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MIS FOR CUSTOMER SUPPORT, ECC & ICA

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Presentation on theme: "MIS FOR CUSTOMER SUPPORT, ECC & ICA"— Presentation transcript:

1 MIS FOR CUSTOMER SUPPORT, ECC & ICA
– WK OF 2nd Feb 2015

2 Customer Support, ECC & ICA
Customer Coverage Status – OEM` 2-Feb-14 Region Transit WHS Norms for Domestic 1 Norms for Europe 6 3 Norms for China 7 STARTERS Norms for North America # PART NUMBER MODEL CUSTOMER EUROPEAN/NA/ AP WHS STOCKS TRANSIT STOCKS TOTAL Average Weekly Volume CUSTOMER COVERAGE - WKS Shortfall Quantity to meet norms Comments A&S 3M5T 11000CF DV6 Saarlouis/Valen 13084 16375 29459 2500 11.8 6959 2 6G9N 11000FA DW10 Ford OEMs 1636 192 1828 130 14.1 658 6G9N 11000AB I4 11821 4992 16813 1664 10.1 1837 5 7G9N 11000AC SIGMA 5702 2176 7878 768 10.3 966 8G AA ASTON MARTIN Aston Martin 384 96 480 50 9.6 30 AV6N 11000CA SIGMA GTDI 2548 375 2923 250 11.7 673 8 CV6T 11000DB V408 2665 1008 3673 288 12.8 1081 9 F1FT 11000EB F1FT 2697 3072 315 9.8 237 10 F1FT 11000MA 3146 3024 6170 504 12.2 1634 11 DG9T 11000AA 4530 300 15.1 1830 12 SML Volvo 1214 125 9.7 89 Obsolute on 30th Mar'15 13 ESM 10125 9600 19725 2112 9.3 717 14 I5P 4686 1230 15 SIGMA SID 2879 11.5 629 Obsolute on 6th April'15 16 DV6 - SS 5487 3000 8487 950 8.9 (63) 17 I5P SS 1660 256 1916 128 15.0 764 2116 nos availed at SML whs 18 CHINA 6656 9088 15744 20.5 8064 Volume 50 %, Awaiting confirmation from customer nos return back to Comstar due to foreign materials inside the container.

3 Customer Support, ECC & ICA
Customer Coverage Status - OEM 2-Feb-14 Region Transit WHS Norms for Domestic 1 Norms for Europe 6 3 Norms for China 7 STARTERS Norms for North America # PART NUMBER MODEL CUSTOMER EUROPEAN/NA/ AP WHS STOCKS TRANSIT STOCKS TOTAL Average Weekly Volume CUSTOMER COVERAGE - WKS Shortfall Quantity to meet norms Comments Domestic Customers 19 TVS-P X1 TML / FIAT 3125 1625 4750 1875 2.5 1000 20 X1 COMM 2496 288 2784 1152 2.4 480 21 FIRE FIAT 500 35 14.3 430 Discussion is going on with customer to cater parts to them. This is because of last four months they didn't pulled as per their schedule 22 CHETAK SUPER ACE 250 2.0 Supplied as per Schedule 23 AXPRESS NANO TML 168 336 504 672 0.8 (840) 716 Pcs are under TML plant as starters. 24 TVS-H F ALP15 Ashok Leyland 768 3264 864 3.8 1536 D3 - 8G1T11000BA 25 BAY 8G1T 11000BA D3 Ford OEMs 87426 53568 140994 10350 13.6 37494 26 AV6N 11000CA SIGMA GTDI 1670 2170 100 21.7 1170 27 CP7C3U 11005AA ARMATURE COMSTAR NA 17044 20790 42244 3800 11.1 4244 28 AC3U 11390AA SOLENOID 19688 25200 44888 11.8 6888

4 Customer Support, ECC & ICA
Refresh Date: 02nd Feb 2015 Data period: 27th Jan to 01st Feb SUPER-G Rating Summary Oct’14 , Nov’14 , Dec’14 & Jan’15: Code Region Oct-14 Nov-14 Dec’14 Jan’15 to date Production AHVFA Asia-Pacific 100 AHVFC Europe 92 AHVFG North America – Bay AHVFH Comstar LLC USA 94 97 Service 90 100 97 Dispute Rejected 95 57 dispute rejected 57 93 Dispute Rejected 85 under Dispute 96 GUR4A - 87 91

