BANKING
Lead Time Reduction in Export & Import Collection Process |
Increase in Cross Sell Numbers |
Lead Time Reduction in E-Filing Process |
Improving Processing time of Invoices of the Invoice Processing team |
To reduce the PPM level of Center hole Crack from 3160 to 100 in CDR (compact disc recordable) lines |
Increase in Call Productivity per Agent Abandonment rate |
Lead Time Reduction in Migration Process |
Improving Processing time of Invoices of the Invoice Processing team |
TAT reduction in LC Issuance Process |
To Increase STP rates in Spanish Stock Loan Equity Settlements and reducing the agent cost |
Lead Time Improvement in Singapore Negotiations |
Lead Time Reduction in Export & Import Collection Process |
Reducing Cycle Process Time for NGDR Process |
Query Resolution Cycle time reduction |
Headcount Reduction - Trims Synergies - Process Improvements |
Reduction in Pricing Errors |
Suspense and Deferred Accounts Tracking |
Funds Transfer Process Merger |
Transit Time reduction for Collections |
Cycle Time Reduction in Account Opening and merger of Account opening Ops for India and Ceemea |
Cycle Time Reduction for IWDW in non-metros |
Optimum Seat utilisation at Malad |
Reduction in Cycle time-Procurement |
Reduction in Communication Cost |
Deliver as per timeliness/Project Planning & Management |
Customer Satisfaction and Risk Minimisation in Debt Processing with spec focus on Corporate Actions |
Debottleneck Processing |
Recruitment Turnaround Time |
No Structural Product & Process Training |
Payroll Queries |
End to end XPU processing |
Improvement and Maintenance of Malad Site |
Improvement and Maintenance of Malad Site |
Improvement of Access Controls-Mumbai |
Increasing agent call productivity and quality-empowerment of CPOs |
Reduce the number of re-dos (internal & eternal to 0) |
Shortening of Learning Curve for new joinees |
Improve Query Resolution Cycle Time |
Error Tracking- Timeliness and Accuracy |
Managing Volumes of Paper |
Data Updation-Cust. Contactability |
Reduction in the num of RTO |
Turn Around Time Reduction from Application date to Card delivery of Credit Card |
PHARMACEUTICAL
To reduce water consumption of cooling towers |
Increase the yield of CCC Crude from Extraction syrup |
Increasing yield of SSS 60% powder produced from SSS Ps syrup |
To Increase the Condensate Recovery at Plant |
Food
Paramix brix process capability improvement from 0.8 to 1.5 |
Sugar Syrup process improvement |
Reduction of pre-form wastage |
Improvement in productivity of bull gear cell |
MANUFACTURING
To increase the fabric production |
To increase Anhydrous Sodium Sulphate Salt Recovery |
Reduce cycle time of sending Export documents to customers |
Reduction in Yarn Strength Variations |
Eliminate acidic instances in yarn |
TEXTILE
IMPROVEMENT OF PRODUCT REALIZATION IN BOXER GARMENT |
TELECOM
Reduction in AMC Renewal Cycle-time |
Reduction in Average call closure time for Customer Complaint - NSC remote Calls |
Reduction in Resolution Time for Customer Complaints |
Reduction in Cycle Time for Receivables” |
Reduction In Project Operating Cost |
Reduction in Project Closure Cycle Time |
Reduce defects in Exception Report |
Improvement of the Interior Finish Quality |
Reduction in Average Talk Time |
Reduction in Mean of Recruitment Cycle Time |
Reduction in Cost-overrun of Infrastructure Projects |
Cycle time reduction in Order Processing & Delivery |
Reduction in Average Talk Time |
To reduce Project Execution Cycle Time |
Improvement of Efficiency of Delivery Group Professional Resources |
Increase in Revenue from New Acquisitions |
Reduce Cycle Time of Material Delivery |
Improvement of Payment Cycle to Suppliers |
Reducing Response Time for Redressal of Dividend Queries/Complaints |
Increase Prospect to Order Conversion Ratio |
Improving Employee Satisfaction |
OIL & PETROLEUM
Reduction of Fuel and Loss |
To reduce slop generation |
To reduce Flare loss |
Yield maximization of distillates |
To minimize level of oil sludge |
To improve reliability of equipments |
To control give away quality in final products by controlling variations |
Operation cost minimization |
Improvement of O & S factor on key equipment |
Maintain right crude basket |
Reduction of Fuel and Loss |
Distribution of product to match the plant capacity |
Single shot approval of product |
To reduce the incidents of Flare losses from X to Y |
To reduce the Yield variations (Product to be identified based on data) |
To increase the MS pass ratio from 20:80 to 80:20 |
To improve the LPG yield in FCC from X to Y% |
Reduction in heavy ends (VR) in FPU1, FPU2 and VDU |
To reduce slop oil generation from X to Y |
Reduction in handling/accounting losses in HSD distribution |
Improve LPG production from 85% of distillation potential to 90% |
Reuse of treated effluent |
Improve realization of LPG in FCC process from X% to X 2% |
Reduce frequent changeover of M.F. bottom pump in RFCCU resulting into throughput reduction |
