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

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Presentation on theme: "1 MIS FOR CUSTOMER SUPPORT, ECC & ICA – WK OF 2 nd Mar 2015."— Presentation transcript:

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

2 2 Customer Support, ECC & ICA Customer Coverage Status - OEM2-Mar-14 Region Trans it WHS Norms for Domestic11 Norms for Europe63 Norms for China73 STARTERS Norms for North America 73 #WHSPART NUMBERMODELCUSTOMER EUROPEAN/N A/ AP WHS STOCKS TRANSIT STOCKS TOTAL Average Weekly Volume CUSTOME R COVERAG E - WKS Shortfall Quantity to meet norms Comments 1A&S3M5T 11000CFDV6 Saarlouis/Vale n 52092150026709200013.48709 3A&S6G9N 11000ABI4Ford OEMs4990985614846139410.62300 5A&S7G9N 11000ACSIGMAFord OEMs14316272770376310.1836 6A&S8G43 11000AAASTON MARTINAston Martin192 384409.624 7A&SAV6N 11000CASIGMA GTDIFord OEMs16732750442325017.72173 8A&SCV6T 11000DBV408Ford OEMs10663108417426016.11834 9A&SF1FT 11000EBF1FTFord OEMs1722187535973759.6222 10A&SF1FT 11000MAF1FTFord OEMs11305628675856012.11718 11A&SDG9T 11000AA Ford OEMs3762 26014.51422 12SML31285512SIGMA GTDIVolvo5892508397012.0209 Obsolete on 30th Mar'15, Service will continue. 13SML30659314ESMVolvo56571420819865166012.04925 14SML30659557I5PVolvo30222816583851211.41230 15SML30659805SIGMA SIDVolvo1612125173716010.9297 Obsolete on 6th April'15, Service will continue. 16SML30644972DV6 - SSVolvo1237425054879245.9(57)Obsolete on 6th April'15 17SML31450235I5P SSVolvo1010896190612814.9754 2116 nos of 31419002 return to Comstar due obsolence 18CHINA31450235I5P SSVolvo640058881228864019.25888 Volume drop up to 50 %, Awaiting confirmation from customer. 3328 nos return back to Comstar due to foreign materials inside the container.

3 3 Customer Support, ECC & ICA Customer Coverage Status - OEM2-Mar-14 Region Tran sit WHS Norms for Domestic11 Norms for Europe63 Norms for China73 STARTERS Norms for North America 73 #WHSPART NUMBERMODELCUSTOMER EUROPEAN/ NA/ AP WHS STOCKS TRANSIT STOCKS TOTAL Average Weekly Volume CUSTOME R COVERAG E - WKS Shortfall Quantity to meet norms Comments Domestic Customers 19TVS-P2871 15100103X1TML / FIAT4250125055007507.34000 20TVS-P5401 15100102X1 COMMTML / FIAT3264 15362.1192 Suddenly TML Increased their volume from 1536 Nos to 4300 Pcs. Nearly 300% increased considering last 6 month average of 1500 Pcs 21TVS-P2871 15100104FIREFIAT500 1500.0498 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 22CHETAK2818 15100105SUPER ACE 250 1252.0 Supplied as per Feb 2015 Schedule 23AXPRESS2834 15100110NANOTML504 10086721.5(336) 504Pcs are under TML plant as starters. 24TVS-HF2024100ALP15Ashok Leyland144076822087682.9672 D3 - 8G1T11000BA 25BAY8G1T 11000BAD3Ford OEMs50617810241316411020012.929641 26BAYAV6N 11000CASIGMA GTDIFord OEMs1795250204510020.51045 27BAYCP7C3U 11005AAARMATURE COMSTAR NA 16079220503812939659.6(1521) 28BAYAC3U 11390AASOLENOID COMSTAR NA 210632250043563396511.03913

4 4 CodeRegionNov-14Dec’14Jan’15 Feb’15 to date Production AHVFAAsia-Pacific 100 97 100 AHVFCEurope100 94 100 AHVFGNorth America – Bay100 AHVFHComstar LLC USA9794100 Service AHVFCEurope10090 10076 97100 AHVFGNorth America – Bay 57 dispute rejected 57 93 Dispute Rejected 85 Dispute Rejected 100 AHVFHComstar LLC USA10096100- GUR4AComstar LLC USA-8794100 Refresh Date: 2 nd Mar 2015 Data period: 23 rd Feb to 27 th Feb SUPER-G Rating Summary Nov’14, Dec’14, Jan’15 & Feb’15: Customer Support, ECC & ICA

