2 1

12 TOTAL 923 785 710 11%

PRODUCT APRIL- VALUE (in Rs. Lakhs)

BUDGET ACHIEVED LY GOLY

FL 63 56 37 51%

TL 17 7 7 -

MWO 36 28 25 12%

DDW 5 7 3 133%

CD 3 4 3 33%

IDW 4 6 2 200%

ILE 6 1 1 -

B. in O. 0.5 0.5 0.7 -28%

Hob 2 0.7 1.3 -46%

Hood 1.3 0.4 0.87 -54%

MK - 5 2.34 113%

TOTAL 138 116 83 40%

SALES PERFORMANCE

COOKERY SHOW – IFB Art Kitchen

INITIATIVES 1. Driving cookery classes to ensure positive word of mouth. We are

conducting this on a weekly basis at the kitchen showroom.

2. New chef has been recruited – idea is to promote the IFB mascot concept. Internet platforms like YouTube, Facebook, etc. to be used for streaming our cookery shows online.

3. “Target the kids” – we have seen the best way to lure people into an IFB store is to target their kids. Special tutorials on certain recipes, its presentation, etc. are being held especially for the kids of parents who are our target audience.

4. Free Service camp & canopy activity conducted @ Model’s Millennium, Kamat Complex & Factory.

5. DW home demo – branch has invested in a DW. Plan for conducting at least 10 home demos every month will be driven from May onwards.

6. Tie up with plumbers and electricians to close installation calls speedily .

Your Questions Please…..

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