Reduce consumption of NH3 in SDU From X to Y MT/Month |
Reduce number of localized source power interruptions |
Improve reliability pumps & motors |
Improve efficiency of pumps & motors |
Reduce slop generation |
Reduction of blending on account of off specification |
Improve availability of LPG mounded bullets |
Reduce changeover time for ATF to Kerosene & vice-versa. |
Reduce start up time for H2 treater from 48 hrs to lower level |
Increase flare gas utilization |
Improve quality spec compliance of Diesel (95% evaporation at 3700 C) in H2 treater |
Reduce fuel consumption in CDU & DCU furnaces |
Develop system for electrical heat tracing instead of steam heat tracing. |
Heavier feed processing at Iso-sive unit. |
Reduce WIP Inventory from 72,000MT to 57,000MT(Anticipated Savings 2.85 crores on a/c of interest 12 crores on a/c of margins). |
Increase wax production from 40,000MT to full potential in crude at present throughput level(600 TMT). |
Reduction of inprocess natural gas consumption |
Reduction of inprocess steam consumption |
Improve equipment reliability of Coke cutting system( Maint) |
Improve equipment reliability of SD unit (Maint.) |
Improve effectiveness of production/ service meeting |
Maximise stream sharing between Guwahati & Digboi(remove hurdles). |
Reduce MIBK (Methyl isobutyl ketone) consumption per ton of wax |
Blending process optimization- product pattern/Mix |
Reduce input crude cost-1- Accounting 2-Quality assessment and pricing |
To increase the cycle length between two regenerations (Catalytic Reformer) |
To increase cycle length between two SAD(Steam Air Decoking) in coking Unit. |
To reduce cycle time of indent to placement of PO (Equipment and spares) |
To reduce cycle time from placement of PO to procurement (Equipment and spares) |
Improve adherence to lead time of order procurement |
To reduce procurement delays |
Reduce inventory |
To reduce cycle time of indent to placement of PO (Capital items) |
To reduce the inventory level of stores and spare items |
To lay down filing and retrieving system |
Reduce Indent to PO lead time from X to Y |
Reduce cycle time from receipt of material to release of payment from X to Y |
Eliminate stock mismatch in Seals & Bearing spare between SAP & Physical from X to Y |
Reduce cycle time from generation of indent to receipt of material |
Eliminate stock outs of store items |
Improve cycle time of order procurement |
Reduce inventory & stock out situations |
Timely payment to suppliers |
To reduce lead time for limited tenders from PR To PO from 70 days to 45 days. |
To reduce lead time from issue of PO to receipt and acceptance of materials. |
To reduce delay in disposal of scrap from declaration to disposal. |
Improvement in analyzer availability from average 78 to 90% |
Minimum 98% availability of temperature instruments of compressor and furnace skin temperature |
Reduction of spurious trips due to instrumentation |
DCS (Distributed Control system) failure reduction in sulphur unit |
Zero interruptions due to critical instruments |
To reduce the time to attend maintenance calls |
Timely availability of spare parts |
Improve reliability of controls & operational flexibility in DCS controls of Boilers while reducing the manpower |
To ensure accuracy of all controllable parameters within 2% around set point. |
To ensure 100% availability of the stack monitoring system |
To arrange all technical drawings, documents and regular updation with Master index |
To ensure 100% availability of all stand-by hardware |
Minimize frequent malfunctioning of Level instruments in Solvent Dewaxing Unit (SDU). |
Minimize mal-functioning of Local Level gauges in WHFU, HP Vessel |
Improve accuracy and precision of measurement system of analyzers |
Minimize frequent failures of level instruments in LRU |
Reduce the failure rate of equipment in Sulphur unit (Air cooler) |
Improve MTTR (Process cooling tower-gear boxes) |
Improve spare parts availability |
Improve on time availability of spare parts |
Improve MTTR |
Improve MTBF |
Reduce incidents of steam leakages |
Improve maintenance time of Heat Exchanger from X to Y |
Reduction in routine maintenance cost by 20% |
Reduction in shut down time of Plant (s) from X to Y |
Reduction in down time of tanks from X to Y |
Timely availability of spare parts |
Improve availability of locos for operations |
Reduce frequent failure of DAO mix pump in PDA unit from X to Y |
Reduce premature bearing failure X to Y |
Improve the availability of LPG pump in FOB From X to Y |
Reduce maintenance expenditure |
Reduce MTTR for rotary equipment |
Reduce repair time & ensure smooth running of Portal crane |
Reduction in handling time of top covers of both reactors R1A & R1B of DCU |
Rectification of API separator pumps of ETP |
Reduce energy & manpower of sewage system & booster pump house of township. |
Develop drainage system for rain water handling to avoid mix up with system & treated water |