5 Customer Support, ECC & ICA
Customer critical parts for next two weeks Nil Critical parts to be produced this week at Comstar to avoid line stoppage at Customer       Jatco – After Market ( Armature Shaft not available)       3S6T AD (B+ Insulator not available) 2T14 CC ( Frame shortage) 2T1U AM (Yoke Pulley Not Available Critical Containers for next two weeks FCSD long pending parts to be produced this week to avoid lost delivery performance Starters Produced against the production plan in %    Week 47 (17th Nov'14 Week) Week 48 (24th Nov'14 Week) Week 49 (01st Dec'14 Week) Week 50 (08th Dec'14 Week) Week 51 (15th Dec'14 Week) Week 52 (22nd Dec'14 Week) Week 2 (05th Jan'15 Week) Week 4 (19th Jan'15 Week) Week 5 (26th Jan'15 Week) Week 6 (2nd Feb’15 Week) Production Plan 33759 31855 31946 31257 31453 31978 31905 31680 25430 31285 Qty Produced against the Plan 33510 31881 31501 31347 31470 31117 32157  31724 24648 Difference (249) 26 (445) 90 17 (861) 252  44 (-782) Achieved in % 99.3 100.1 98.6 100.3 97.3 100.8  100.1 96.9

6 Customer Support, ECC & ICA
EXT - WHS sales booking status SML Whs – Sales booked up to 2nd Feb’15 A/S Whs – Sales booked up to 2nd Feb’15 BAY Whs – Sales booked up to 2nd Feb’15 China Whs – Sales booked up to 2nd Feb’15 Customer Reconciliation Status BAY Whs – Completed up to 28th Dec’14 SML Whs & A/S Whs - Completed up to 28th Dec’14 China Whs – Completed up to 28th Dec’14 Comstar LLC (NA) - Completed up to 28th Dec’14 Direct Customers – To be Completed Jan’15

7 Customer Support, ECC & ICA
Aftermarket Budget Volume Vs Actual - So Far in Jan’15

8 Customer Support, ECC & ICA
Aftermarket pending orders - Approximate value is Rs. 1.75Cr Item Number OEM Ref Product Total Value 96FB ME Str 10 34400 98AB AC 45 198000 7G9N AC 158 505600 1BYU AA 20 73600 835X AC 96 422400 2S6U EE 500 2S7T DC 980 3M5T AE 30 127200 3M5T CF 120000 2T14 BC 154800 6G9N FA 333 6G9N EC 226800 YC1U AF 245 2T14 CC 75 414000 2S6T FC Alt 180 691200 3S6T AD 360 5S6Y AD 136000 1S7T CF 65 374400 YC1U EA 316800 2T1U BE 90 564480 2T1U CF 770400 2T1U AM 115 AMDF5C 11000AA 6C1T AA 300 Grand Total 3877          17,351,392

9 Aftermarket Orders Aging
Customer Item Number OE Ref Product Quantity Open Due Date Age Remarks AEE03 2S7T DC Str 200.0 12/22/2014 47 Awaiting for shipment EDR01 2T14 CC 30.0 DTS01 6G9N FA 45.0 1/5/2015 33 6G9N EC 1S7T CF Alt YC1U AF 7G9N AC 96FB ME 10.0 ARTEC 1/12/2015 26 98AB AC BIGOT 2T1U AM 25.0 1/15/2015 23 300.0 1/19/2015 19 AMDF5C 11000AA 6C1T AA HCA01 YC1U EA 1/22/2015 16 20.0 2T14 BC CASCO 2S6T FC 180.0 1/31/2015 7 3S6T AD 360.0 5S6Y AD 2T1U BE 90.0 2T1U CF 835X AC 96.0 480.0 2S6U EE 500.0 3M5T CF 3M5T AE 288.0 1BYU AA 128.0

10 Aftermarket Orders availability Status
AFTER MARKET PARTS SALES HIGH LIGHTS Sales Value for week 4 (26th Jan to 01st Feb’15) –   INR 2,670,597 Sales Value for the Month to Date (Jan’15) -   INR 4,495,941 Sales Value Year to date (YTD) – INR 4,495,941 (INR 4 Million) Aftermarket Orders availability Status Product Open Orders as on 26th Jan'15 Fresh Orders received Quantity produced last  week Quantity Shipped last  week Additional Qty on Comstar Total Balance Open Quantity as on 02nd Feb’15 Min. Required by this week Starters 19956 455 847 704 1507 18200 2101 Alternators 6689 875 150 420 7144 479 Total 26645 1330 997 1927 25344 2580