5  Customer critical parts for next two weeks  Nil  Critical parts to be produced this week at Comstar to avoid line stoppage at Customer o Jatco, 98AB AC & 835X AC – After Market ( Armature Shaft Constrain) o 3S6T AD After Market (B+ Insulator Constrain) o Nano, F Series Armature, DV6SS – 125starters  Critical Containers for next two weeks o EMCU 1443700, TGHU 5137924  FCSD long pending parts to be produced this week to avoid lost delivery performance  Nil  Starters Produced against the production plan in % Customer Support, ECC & ICA 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) Week 7 (09th Feb'15 Week) Week 8 (16th Feb'15 Week) Week 9 (23rd Feb'15 Week) Week 10 (02nd Mar'15 Week) Production Plan 31453319783190531680254303128531065302503005628732 Qty Produced against the Plan 314703111732157317242464831151314602959730253 Difference 17(861)25244(782)(134)395(653)197 Achieved in %100.197.3100.8100.196.999.6101.397.8100.7

6 6  EXT - WHS sales booking status SML Whs – Sales booked up to 2 nd Mar’15 A/S Whs – Sales booked up to 2 nd Mar’15 BAY Whs – Sales booked up to 2 nd Mar’15 China Whs – Sales booked up to 2 nd Mar’15  Customer Reconciliation Status BAY Whs – Completed up to 8 th Feb’15 SML Whs & A/S Whs - Completed up to 8 th Feb’15 China Whs – Completed up to 8 th Feb’15 Comstar LLC (NA) - Completed up to 8 th Feb’15 Direct Customers – to be Completed for Feb’15 Customer Support, ECC & ICA

7 7  Aftermarket Budget Volume Vs Actual

8 8 Customer Support, ECC & ICA  Aftermarket pending orders - Approximate value is Rs. 1.9Cr Item NumberOEM RefProductTotalValueRemarks 20 10001008 98AB ACStr 384 1566720Armature shaft Constrain 20 10001020 835X ACStr 192 844800Armature shaft Constrain 20 10001022 2S7T DCStr 1731 7616400Armature shaft Constrain 20 10001044 6G9N ECStr 90 388800Alert to be raised for Flange 20 10001050 YC1U AFStr 158 758400Armature shaft Constrain 20 15001001 2S6T FCAlt 45 187200Slip ring Constrain 20 15001002 3S6T ADAlt 810 3823200B+ Insulator Constrain 20 15001004 1S7T CFAlt 296 1704960Slip ring Constrain 20 15001005 1S7T BEAlt 12 81600Slip ring Constrain 20 15001007 YC1U EAAlt 147 1140720Slip ring Constrain 20 15001008 2T1U BEAlt 50 428000Slip ring Constrain 20 15001034 2S6T ACAlt 220 1372800B+ Insulator Constrain Grand Total 413519913600

9 9 Customer Support, ECC & ICA  Aftermarket pending orders – Aging CustomerItem Number Quantity Open Due DateAge ARTEC20 100010508.01/12/2015 52 BOSCH20 1500100496.01/28/2015 36 BOSCH20 1000102296.01/28/2015 36 CASCO20 15001002360.01/31/2015 33 CASCO20 1500100890.01/31/2015 33 CASCO20 1000102096.01/31/2015 33 CASCO20 10001022384.01/31/2015 33 AEE0120 10001022120.02/2/2015 31 AEE0120 1500100712.02/2/2015 31 AEE0120 1500100512.02/2/2015 31 AEE0120 10001010108.02/2/2015 31 PSHCV20 10001008384.02/2/2015 31 PSHCV20 1500100490.02/2/2015 31 PSHCV20 1500103490.02/2/2015 31 PSHCV20 1000102096.02/2/2015 31 PSHCV20 10001022576.02/2/2015 31 BIGOT20 1000102275.02/9/2015 24 HCA0120 1500100245.02/9/2015 24 ARTEC20 1500103440.02/16/2015 17 ARTEC20 10001050150.02/16/2015 17 HCA0120 1500100245.02/16/2015 17 HCA0120 1500100145.02/16/2015 17 PSHCV20 1500103490.02/16/2015 17 VALEO20 1000104490.02/16/2015 17 CASCO20 1500100490.02/28/2015 5 CASCO20 15001002360.02/28/2015 5 CASCO20 1500100790.02/28/2015 5 CASCO20 10001022480.02/28/2015 5 CASCO20 10001029128.02/28/2015 5 CASCO20 10001010128.02/28/2015 5