Improve process of sump cleaning of ETP to reduce time and minimize usage of crane. |
To improve reliability of rotary equipment |
To improve reliability of rotary drum filter(SDU) |
To improve reliability of chillers at SDU |
To reduce delay in codification of spares |
To improve cooling water quality and pressure |
To reduce MTTR |
To improve MTBF |
To improve system for SDU/WHFU tank farm operation |
To improve MTBF of 1st & 2nd stage condenser at WHFU |
To improve availability of slurry thickener system at DCU |
To improve reliability of coolers & condensers in cocker unit |
To improve reliability of coke cutting unit |
To reduce repair/ maintenance cost |
To reduce consumption of seals & bearings |
To improve indenting cycle time for non inventory items |
To create system for defining Min/Max level of inventory for stock items with clear specs. |
To improve cost estimation process of parts being indented and works contracts. |
To reduce inventory of General stores from Rs. 100 to 70 Crores (Review the do-ability in 5-7 months) |
To achieve the payment time to suppliers/contractors as per agreed terms |
Cost reduction by 10% in chemical and catalyst items |
Reduction of Fuel and loss |
Timely payment to suppliers of refinery and project |
To achieve the payment time to suppliers/contractors as per agreed terms |
Timely payment of claims (Medical reimbursement) to employees |
Reduce financial concurrences cycle time from X days to Y Days. |
Reduce interest losses by better management of CENVAT, Service Tax, Export Credit) X to Y per ton |
Reduce time lag for GRV related payment to the vendor |
Reduce final bill payment cycle time for contracts |
Reduce advise delays related to employee allowances |
Improve response time in payments to suppliers/ contractors. |
Minimize delays in miscellaneous payments to employees like Medical, LTC, etc. |
To reduce lead time in finance concurrence for approval of purchase and project contracts. |
To reduce payment time for purchase and all other contracts as per agreed payment terms. |
Zero interruptions in power generation |
Zero interruptions in power distribution |
Reduction of process steam consumption from 125 MT to 100 MT per hour |
Reduce DM water consumption from 200 to 190 MT/hour |
Zero interruptions in power generation |
Zero interruptions in Instrument air |
Cost reduction in chemical consumption for water treatment |
Improve steam fuel ratio from X to X 0.1 |
Reduce average steam consumption |
Reduce air consumption |
Reduce cost of power generation |
Eliminate unit power interruption |
Increase steam-fuel oil ratio in boilers from 13.3 to 13.45 ton of steam per ton of fuel. |
Improve vacuum in TG3 & TG4 for reduction of specific steam consumption. |
Reduction of water consumption in refinery by 20%. |
Reduction of boiler no. 4 stack temperature from 180 to 1550 C |
Improve reliability of intake water pumps. |
Improve pH & phosphate norms to design levels. |
Reduction in power consumption/ generation |
Reduce consumption of make up water to cooling towers from 60 cu. Mtr. Per hour to 30 cub. Mtr. Per hour.( Anticipated savings of 0.5 crore ). |
Reduce biological corrosion to avoid production loss of 6 days.( Anticipated savings of 1.9 crores) |
Improve response time of GT service support. |
To bring down, steam consumption By controlling losses in distribution system. |
Improve recovery of steam condensate from 7T to 10T/hr ensuring right quality. |
To optimize the level of drug purchase fro 55:45 to 80:20 |
To improve compliance level of annual medical check up |
To reduce cycle time of indent to receipt of drugs to stores |
Improve employee satisfaction level from medical care services from X to Y |
Reduce external referral cost by X% |
To measure & improve customer satisfaction |
To ensure 100% compliance to periodical medical check-up for well persons |
To ensure full implementation of hospital software. |
Improve satisfaction to employees |
To make hospital operation to earn and meet total cost. |
To reduce no of referral cases |
Improve PME compliance of employees |
Reduction in cycle time of recycling of effluents by reducing break down of Barari pumps |
To reduce incidents |
To reduce the cycle time of indent to PO preparation from 6 M to 4 M |
Timely execution of process schemes (Scope??) |
To reduce errors in design/process documentation |
Reduce cycle time from receipt of process scheme to issue of detail engineering drawing from 4 Month to 1 Month simultaneously improve quality of drawing |
To optimize cycle time for contract finalization in case of open tender |
To ensure timely availability of drawings & materials at the time of award of contract. |
Improve customer satisfaction by reducing customer complaints from 340 / month to 100 / month & finally to zero. |
Optimise drinking water consumption from 10000 cub mtr to 8000. |
Reduction in lead time of award of contracts |