11 Customer Support, ECC & ICA
Oct’14 – 17.2Lakhs. Nov’14 – 9.7Lakhs Actual. Dec’14–12.7Lakhs Actual. Jan’15 – 24Lakhs planned and 24Lakhs Actual

12 Customer Support, ECC & ICA
Action plan for further reduction and support required : 42Lakhs will be opening for 1st April’15 and Of which Action planned 21Lakhs can be sold before July’15 12Lakhs is retained for next whole year orders based on previous 3years customer pull 4Lakhs material planned to bring back to Comstar India – Part sailed and ETA Chennai on 1st week of Mar’15 along with Solenoids Support required 5.72 Lakhs BB5Z 11002C – Lying at Bay Ware house and need CBG support to get release for FCSD NA

13 ETA at Europe (RTM / Zeebrugee) Tentative Delivery Plan
Customer Support, ECC & ICA Container Tracking - Europe ETA at Europe (RTM / Zeebrugee) Shipment Date Cutoff Date Warehouse Forwarder Liner Container No Original ETA Revised ETA 1 Revised ETA 2 Revised ETA 3 Actual ETA Tentative Delivery Plan Actual Delivery date Transit Delay Total Transit Time 3/Sep 4/Sep SML DHL CMA CMAU 7/Oct 7-Oct 15th Oct 15-Oct 41 A&S CEVA EVERGREEN FSCU 12/Oct 13/Oct 12-Oct 16-Oct 42 10/Sep 11/Sep IMTU 35 TGHU 19/Oct 20/Oct 20-Oct 24-Oct 8 43 18/Sep TGHU 36 LTIU 23-Oct 1 25/Sep HLXU 27/Oct 27-Oct 30-Oct 26/Sep 2/Oct Round Trip DFSU 9/Nov 10/Nov 10-Nov 13-Nov 30/Sep FSCU 2/Nov 3/Nov 3-Nov 5-Nov 6-Nov 8/Oct 9/Oct HLXU 14/Oct 16/Oct HLXU 17/Nov 18/Nov 18-Nov 21-Nov MRKU 14/Nov 14-Nov 20-Nov PONU 19-Nov 34 30/Oct TGHU 28/Nov 28-Nov 3-Dec 29 29/Oct SCH ECMU 8/Dec 8-Dec 39 5/Nov 6/Nov TGHU 32 Maersk MSKU 5/Dec 5-Dec 12/Nov 13/Nov TEXU 12/Dec 12-Dec MRKU PONU 5-Jan 53 20/Nov TGHU 19-Dec 46 19/Nov PONU 27/Nov PONU 25/Dec 25-Dec 6-Jan 40 MRKU 4/Dec PONU 1/Jan 16-Jan 20-Jan 15 47 INBU 1-Jan 33 18/Dec SCMU 20/Jan 11/Dec MAEU 19/Jan PONU 23/Dec MRKU 30/Jan 26/Dec MSKU 8/Jan ECMU 12/Feb CMAU

14 Tentative Delivery Plan
Customer Support, ECC & ICA Container Tracking - USA ETA at USA (Newyork) Train = 49 days Truck = 42 days Sl.No Shipment Date Cutoff Date Mode Forwarder Liner Container No Original ETA Revised ETA 1 Revised ETA 2 Revised ETA 3 Actual ETA Tentative Delivery Plan Actual Delivery date Transit Delay Total Transit Time 63 31-Oct 03-Nov Train SCH HAPPAG HLXU 03-Dec 06-Dec 08-Dec 10-Dec 22-Dec 19 49 64 Train to Truck HLXU 12-Dec 7 39 65 CPSU 14-Dec Dec-14 Dec-23 15-Dec -2 42 66 06-Nov 10-Nov HLXU Dec-22 4 67 HLXU 05-Jan 56 68 07-Nov GESU Dec-17 17-Dec 37 69 12-Nov 17-Nov HLXU Dec-19 19-Dec 32 70 15-Nov HLXU 23-Dec 36 71 BMOU 28-Dec 30-Dec 12-Jan 2 72 19-Nov 24-Nov FSCU 14-Jan 51 73 21-Nov HLXU 74 HLXU 15-Jan 52 75 26-Nov 01-Dec HLXU 02-Jan 04-Jan 16-Jan 46 76 29-Nov HLBU 10-Jan 22-Jan 8 77 HLBU 78 04-Dec TCLU 23-Jan 79 05-Dec HLXU 09-Jan 18-Jan 80 09-Dec ITAU 81 13-Dec HLXU 82 TGHU 83 18-Dec HLXU 25-Jan 84 HLXU 86 26-Dec 29-Dec HLXU 30-Jan 88 24-Dec TRLU 90 06-Jan HLXU 13-Feb 92 07-Jan HLXU 94 HLXU 20-Feb 98 20-Jan 26-Jan HLBU 100 TGHU 27-Feb