10 10  AFTER MARKET PARTS SALES HIGH LIGHTS Sales Value for week 9 (23 rd Feb to 1 st Mar’15) – INR 4,267,387 Sales Value for the Month to Date (Feb’15) - INR 18,386,547 Sales Value Year to date (YTD) – INR 22,882,448 ( INR 22 Million)  Aftermarket Orders availability Status Product Open Orders as on 23rd Feb'15 Fresh Orders received Quantity produced last week Quantity Shipped last week Additional Qty on Hand @ Comstar Total Balance Open Quantity as on 02nd Mar’15 Min. Required by this week Starters18899225616 1159 1100168651680 Alternators674904131906755884420 Total25648225102913491775227492100

11 EI - INVENTORY REDUCTION TREND Oct’14 – 17.2Lakhs. Nov’14 – 9.7Lakhs Actual. Dec’14–12.7Lakhs Actual. Jan’15 – 24Lakhs Actual Feb’15 - 5.92Lakhs planned and 10.48Lakhs Achieved so far. Oct’14 – 17.2Lakhs. Nov’14 – 9.7Lakhs Actual. Dec’14–12.7Lakhs Actual. Jan’15 – 24Lakhs Actual Feb’15 - 5.92Lakhs planned and 10.48Lakhs Achieved so far.

12 12 Customer Support, ECC & ICA  Total Pending – 93.2Lakhs  FCSD Sale Planned in Feb’15 & Mar’15 – 17.4Lakhs  To Bring Back to Comstar – 33.5Lakhs ( In Transit to Comstar)  31419002 – 2114pcs (29.6Lakhs)  6G9N 11000EC – 63pcs (1.0Lakhs)  BG9T 11000AA – 125Pcs (1.5Lakhs)  30795405 – 123pcs (1.4Lakhs)  Total Pending stock as on 1 St Apr’15 – 42.4Lakhs  Awaiting Ford NA FCSD order – 5.70Lakhs – Ford Buyer Confirmed 100pcs per month pull from Dec’15  BB5Z 11002C – 488pcs (5.70Lakhs)  Remaining – 36.7 Lakhs ( 3.5months FCSD Sales value) retained for future order

13 CYCLE COUNT ACTUAL – WEEK 09  Starter Housing \ Alternator Housing,Pulley, Regulator,Stator line Classification Parts counted Week -09 FEB-15 Total PlanFEB-15 So far Class 'A'172625 Class 'B'74452 Class 'C'336682 Total57136159 Variance details: Gross Variance 93,105 Net Variance 19,449  Starter Housing Variance Booked.  All Alternator Parts Variance booked by this week.

14 Cycle Count Variance –MIS WEEK - 09 Sl #Item NumberDescription Item type Class Cost ACVA '14 Variance Last Audit sys stock Variance Qty Variance Value 12XS6U 10336AA StatorR ASY - ALT PPC211.5 158 (48) 3,395 (43) (9,095) 1CPBV5U 11055AA BRSH ASY-STR MTR INS CSA119.3 (112) (14) 4,635 (67) (7,996) 21VP2C1U 10A352AA HB ASY-ALT PLY PPA2095.6 (2) - 1,209 (3) (6,287) 16VP3S7U 10505AA RegulatorLATOR - PCM PPB581.8 131 29 10 (10) (5,818) 13VP3S7U 10A303AA BRG - ALT FRT PPC70.7 226 (52) 1,918 (28) (1,979) 201S7U 10336AA StatorR ASY - ALT PPB204.7 18 (34) 2,239 (5) (1,024) 14XS6U 10A352A1A HB - ALT PLY(MACHINED) PPC57.4 105 (46) 820 (16) (918) 9F75U 11A192AA CONNECTING ROD - STR ASY PPB1.5 2,113 891 10,300 1,134 1,758 8VP6G9U 11A183AA CONT-STR MTR Solenoid PPB2.0 3,394 61 9,056 1,015 2,030 7VP1S7U 11131AA HSG-STR MTR MTR DRIVE EN PPA136.7 (24) - 2,115 15 2,051 56VPXS6U 10A351CA HOUSING - ALT FRONT W.O PPA233.6 53 (68) 1,204 35 8,176 55VP3S7U 10316BA REINF RR FLR S/M @ BMPR ASA665.0 - - 27,152 16 10,640 57R1425 M2L46ANAT ENAMELLED COPPER WIRE RMA516.9 (73) (46) 2,117 54 27,778

15 15  Engineering Change Control Status ECC TOTAL OPEN CHANGES DEPT WISE Dept No. Pending activities TOTAL OPEN CHANGES 87 Changes Implemented 119 Changed on Hold 1 Changes Closed/Dropped 86 PD 25 Purchase 11 SPE 43 MFG 6 Quality/IQ 4 CBG 1 MPL 6 ECC 0