Reducing delay in award of contracts (20% to 0) |
Optimization of “Contract bank” (300 to 75) |
Reduction in lead time of award of contracts for two bid system tenders from X to Y days |
Reduce tender cycle time from 90 days to 60 days |
Reduce delay in contract execution |
Improve PWD(Pressable Waxy Distillate) Quality & Yield Consistency from distillation Process v/s potential |
Reduce Benzene content in Motor Spirit to meet Euro II/Bharat stage II. Norms |
SDU refrigerant condenser water flow reduces with in 2 days to 2 months of cleaning against target of 2 years(P&U) |
To improve cost factor of white and black oil |
Inventory control of Consumables |
To reduce number of intermediate tank sampling |
Improvement in the ratio of certified tanks to offered tanks from X to Y |
Optimize disposal plan for recovered oil from sludge. |
Reduce cycle time for MS certification. |
Reduce down time of automatic testing equipments. |
To improve measurement accuracy & precision of recycle gas moisture testing process |
To reduce the inventory carrying cost |
To formulate system for non-moving items |
To improve the productive man hours of contractors |
Problems highlighted already taken care at other functions |
On time completion of Projects (less than Rs. 1 crore) (Do-ability in 5-7 months???) |
To reduce contracts closing time from X to Y |
Reduction in time for tank M&I from X to Y |
Reducing time taken for tank M&I |
Arresting leakage of fire water line (Shift to Maintenance) |
To reduce incidents |
To reduce the number of near miss incidents |
To improve the PPE compliance from X to Y |
Control of leakage from fire hydrant to maintain pressure & save energy. |
100% availability of fire hydrant and monitors for fire fighting readiness |
Improving the stream factor of process units by keeping the static equipments more reliable |
Quality of work by service contractor |
To reduce the inspection time from X to Y??? |
Improving the on stream factor for secondary Units-FCCU and HCU (Do-ability) |
Minimize scale depositions in coolers & condensers resulting in increased maintenance hours |
Timely response to employees on HR services |
Optimal utilization of LMV |
Simplifying the procedure of quarter allotment |
Adherence to time set for identified services e.g., HBA |
Reducing number of complaints per week in canteen |
To enhance Employee satisfaction level from X to Y (Do-ability in 3-4 months????) |
On time availability of uniform/facilities (To be identified) to employees |
To reduce the waiting time of visitors at the main gate from X to Y |
Increase number of skill development program for employees from X to Y and monitoring the skill transfer there of |
Ensure availability of HR records within X Min |
Streamlining the leave management system.(Quantification) |
Improve skill level of workforce |
Optimization of manpower |
Reduction of cycle time of HR services to employee & external suppliers |
To reduce cost of LMV transportation |
To improve stationery effectiveness |
To optimize cycle time of loan/ advances processing. |
To improve up skilling of employees for re-deploy ability |
To optimize cost of skill development programs |
Improve employee participation in development programmes and effectiveness feedback from concerned departments |
Reduce variable speed drive tripping |
Reduce electrical flashovers |
Reduce Air pre-heater basket failures |
Reduce failures in fuel oil booster pump (GT) |
Reduction in B/D of motors from X to Y |
Minimise frequent motor bearing failure of refrigeration compressor in SDU |
Improve power factor from 0.77 to 0.85 |
To reduce cleaning time of crude oil/black oil tanks from X to Y |
Improve housekeeping |
Timely availability of synthetic/industrial paints |
Minimise the cycle time from receipt of indent to completion of work. |
Minimise the cycle time for bill processing from date of completion of job to release of bill to finance. |
Improve connectivity of SAP from 90 to 95% |
Improve availability of e-mail from 90 to 95% |
Improve availability of intranet from 90 to 95% |
Improve availability, quality & security of network & server from X to 99% |
To improve uptime of computers, printers and other peripherals. |
Electronic mapping of business processes like end of month leave data |
To reduce lead time for commissioning of outlets from 2 years to 9 months for all approved outlets. |
Streamline recovery of railway claims. |
ENGINEERING
Reduction of Energy consumption at Air compressor operation and usage. |
Helium gas consumption reduction |
REDUCTION IN CAL DEFECTS / IMPROVE PPM OF DEFECTS |
Develop water dispenser system |
WIP Inventory Reduction |
LGT Improvement in Vacuum Forming |
TO reduce mould changeover time from 7 hrs to 3 hrs |
Scrap cost reduction in cab foaming |
Door Metal line productivity improvement |
Increase in line go through of Paint shop from 89% t0 94% |
PNA calls reduction |
Repeat gas charging reduction |
Noise calls reduction |