15 ETA at SHANGHAI (CHINA) Tentative Delivery Plan
Customer Support, ECC & ICA Container Tracking - CHINA ETA at SHANGHAI (CHINA) Shipment Date Cutoff Date Mode Forwarder Liner Container No Original ETA Revised ETA 1 Revised ETA 2 Revised ETA 3 Actual ETA Tentative Delivery Plan Actual Delivery date Transit Delay Total Transit Time 6-Jun Truck SCH HYUNDAI TGHU N/A 7-Jul 31 20-Jun Barge BMOU 16-Jul 17-Jul 2-Aug 5-Aug 1 46 4-Jul FCIU 30-Jul 29-Jul 31-Jul 21-Aug 48 18-Jul BMOU 6-Aug 13-Aug 1-Sep 7 45 1-Aug TRHU 20-Aug 15-Sep 22-Aug FCIU 10-Sep 17-Sep 13th Oct 13-Oct 52 12-Sep SEGU 1-Oct 6-Nov 55 30-Sep 3-Oct CNSU 22-Oct 19-Nov 47 31-Oct TRHU 22-Nov 18-Dec 3 14-Nov TEMU 12-Dec 10-Jan 57 29-Nov 28-Nov TRHU 15-Jan BSIU 24-Dec 26-Dec HDMU

16 CYCLE COUNT ACTUAL – WEEK 05
CATALYST & VARNISH / ALL MODEL ENDPLATES / SID & NANO ARMATURE Classification Parts counted Week -03 Jan-15 Total Plan Jan-15 So far Class 'A' 02 10 26 Class 'B' 32 35 Class 'C' 27 95 59 Total 39 137 120 Variance details: Gross Variance 261,068 Net Variance 83,230 CATALYST & VARNISH / ALL MODEL ENDPLATES variance Booked SID & NANO ARMATURE to be booked by this week

17 Cycle Count Variance –MIS WEEK - 05
S.NO PART NUMBER DESCRIPTION TYPE CLASS PRICE ACVA-14 System Stock physical Stock Variance Qty Variance value 1 CP8G1U 11A163AA BND-STR MTR ARMA PP B 4 12139 4870 -7269 -32224 2 CPCV3S 11015AA COMM ASY-STR MTR 83 -212 1793 1560 -233 -19255 3 CP4PFF 11015CB COMM ASY - STR MTR C 65 -39 1765 1582 -183 -11932 CPCV3S 11035AA LAM STR MTR ARMA END 5 347 6467 5222 -1245 -5798 CPDV4S 11051AA END PLTATE 29 1223 1049 -174 -4994 6 R1375 M2L46A ENAMELLED COPPER WIRE (1 RM 488 43 114 154 40 19439 7 R215 M3L89A PAPER - INSLTR (SLOT LIN BK 440 119 56 24608 8 W701671S900 RING RETAINING 21.0 EXT -1852 5101 24792 19691 25590 9 ESF M7J40AR1 RESIN / STR ASY 126 672 172 436 264 33281 10 VP6N2U 11A163AA 1443 1810 9611 7801 46182

18 TOTAL OPEN CHANGES DEPT WISE Changes Closed/Dropped
ECC Engineering Change Control Status TOTAL OPEN CHANGES DEPT WISE Dept No. Pending activities TOTAL OPEN CHANGES 93 Changes Implemented 110 Changed on Hold 1 Changes Closed/Dropped 81 PD 20 Purchase 33 SPE 27 MFG 13 Quality/IQ 3 CBG MPL ECC 5

