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Making India a Globally Competitive Manufacturing Hub through Total Quality Excellence Arvind K Shukla Executive Vice President & Head Business Group – IV, JBM Group akshukla@jbm. co. in +91 9999913074 Jan 2011 Copyright of JBM Group. Duplication Prohibited. 2
Our Vision Expanding leadership in our business through people, keeping pace with market trends and technology. Jan 2011 Copyright of JBM Group. Duplication Prohibited. 3
Key Facts & Figures 33 Manufacturing Sites Employees : 15, 000+ Turnover: 4500 Cr. Headquarter: New Delhi Founded: 1983 Jan 2011 Copyright of JBM Group. Duplication Prohibited. 4
Diversification Education Engg Services Tailor Welded Blanks Tubes Integrated Welded Modules Small Sheet Metal Components LPG Cylinders Welded Assemblies 1983 1985 1989 Jan 2011 Dies, Jigs, Fixtures Skin Panels Large Sheet Metal Components Special Purpose Vehicles Solid Waste Mgmt. Steel Processing Exhaust Systems 1990 1994 1996 1997 1998 2002 2005 2006 2007 2009 2010 Copyright of JBM Group. Duplication Prohibited. 5
Our Alliances Europe North America Arcelor Tailored Blank Dassault Systemes MA (Magnetto) MSC Software India South America Fanalca Jan 2011 Ashok Leyland Maruti Suzuki Sandhar Technologies Copyright of JBM Group. Duplication Prohibited. Japan Daiwa Excel Futaba Hamamatsu Pipe JFE Metal One Nisshin Okamoto Sumitomo Yorozu Thailand Thai Summit Auto Ogihara 6
Our Reach The underlining business philosophy of the JBM Group has been to expand its reach. This is demonstrated by the following: q Plants Located across the country q Catering to wide Industry segments q Wide Customer base q Offerings of Products & Services Jan 2011 Copyright of JBM Group. Duplication Prohibited. 7
Our Locations 33 Plants spread across 14 locations Nalagarh Haridwar Pantnagar Delhi Gurgaon Greater Noida Faridabad Kosi Sanand Indore Nashik Pune Aurangabad Head Office Current Locations Upcoming Locations Bangalore Hosur Jan 2011 Chennai Copyright of JBM Group. Duplication Prohibited. 8
Industry Segments Jan 2011 Copyright of JBM Group. Duplication Prohibited. 9
Customer Base Jan 2011 Copyright of JBM Group. Duplication Prohibited. 10
Exports / International Business North America Europe Judricks Delphi Volvo Bus Husqvarna JCB Terex Ingersoll Rand Asia Al Shirawi South Africa General Motors Renault Jan 2011 Copyright of JBM Group. Duplication Prohibited. 11
Food for thought "Without changing our patterns of thought, we will not be able to solve the problems that we created with our current patterns of thought. “ Jan 2011 Copyright of JBM Group. Duplication Prohibited. ~ Albert Einstein 12
Total Quality The Old Way Andrew Carnegie Jan 2011 Excellence “Watch the costs and the profits will take care of themselves. ” “Watch the Quality (Right First Time) and the profits will take care of themselves. ” Copyright of JBM Group. Duplication Prohibited. The Secret to Success? The New Way W. Edward Deming 13
‘Total Quality Excellence’ for Competitive edge – The JBM way Jan 2011 Copyright of JBM Group. Duplication Prohibited. 14
Winning Organisation for the New Economy Different levels of knowledge management KNOWLEDGE MANAGEMENT ( Both Explicit and Tacit ) Teaching Organisation Learning Organisation Every Body is Learning Teaching and being taught Coaching Organisation Every Body is Learning Teaching and being taught Coaching and being Coached Typical Organisation Every Body is busy; Firefighting in routine Jan 2011 RESULTS ( Sustained Growth and Value Creation ) Copyright of JBM Group. Duplication Prohibited. 15
Winning Organisation for the New Economy NEEDS • Leaders Who can set example & demonstrate • Change Agents Who have the conviction to state the facts based on data even if the consequences are associated with unpleasantness. Jan 2011 Copyright of JBM Group. Duplication Prohibited. 16
“Perfection is not Attainable. But if we Chase Perfection we can catch Excellence” Jan 2011 Copyright of JBM Group. Duplication Prohibited. 17
PERFECT ULTIMATE • • Jan 2011 Right-First Time Right-On Time Both every time By every one In every job In every activity Without inspection Copyright of JBM Group. Duplication Prohibited. 18
“To improve is to change ; To be perfect is to change often ” Jan 2011 Copyright of JBM Group. Duplication Prohibited. 19
Vision Mission Values Goals Process Flow Speed Team work Defects & Variation Improve Process VOC Quality 1. Delight your Customers with Speed and Quality Data & Facts Jan 2011 Copyright of JBM Group. Duplication Prohibited. 20