Explanation calls reduction |
Cost Optimisation of Sealed system in 220L NF Models |
Cost Optimisation of Suction tube assy by redesign |
DE-MOULD TIME REDN. IN CABINET FOAMING |
WARRANTY CALL REDUCTION |
Zero breakdown of tools |
Productivity improvement of cut to length line. |
Air flow noise reduction in 285L -3G |
Cost optimization of electronic control board in Intelcool |
Reduction in Electrical Energy cost. |
Repair & Maintenance Cost Reduction |
Packaging Redesign for Cost Reduction |
AC Sound level Reduction |
Manufacturing ZBOC - Inventory Reduction |
CHU & FINAL Assembly Productivity Improvements |
Manufacturing In-process WIP Reduction |
OPTIMISATION OF DEFROST CONTROL SYSTEM |
PERCEIVED QUALITY SPARES THROUGHPUT TIME |
Reduction in Power and fuel consumption at Press and Paint shop |
REDUCTION IN SCRAP OF FOAMED CABINETS IN MAIN ASSEMBLY |
OPTIMIZATION OF DEFROSTING SYSTEM |
REDUCTION IN CAL DEFECTS/IMPROVE PPM OF DEFECTS |
Develop electronic controls for Direct cool Refrigerator |
IMPROVING DC COMPRESSOR CHARGEBACK |
Optimization of Motor ( auto washer) |
Indigenisation of Pressure switch |
Design of upper coupling with alternate material in Blade Coffee Grinder |
Noise reduction of Blade Coffee Grinder |
Design and development of 12 cup Blade Coffee Grinder - Programmable |
To bring down the TT washing machine rework w.r.t.spin basket hitting on the tub |
To optimize the Swift washer motor design and subsequently cost saving (per motor 25 Rs) |
Stain removal cycle development |
Cycle development for automatic water level selection for WM next generation |
Reduction in Liner crack by 70% |
Improvement in Ceiling Fan First pass including unbalance |
Reduce deviated (Data Sheet) rejection in Top Cover in terms of drawing from 726207 to 20000 PPM |
Improvement in First Pass in Portable Fan |
To reduce the rejection due to unbalance in the assy lines from 28000 ppm to 5000 ppm |
To reduce Dry Film Thickness (DFT) variation in painted components |
IMPROVEMENT IN FALL OFF RATES (FOR) IN PORTABLE FAN DUE TO DISCONTINUITY |
Die Casting Supplier Process Improvement |
Reduce portable fan line rejection due to sound |
To reduce the stator qty (despatch against defective) from 24600 nos yearly to 12000 nos |
Reducing Rejection in Injection Molding & Vacuum Metallising Process |
To reduce the rotor rejection |
TO REDUCE REJECTIONS IN PAINT SHOP |
To reduce Top Cover & False Cover Rejection in Paint Shop to 5000 PPM |
Reduction in Di Butyl Ether (DBE) Consumption on Stage 5 Cups Lines |
Improvement in Productivity in Portable Fan Assembly (Line No.1) |
Inventory Reduction |
Ceiling Fan Assembly rejection reduction |
Improve Quality – STANDING ORDERS |
Improve Quality – STANDING ORDERS – BITES EMAIL |
Accuracy percentage (TSLE Scores) – ANCC |
ICC Cycle Time Project |
To Improve SLA Met% in Email process |
Reducing % Discount lost For ASI – Canada |
Efficiency Improvement for Correspondence Team |
Increasing SLA % in VCR – IMS (USA) |
Reduction in Power Consumption |
Improve the Accuracy of BOSC Checks |
Reduce % of AR overdue |
REDUCTION OF CYCLE TIME OF READINESS OF AN EMPLOYEE – BITES EMAIL |
Error Reduction –Duplicate Invoice Processing |
Spares & Consumables Cost reduction Steag Maintenance |
Reduction of Transport Cost |
Improve the Accuracy of BOSC Checks |
Reduce SVDO Rejections |
Increase in login hours – ANCC |
Productivity Improvement – UK HelpDesk Team |
Increasing the Productivity % for Vendor Maintenance |
BPO
Reducing no. of zeroes in process quality for customer correspondence process |
Improving Quality of GA (Acorn) |
Reduction of Queries in ACORN GA Process |
Reduce customer queries in customer correspondence |
DATA STORAGE
Cost Reduction in WIP Packing |
IT develop Aqua Shield Ink Jet Printable (AS IJP) Disc |
Improvement in IMATION process to bring down failure rate of Mechanical & Electrical Parameters at OQA-2 stage |
In house made DVDR stamper yield improvement |
INHOUSE STAMPER LIFE IMPROVEMENT |
Improve Net Yield A B in Challenger-I, Plant1 |
CDRW Origin Line – Improved Cycle time |
Process optimisation of BDRE (1x-2x) discs |
Reduction in Cycle Time in Converted CDR Challenger – 3 Lines |
IMPROVEMENT IN WRS PROPERTIES OF MBI DISC SIMILAR TO TAIYO YUDEN DISC. |
BD-LOW TO HIGH(L2H) DEVELOPMENT |
IMPROVEMENT IN MECHANICAL AND ELECTRICAL DISC PARAMETERS AT OQA II. |
New DVDRW 4X with higher Archival & Shelf Life |
Reduction in Lead time of Disc transfer from Mono line to Printing |
Mould Loading/Unloading Time Reduction at Netstal Moulder |
Format Changeover time reduction by 50% |
SMED Printing Change over |
Reduction in job change over time from avg of 40 minutes to avg of |
DVD-ROM Cost reduction |
To reduce the breakage of Solar Cells From Laser to Shrink Wrap section, from current level of 5% to with in 2.5% at throughput rate of 3000 cells per hr. |
ROM-STAMPER COST REDUCTION |
P&P operation cost reduction by packaging CBs on Kamman Printing M/C |