19 Revised target/ decided in meeting
ECC Pending CMCs Stratification DESCRIPTION NO OF CMCs Number of CMCs open since 2011 1 Number of CMCs open since 2012 4 Number of CMCs open since 2013 5 Number of CMCs open since 2014 83 2011 & Pending CMCs CMC Number Requestor Dept CMC Raised date Change Description Part number Current supplier proposed supplier Current Status Revised target/ decided in meeting Dept CMC00262 Purchase 13-Dec-11 Steel to Aluminium End Plate - VP6G9U AA (Al) instead of YS4U (Steel) YS4U 11051BA Egon Gencor Ramp down of existing steel end plate & Customer approval-Aft Mkt & TML 19-Jan-2015 ECC CMC00384 23-Feb-12 Additional sourcing of F7RU 11448CA Bush to SSPL F7RU 11448CA (F7RU 11448CA1) GKN India SSPL Re-FCR access in online system 18th July'14 20th Aug'14 10th Sep'14 TBD SPE/IQ CMC00407 11-Apr-12 Alternate source for VP6G9U 11051AA End plate to JAEIL Metals VP6G9U 11051AA to AB Sunbeam/ Gencor Jaeil Gencor die modification FCR Rejected RFI to be given 19th Jan'15 23rd Jan'15 SPE CMC00414 26-Apr-12 Fully finished VP6G9U 11010CA Armature shaft from SRIMUKHA VP6G9U 11010CA (new part no: CP6G9U 11010EA) TKP + Inhouse Srimukha FCR Rejected RE-PPAP inspection rejected 9th July' th July' TBD SPE/MFG CMC00441 18-Oct-12 Drill depth added CPBV5U 11131AA-Gencor (also SCR00798) CPBV5U AA re-Build / IQ to clarify 12th May'14 16th Jun'14 4th July' TBD IQ

20 Revised target/ decided in meeting
ECC Pending CMCs Stratification 2013 Pending CMCs CMC Number Requestor Dept CMC Raised date Change Description Part number Current supplier proposed supplier Current Status Revised target/ decided in meeting Dept CMC00491 Purchase 17-Apr-13 F2TU 11135AA Hsg Bush alternate source SSPL(ALP) F2TU 11135AA GKN ITaly SSPL RE-PPAP. Cost finalising 2nd Jul' TBD CMC00534 30-Oct-13 Additional sourcing for VP6G9U 11390AA Solenoid assy Huanfang automobile(China) VP6G9U 11390AA In_house Huanfang automobile(China) Re-PPAP 4th Dec'14 7th Jan'15 10th Feb'15 SPE CMC00610 PD 28-May-13 Two piece F8RU 11A206AA Shunt - Busbar for all LXB and ser B models - Necco F8RU 11A206AA (CP7G9U 11055BA & CP2S6U 11055BA ) AVO Necco CP7G9U PPAP Submission. TBD PURCHASE CMC00611 1-Nov-13 Fiber band instead of 1C3U 11A163AB steel band in ESM & F series models 1C3U 11A163AB(CPBV5U 11A163AA) Angu test plan CMC00614 Fiber band instead of F7RU 11A163AA steel band in All LXD models F7RU 11A163AA (CP6G9U 11A163AA) PV Testing 20th Aug'14 TBD 2014 > 6months 35 Pending CMCs of which 12CMCs for Rohith Springs, 4 CMCs for Saalasar Cu Wire

21 BUILD STATUS FOR THIS WEEK
ECC BUILD STATUS FOR THIS WEEK CMC NUMBER DESCRIPTION PART NUMBER CURRENT SOURCE PROPOSED SOURCE Model No. of motors required Chunk Build request date Build completion date Build ageing Remarks (in days) CMC00562 Drive spring CP4PFF 11A000AA Bauman Rohit 3 Chunk-21b 25-Dec-15 20 Pending CMC00563 Solenoid spring CP6PSS 11399AA CMC00564 CP6PSS 11A189AA CMC00574 CP6PSS 11A184AA CMC00714  Carrier Rod CP6PSS 11A187AA Aswin Will power CMC00715  Plunger Ring CP6PSS 11A188AA

22 ECC TEST IN-PROGRESS DESCRIPTION MODEL NO OF MOTORS REQUIRED
BUILD COMPLETION DATE TEST START DATE TEST AGING Status (in days) (in Months) CHUNK - 22A 6G9N 11000FA 29 4-Nov-14 5-Nov-14 91 3 Need result CHUNK - 22B 24 -Nov-14 DV6SS CHUNK - 22C 6G9N 11000AB 28 9-Oct-14 10-Oct-14 117 3.9 Engine occupied by New program. So could not able to start Engine durability test. Target : End of Jan’15 Tube Frame 8G AA 10 13-Oct-14 14-Oct-14 113 3.8 2.5mm Frame Retainer New tool & China Drive new Grease 8G1T 11000BA 13 10-Nov-14 11-Nov-14 85 2.8 Part received & testing yet to be started(Delay due to lab migration activity) Target : End of Dec’14 2 11-Dec-14 12-Dec-14 54 1.8 3mm Frame F81U 11A171AA Seal form TEKLIGHT

23 THANK YOU


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