Vision Mission Values Goals Process Flow Speed Quality Team work Defects & Variation Improve Process VOC 2. Improve your process by eliminating variation, improve process flow and speed by eliminating / reducing 3 MUs in the process. Data & Facts Jan 2011 Copyright of JBM Group. Duplication Prohibited. 21
Vision Mission Values Goals Process Flow Speed Quality Team work Defects & Variation Improve Process VOC 3. Engage Teams through taking Responsibility and Accountability for Quality, Speed, Cost Effectiveness, and People (Safety & Morale) Data & Facts Jan 2011 Copyright of JBM Group. Duplication Prohibited. 22
Vision Mission Values Goals Process Flow Speed Quality Team work Defects & Variation Improve Process VOC Data & Facts Jan 2011 Copyright of JBM Group. Duplication Prohibited. 4. Decisions based on authentic Data and Facts 23
Vision Mission Values Goals Process Flow Speed Quality Team work Defects & Variation Improve Process VOC 5. Purpose driven organisation Living Vision, Mission, Values and Goals Data & Facts Jan 2011 Copyright of JBM Group. Duplication Prohibited. 24
Total Quality Excellence Culture of LEAN PURSUIT OF SIMPLICITY, EFFICIENCY FOCUS SIX SIGMA PURSUIT OF PERFECTION, EFFECTIVENESS FOCUS Continuous Improvement ISO 9001, ISO/TS 16949, ISO 14001, OHSAS 18001 Jan 2011 Copyright of JBM Group. Duplication Prohibited. 25
Lean Six Sigma is 20% Technical and 80% Behaivioral Jan 2011 Copyright of JBM Group. Duplication Prohibited. 26
Getting a Right Cultural foot • Delay roll-out of Lean Six Sigma until, enough, right people are ready to PULL trainings, PUSH will not deliver results • Until we know which employees and teams are most willing and able to embrace the initiative and lead peers • Reward those so identified (with appropriate motivation for that individual) Jan 2011 Copyright of JBM Group. Duplication Prohibited. 27
Culture • Culture can only be grown; it can never be manufactured. Culture for an organisation is like personality for a person. • It can not be copied or transplanted. It can only be developed over time. Jan 2011 Copyright of JBM Group. Duplication Prohibited. 28
Kaizen Culture: in which everyone can freely admit & expose these problems • If you can not expose Problems & Wastes you can not improve Jan 2011 Copyright of JBM Group. Duplication Prohibited. 30
Problem Solving Individual Or Small Group 3 Mu (NVA) Elimination Individual Or Small Group Human Development Individual Or Small Group Kaizen (Lean) at JBM Jan 2011 Copyright of JBM Group. Duplication Prohibited. 31
‘Total Quality Excellence’ for Competitive edge – The JBM way Ø Ø Jan 2011 Improve Customer Experience Improve Quality Reduce Lead time Reduce Total Cost Copyright of JBM Group. Duplication Prohibited. 32
‘Total Quality Excellence’ for Competitive edge – The JBM way Ø Ø Ø Jan 2011 Deliver Exact things At Exact time In Exact amount At Exact place Every time Copyright of JBM Group. Duplication Prohibited. 33
Total Quality Excellence for Competitive edge – The JBM way Jan 2011 Copyright of JBM Group. Duplication Prohibited. 34
Ten ‘Total Quality Excellence’ Principles – The JBM way 1. The safety and well-being of our employees, customers & suppliers is number 1. 2. We must strive everyday to improve the quality of our products, services and processes. 3. We must continually work toward exceeding our customer, supplier, community, employee and stakeholder needs & expectations. Jan 2011 Copyright of JBM Group. Duplication Prohibited. 35
Ten ‘Total Quality Excellence’ Principles – The JBM way 4. Employ lean concepts and kaizen events to regularly remove waste from our processes and drive results. 5. Create a continuous learning organization by teaching and then apply that learning immediately; learn a little, do a little. 6. Develop employees to their fullest potential; teach them urgency, accountability and humility; have them mentor others. Jan 2011 Copyright of JBM Group. Duplication Prohibited. 36
Ten ‘Total Quality Excellence’ Principles – The JBM way 7. Practice fact-based decision making; always go to the process and observe before proceeding. React based on statistically relevant data. 8. Measure only what is truly important; recognize and reward team achievement. 9. Use the principle of pull to drive demand from upstream processes to prevent both pushing and overproduction Jan 2011 Copyright of JBM Group. Duplication Prohibited. 37
Ten ‘Total Quality Excellence’ Principles – The JBM way 10. Develop supplier, contractor and customer partnerships and work together to continually improve the supply chain’s quality and responsiveness Jan 2011 Copyright of JBM Group. Duplication Prohibited. 38
Questions? Comments? Thank you for your time Jan 2011 Copyright of JBM Group. Duplication Prohibited. 39
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