HDDVD 2x Process Development |
Cycle time in Origin Lines to be reduced from 3.0 sec to 2.7 sec |
Cost Reduction in WIP Packing |
Reduction in inventory of silver |
Improve Net Yield A B in Challenger-I, Plant1 |
Cycle Time reduction of CD-ROM lines upto 1.65 sec.(Hybrid) & 1.70 sec(Combination of Hydraulic & Hybrid) |
Improve customer resolution process |
New DVDRW 4X with higher Archival & Shelf Life |
To reduce the breakage of Solar Cells on Cell Sorter m/c from current level of 6% to with in 2% at min. throughput of 1500 cells per hr. |
Improvement in IMATION process to bring down failure rate of Mechanical & Electrical Parameters at OQA-2 stage |
IMPROVEMENT IN WRS PROPERTIES OF MBI DISC SIMILAR TO TAIYO YUDEN DISC |
In house made DVDR stamper yield improvement |
Reduction in cycle time of CD-R M/C |
CDRW Origin Line – Improved Cycle time |
Poly Carbonate (PC) Saving |
BD-LOW TO HIGH(L2H) DEVELOPMENT |
To develop Aqua Shield Ink Jet Printable (AS IJP) Disc |
To reduce the PPM level of Center hole Crack from 3160 to 100 in CDR (compact disc recordable) lines |
To Increase STP rates in Spanish Stock Loan Equity Settlements and reducing the agent cost |
INHOUSE STAMPER LIFE IMPROVEMENT |
Improvement in vendor payment process |
Improvement in tracking errors and focusing error |
IMPROVEMENT IN MECHANICAL AND ELECTRICAL DISC PARAMETERS AT OQA II. |
Reduction in Cycle Time in Converted CDR Challenger – 3 Lines |
Process optimisation of BDRE (1x-2x) discs |
Reduction of Transportation Cost from Plant to ICD |
Top 3 Moulding Alarm Reduction |
Development of 6 layer BDR process instead of existing 7 layer process. |
Improving Internal Communication Process |
Reduction in Physical Vapor Deposition (PVD) Rejections |
Reduction of “MVNR” alarm |
Improving Compliance of discharging service tax liability |
Development of Engineering samples for DVD-RW/6x format and its submission to drive makers |
Reduction in PC Wastage |
Re-design the DVDR Stamper to make it robust and improve Cp/Cpk of mechanical parameters |
Reduction in cycle time of CD-R M/C from 2.80 sec to 2.60 sec |
To reduce the printing rejection at Buffer 4 from current level of 0.4% to with in 0.1% |
Reduce Average cycle time from gate-in to ERP stock |
Reduction in nickel consumption |
To Increase Overall Equipment Efficiency of Over Wrapping |
Reduction in Jewel Box-Cake Box scrap generation by 50% of existing level. |
To reduce Packaging, Raw & BOM Material GRN Clearance cycle time from 48 hrs to 12 hrs by Dec’08. |
New Title Launch |
Reduction in Lead time from order Acceptance to PGO Confirmation. |
REDUCTION IN PPM of PRINT REJECT |
Label Printing Cost Reduction |
Increase Mileage & Decrease Rejection PPM |
To reduce the consumption of TIM 3 Adhesive |
Reduction in cycle time of CD-R M/C from 1.46 sec to 1.40 sec |
SONY STAMPER LIFE IMPROVEMENT |
Reduction of Visual Defects in Solar Cells |
Sleeve Cost reduction |
Optimize the usage of Weiss unit with 2503 CD-R lines to reduce overall equipment cost and energy cost saving |
To improve ink mileage of PTC 10 product |
Improvement of the Sample Request Indent System |
MCL AZO Line –AZO TFP dye consumption Reduction |
Top 3 Moulding Alarm Reduction |
Reduction of cycle time from PGO (Plant Gate out) to Raising of consumption invoice for Sony VMI (Vendor Managed Inventory) shipments |
Reduction in Screen Damage during Printing Process |
To reduce Weight of Regular Jewel case |
Ink consumption by 5% in top 4 inks & Special inks |
CDR-Super Glyphics with Uniform L*a*b values |
Spares & Consumables Cost reduction Production, Lab & MPC |
Yield Improvement of printed OPS pouch across vendors from average 80% to 97% |
Cost Saving thru Replacing the Silver alloy Target by Pure Silver Target in Anwell DVDROM line. |
To Develop the Low Cost IJL Ink |
Ink Mileage improvement on IJL, Thermal and Light Scribe ink printing |
Cycle time Reduction in Challenger IV lines |
Reduction in scratch ppm of CD-R M/C from 1059 ppm to 200 ppm |
To redesign the existing RW-line for ensuring the production feasibility of BDR at MBI -GN. |
Improvement in visual downgrading by improving capability of DVDRW lines |
Streamline Contract Awarding process to reduce cycle time |
SONY CD-R STAMPER LIFE IMPROVEMENT |
Reduction in Dibutyl ether (DBE) Consumption on Steag 5 Cups Lines |
Improvement In Accelerated Aging Test For Professional Gold DVDR 16X Media |
Inventory Reduction of BOM Items Other Than PC ( From 39.5 to 33 Days) |
Reduction of Visual Defect PPM in DVDR |
Blank Substrate Weight Reduction |
To reduce Monthly average breakdown time of Printing line from 450 minutes/month to 200 minutes/month. |
Reduce IMM Cycle Time on Mitsui Tx Steag Lines from 4.50s to 4.38s |
Printing Rejection Reduction |
Mold modification for using ID 34mm & ID 22mm stamper in the same 3.2Version Mould |
Spares Cost reduction Replication & Printing Maintenance-CD-ROM |
Cost Reduction - Printing |
CDRW Shibura-Origin Lines–Machine Cycle time Improvement |