16 16  Pending CMCs Stratification ECC DESCRIPTIONNO OF CMCs Number of CMCs open since 20124 Number of CMCs open since 20133 Number of CMCs open since 201478 Number of CMCs open since 20151 2012 & 2013- CMCs- SUPPORT REQUIRED CMC Number Requesto r Requestor Dept CMC Raised date Change DescriptionPart number Current supplier proposed supplier Current StatusDept SUPPORT REQUIRED CMC00384garunkumPurchase23-Feb-12 Additional sourcing of F7RU 11448CA Bush to SSPL (Panther, V227, ESM) F7RU 11448CA (F7RU 11448CA1) GKN IndiaSSPLFCR StatusMFG FCR feedback from Mfg. Sudar-MFg CMC00407rsaravanPurchase11-Apr-12 Alternate source for VP6G9U 11051AA End plate to JAEIL Metals VP6G9U 11051AA to AB Sunbeam/ Gencor Jaeil Gencor die modification FCR Rejected PPAP lot & Alert for available lot SPE PPAP Lot & Alert for available 5000nos- Durai-SPE. CMC00414rsathiesPurchase26-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 MFG trial, SCR & PPAP SPE Mfg trial, SCR & PPAP Durai-SPE. CMC00441kmariappSPE18-Oct-12 Drill depth added CPBV5U 11131AA-Gencor (also SCR00798) CPBV5U 11131AA Gencor SPE/PD to clarifyIQ/SPE Thilawar-SPE CMC00534ranandPurchase30-Oct-13 Additional sourcing for VP6G9U 11390AA Solenoid assy Huanfang automobile(China) VP6G9U 11390AAIn_house Huanfang automobile(China) Re-PPAPSPE Durai-SPE CMC00611rharishPD1-Nov-13 Fiber band instead of 1C3U 11A163AB steel band in ESM & F series models 1C3U 11A163AB(CPBV5 U 11A163AA) NeccoAngu PV Testing & Cust approval PD Ser-FTest--Parameswari-PD ESM Build-- Meenakshi-Mfg CMC00614rharishPD1-Nov-13 Fiber band instead of F7RU 11A163AA steel band in All LXD models F7RU 11A163AA (CP6G9U 11A163AA) NeccoAngu Cust. Approval requirement for FCSD(FA Model) PD FA obsolete, FCSD approval requirement- Veera-PD.

17 17 ECC BUILD STATUS FOR THIS WEEK S.NoDESCRIPTION NUMBER OF CHILD PARTS IN THIS BUILD MODEL NO OF MOTORS REQUIRED BUILD REQUEST DATE BUILD COMPLETION DATE BUILD AGING (in days) REMARKS 1 Chunk-23A5 30659805 (CPCV3S 11000AA) Sigma SID 17 24-Feb-15TBD7Pending Chunk-23B18G1T 11000BA2 Chunk-23C6 30659314 (CPBV5U 11000AA) 20 Chunk-23D56G9N 11000FA2 2 YS4U 11A209AB INITIAL SUBMISSION NEW CAVITY #3,4 FROM HTP 1AV6N 11000CA924-Feb-1527-Feb-154Completed

18 18 ECC TEST STATUS IN PROGRESS DESCRIPTIONMODEL NO OF MOTORS REQUIRED BUILD COMPLETION DATE TEST START DATE TEST COMPLETION TARGET TEST AGING (in days) TEST AGING (in Months) Status INITIALREVISED CHUNK - 22A6G9N 11000FA294-Nov-145-Nov-148-Jan-1516-Mar-1500.0 Testing in progress CHUNK - 22B 30644972 DV6SS 244-Nov-145-Nov-148-Jan-1516-Mar-1500.0 Testing in progress CHUNK - 22C6G9N 11000AB289-Oct-1410-Oct-1413-Dec-1416-Mar-1500.0 Testing in progress Retainer New tool & China Drive new Grease 8G1T 11000BA1310-Nov-1411-Nov-1414-Jan-15TBD491.6 Target exceeded, need disposition F81U 11A171AA Seal form TEKLIGHT & 3mm Tube frame 8G43 11000AA211-Dec-1412-Dec-1414-Feb-15TBD180.6 Testing in progress CHUNK-21B Additional test 2834 15100110310-Feb-1511-Feb-1520-Feb-15TBD190.6 Testing in progress CHUNK-21B Additional test 2834 15100110 & CPAT2C 11390CA 2 + 420-Feb-1521-Feb7-Mar-15TBD00.0 Testing in progress YS4U 11A209AB INITIAL SUBMISSION NEW CAVITY #3,4 FROM HTP AV6N 11000CA927-Feb-152-Mar-1512-Mar-15TBD00 Testing in progress

19 19 THANK YOU


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