Overall Yield Improvement in ROM-M&G |
To Reduce weight of 10 cd cake box by 2gm. |
Reduction in cycle time of CD-R M/C from 1.46 sec to 1.40 sec |
To Reduce the % rejection of stampers because of Visual Defects |
Reduction in change over time on cake box and BOS(Bulk on spindle) tunnels. |
WIP REDUCTION |
Reduction in Dye Tank & Dye Cup Change over Time |
Development of 80mm mini CDR moulds from rejected 120mm CDR moulds |
Process Capability (CpK) Improvement of Electrical Parameters |
In house stamper yield improvement |
Improve recovery of used stampers |
PC Weight reduction of DVD-ROM by rejection control. |
Replacement of OPS pouches with alternative low cost option in all Domestic & Non OEM brands customers |
Use of edge wash recovered dye up to 5 % in “A” grade DVDR production (MBI/MKM 16x) to reduce the dye BOM cost. |
Ink consumption by 5% in top 4 inks & Special inks |
Reduction in spare part and consumables cost by 10% |
To reduce Cell Sorter break down time from average 2600 min/month to 500 min/month. |
On line CB packing on Kammann Machine |
Use of Pseudo Gold in place of silver target by keeping other things same on Steag P01 Dye lines |
BREAK DOWN REDUCTION FOR CD ROM MACHINES |
Recycling of Glass |
Resourcing of Back panel from Local supplier |
To reduce breakage of Wafers on Load cell Line from current level of 0.5% to 0.15% for 6” Multi crystalline |
Steag AZO Line – AZO TFP Dye Consumption Reduction |
3D Boom & Dipper Weight optimization |
ROM-STAMPER COST REDUCTION |
Reduce D-grade Generation by 50% after line Conversion and Preventive Maintenance |
To reduce 10% cost of Normal Printing and Mesh Cloth |
AUTOMOTIVE
Optimization of inventory |
3D Boom & Dipper Weight optimization |
Improvement in Inventory Turn and Availability |
Improvement in CNC MACHINE UTILISATION |
Reduce surface undulation in internal walls |
Reduce Troubleshooting time in Local Area Network |
Quality Improvement Project for New Models i.e.235 BP & 245 BP Tractors |
Reduction in Raw Material Vehicle Detention |
Maintaining mean inventory level of 7 days |
Elimination of assembly defects at Backlash stage in Transmission Assembly |
Productivity Improvement at 245 DI Cylinder Head Machining |
Reduction in assembly lapses at mounting stage in Transmission Assembly |
Quality Improvement Project for New Models i.e.235 BP & 245 BP Tractors related to Engines. |
Reducing Inlet & Exhaust valve rejection |
Millipore Improvement in Transmission Manufacturing |
Elimination of assembly defects at all Sub Assembly stages in Transmission Assembly |
Problems at Tractor Main line due to Engine Quality issue |
Improving effectiveness of Policy Deployment |
Noise Reduction in Transmission PG |
Scrap Cost Reduction in Tractor Assembly |
Improve Tractor Pre - Painting Quality at Nagpur |
Reduction of defects in Hydraulics due to Piston Assembly |
Reducing the lead time for VTU* housings from PCS** preparation to Dispatch of VTU* assembly. |
Improve Tractor Post painting line Quality at Nagpur |
Reduction in rejection of engine cylinder head. |
Reduction in assembler repetitive lapses in transmission assembly |
Reduce Injuries in transmission PG |
Testing rejection reduction in 245 DI engines |
Rejection & Rework reduction in testing of 235 DI Engines |
Reduce scrap cost in engine assembly and testing. |
Eliminate post tractor assembly leakages in Engines |
Reduce scrap cost in engine assembly and testing. |
Component defect reduction in casting supplier parts |
Reducing the Lead Time for Transmission Cases from PCS preparation Gate up to Dispatch of Transmission skids assembly |
To improve event effectiveness by 10% |
Reduction in R/1000 of clutch |
To reduce discrepancies in attendance and payroll system |
Elimination of assembly defects at Backlash stage in Transmission Assembly |
Productivity Improvement at 245 DI Cylinder Head Machining |
Reduction in assembly lapses at mounting stage in Transmission Assembly |
Improvement in Internal Customer Satisfaction |
Millipore improvement in transmission manufacturing |
Scrap Cost Reduction in Tractor Assembly |
Improve Tractor Pre - Painting Quality at Nagpur |
Reduction of defects in Hydraulics due to Piston Assembly |
Reducing the lead time for VTU housings from PCS preparation to Dispatch of VTU assembly. |
Improve Tractor Post painting line Quality at Nagpur |
Reducing crank case lead time from PCS making to engine dispatch to tractor. |
Improvement in Internal Customer Satisfaction |
Scrap Cost Reduction in Tractor Assembly |
Reduction of Defects in Hydraulics due to Piston Assembly |
Improve Tractor Post painting line Quality at Nagpur |
Reducing Lead Time of Front Axles From PCS stage to docking on Tractors |
Improve Tractor Pre - Painting Quality at Nagpur |
Reducing the lead time for VTU housings from PCS preparation to Dispatch of VTU assembly |
Reduction of Top 5 defects in Hydraulic due to Human errors |
Problems at Tractor Main line due to Engine Quality issue |
Improving Effectiveness Of Project Management in New Product Development. |
Improve ESS & reduce attrition rate at PDRDS |
Enhance market share of Jaipur Area Office |
Improve the effectiveness of new product launch process |
Improve the dealers’ performance by 5% market share points at select 5 dealers by Mar F05. |
Improving Effectiveness Of Project Management in New Product Development. |
Reduce Welfare Expenses |
Improve effectiveness of incentive spend |
Supply Chain effectiveness at FES |
Improving Effectiveness Of Project Management in New Product Development. |
IMPROVEMENT IN RELIABILITY OF TRANSMISSION OIL SEALS |
Spare supply improvement in international market |
Capacity utilization of NEF crankcase |
Enhancement of capacity of engine |
Enhance engine testing capacity |
Elimination of assembly defects at all Sub Assembly stages in Transmission Assembly |
Elimination of assembly defects at all Sub Assembly stages in Transmission Assembly |
Reducing Inlet & Exhaust valve rejection |
Capacity enhancement in CLG-27 machine, being used for Grinding Main Spool, Compensator spool and Main sleeve. |
Reduction in eye injuries in FES |
CONSTRUCTION
Reduction in complaint resolution time. |
Reduction in failure rate of Engine Mounting Pad |
TRAINING & QUALITY
Improve Raw Material Accounting Process |
Quality improvement on Spanish Extrusion machine |
Reduction of premium freight for Kolhapur hub to Rudrapur plant |
Reducing the problem of the hood blackening on the 235DI |
Reducing of scrap in two wheeler starter line |
REDUCTION OF FORGING DEFECTS IN STUB AXLE ( D#1028) |
Reduction of armature scrap due to earth |
Reduction in variation in Door Closing Effort of LOGAN |
REDUCTION OF CASTING DEFECT IN CRANKCASE (TURBO ENGINE) |
Reduction in Variation of oil level in Scorpio Engine |
Reduction of water consumption |
Reduction in failure rate of Engine Mounting Pad |
To improve Transmission Assembly Quality |
Reduction in Power and Fuel Consumption |
Reduction in VTU (Hydraulic) Testing Rejection |
To reduce the Transmission Testing Rejection |
Minimise Part Loose / Part Miss Defects in Pre Painting Line |
Development of Critical Component |
To reduce Jerky and Noisy braking operations during brake testing of Tractor |
Reduction in Material Scrap Cost |
Reduction of Defects due to Assembly Operation Mistakes in VTU Assy. |
Improve Supplier Rejection PPM of Tractor Parts |
Enhancement in data centre network security |
CHEMICALS
Optimisation of Synthesis loop |
To reduce discrepancies between physical and book stock |
Improve lubrication system for rotary drives |
Reduce repeat maintenance jobs |
Improve accuracy and precision of critical analysis carried out by spectrophotometer |
To maintain FRC in cooling water |
Optimization of synthesis loop |
Improve adherence of safety work Permit |
Reduce unplanned calibration of instruments |
Improve urea prill quality |
To improve quality of HDPE bags |
Reduction in transit and standardisation losses |
Optimisation of throughput (reduction in chemical consumption) and regeneration cycle (reduction in effluent generation/Water Consumption) |
To Reduce Breakdown Cost of Electrical Equipments |
Reduction in Transit & Standardisation Losses |
To improve the reliability of ATR jobs |
To Improve Reliability of Annual Turnaround Maintenance of Electrical Equipments |
To Improve Reliability of Annual Turnaround Maintenance of Mechanical Equipment |
PRIMARY REFORMER FUEL FEED OPTIMISATION |
Optimize cooling tower performance by improving approach |
Reduction of cycle time in claim settlement |
To improve Quality of HDPE Bags – reducing printing defects and variation in weight & strength |
Reduction in Raw Water Consumption by 2.0 to 2.5% (Stretched target) over previous year base inM³/MT of Urea |
OPTIMIZATION OF PROCESS CONDENSATE STRIPPER |
TO OPTIMIZE LP SECTION PRESSURE - UREA PLANT |
To reduce Bearing failure of Rotating Electrical Machines |
Reduction of Specific steam in Urea Process |
Reduction in cycle time of the Implementation of Suggestions through Suggestion Scheme |
To Reduce Cycle Time For Plant Modification Process |
To increase availability of critical spares of critical instruments |
Reduce Average Days Collection Period |
Avoid Missed Out Sales - Pesticides |
REDUCTION OF AVERAGE CYCLE TIME IN ISSUANCE OF PESTICIDES CREDIT NOTE TO TKS |
Reduction in Average Cycle Time for Soil Sample Analysis |
Reduction in Average Complaint Resolution Days |
Reduction of cycle time in claim settlement |
Reduction of QCT Bugs in Software Development |
SOFTWARE
Handover and commitment between BDG and Delivery |
CHEMICAL COST REDUCTION IN COW LEATHER MANUFACTURING |
Streamlining the process of Handover of commitment (made to clients) from BDG to Delivery Teams |
Reduction of QCT Bugs in Software Development |
Improving the Quality of MIS |
To reduce the MTTR in Product Support from 7 days to 4 days |