2. Dhananjay Metal Craft Pvt. Ltd. Unit 1 Plot No A-105, Shendra MIDC June 2014 “Achieve Excellence Through TPM” “T he P rime M over towards excellence ” 1

3. ParametersBenchmarkCriteriaTargetJanFebMarAprilMay 1S/2S 1S/2S self assessment score 85%100% 86%86.5%88% 80% P Production Plan VS Actual 79%100%95% 64.9472.6282.6477.5097.5 Out put / Hour 5620> 20% Up 5483561256286106 5269 PM Plan Adherence 100% Repetitive Breakdown 0Zero 00000 Quality Objective Targets & Status 2

4. 3 1S & 2S BEFOREAFTER

5. Quality Objective Targets & Status 4 1S & 2S BEFOREAFTER

6. Quality Objective Targets & Status 5 1S & 2S BEFOREAFTER

7. Quality Objective Targets & Status 6 1S & 2S BEFOREAFTER

8. ParametersB.MCriteriaTargetsJan’14Feb’14Mar’14Apr’14May’14Remark Q Supplier PPM Best Supplier 100----- Customer Complaints (Occurrence) (Nos.) 2Zero051221 Customer complaint (PPM) 275 Best QA in the Group 0 1900 13505 In-house Rejection (PPM) 83660% Down500 790610554 11001126 Calibration /MSA Plan VS Actual 100 % Cost of poor Quality (To be brought down up to 3% by the end of Dec-13) 1% 3% of sale value 2.50.860.380.590.3 C Premium Freight0ZeroRupees00000 Inventory cost in percentage of production value 85% ----- Quality Objective Targets & Status 7

9. ParametersB.MCriteriaTargetsJan’14Feb’14Mar’14Apr’14May’14Remark D Schedule Vs. plan94%100% 909296 9496 Delivery Adherence (%) 88%100% 909296 94 On time delivery100% 99% Right first time (NPD) 090% 00000 NPD time plan Vs Actual 90% 0---- S Accidents - Major (Nos. / Month) 00000000 Accidents - Minor (Nos. / Month) 40065343 M Absenteeism< 5% -- --- Training calendar adherence QM,KH,K K, ISO/TS 100%----- Nos. of Kaizen / Employee / Month (Nos.) 0.5 Best Kaizen Plant 1 0.450.520.58 0.400.42 Quality Objective Targets & Status 8

10. Productivity 9

11. Production Achieve Percentage 10

12. Output Per Hour 11

13. PM Plan Adherence 12 Dhananjay Group Of Industries Plan Plants : DMCPL-I On Time Done Dela y Annual Preventive Maintenance Plan For One Year -2014 Format No : F/MNT/01 Rev.00 Sr.N o Machine NoM/C.Desc. Capacity Dec.JanFebMarchApr.MayJunJulyAug.Sep.oct.Nov. Weeks IIIIIIIVIIIIIIIVIIIIIIIVIIIIIIIVIIIIIIIVIIIIIIIVIIIIIIIVIIIIIIIVIIIIIIIVIIIIIIIVIIIIIIIVIIIIIIIV 1 Mpr00087 AIDA 100T 12 1 2 Mpr00083 AIDA 100 T 13 3 3 Mpr00010 RHODES 100T 14 5 4 Mpr00011 RHODES 100T 15 7 5 Mpr00015 NIGARU 100T 16 9 6 Mpr00016 GODREJ 63T 17 11 7 Mpr00013 SCHULER 80 T 18 13 8 Mpr00031 RATTAN 150T 19 15 9 Mhy0009 MARUTI 63T 20 17 10 BRUDERER 63 T 23 19 11 Mpr00086 MANZONI 150T 24 21 12 Mhy0003 MARUTI 100 T 25 23 13 Mhy0001MARUTI 125 T 27 26 14 Mhy00010SHAHA 25 T 1 28 15 Mhy00011SHAHA 25 T 2 30 16 Mpr00069 SHINSHARA 150T 3 2 17 Mpr00022 AMEETEP 63T 4 3 18 Mpr00077 WASINO 75 T 5 5 19 Mpr00084 AIDA 75 T 6 7 20 Mpr00023 AMADA 35 T 7 9 21 Mpr00019 AMADA 60 T 8 11 22 Mpr00024 AKORA 75 T 9 13 23 Mpr00020 AMADA 45 T 10 15 24 Mpr00085 AIDA 45 T 11 17 25 Mpr00085 AIDA 75 T 12 19 26 SERVO Press100T 100 T 13 21 27 SERVO Press100T 100T 15 23 28 MSG001Cylindrical Grinding 16 25 29 MSG002Surface Grinder 17 27 30 MSG003Surface Grinder 18 29 31 MRG001Rotary Grinding 19 31 32 MLH002Lathe Machine 20 1 33 MLH001Lathe Machine 21 3 34 MMC001DRO Milling-1 1 5 35 MMC002DRO Milling-2 2 7 36 MMC003DRO Milling-3 3 9 37 MMC004MILLING M/C -1 4 11 38 MMC005MILLING M/C -2 5 13 39 MDR001DRILLING M/C -1 6 15 40 MDR002DRILLING M/C -2 7 17 41 DWP001D M WATER PLANT 8 19 42 OHC 01 CRANE 5 TON 9 21 43 0HC 02 CRANE 5 TON 10 23 44 MWC001WIRECUT-1 11 25 45 MWC002WIRECUT-2 12 27 46 MWC003WIRECUT-3 13 29 47 ACB 03AIR DRYER 14 30 48 ACB 01AIR COMPRESSOR 01 15 1 49 ACB 02AIR COMPRESSOR 02 16 3 50 D G SET 160KVA 17 5 51 Hydro Pnumatic Press 10Ton 18 7 52 FLENTTOOL 200T 19 9

14. PM Plan Adherence 13 Total Machines Critical Machines PM Frequency % Completed Reason for Less % Action Taken 5211Weekly100%NA

15. Break down (Occurrence) - Plant 14

16. JH Activities 15

17. Present JH Status 16 Sr NoM/C JH1JH2JH3BalTgt Dt 1PRESS M/C2725 2June,14 4DEBURING M/C33221June,14 5SURFACE GRINDER10001June,14 6LATHE10001June,14 7DRILLING10001June,14 TTL M/C 33 JH Status 2827 6Oct,13

18. KK Pillar Activity 17

19. Indicat or Sr. No.Parameter Unit BM (Oct’11 to Dec’12) Target Jan’14 Feb’14Mar’14Apr’14May’14Jun’14 P 1O.E.E.Nos.69.57 %>80% 87%89%90%85% 86% 2 Production /Hour Nos.4550 UP >20% 548356125628 61055269 Q4 In House rejections – Scrap PPM2394>60% 790610554 1350 1126 C5 C – Variable Manufacturing cost Rs/ pc ------- D 6 Deliv ery Adhe renc e DE,DAP,KIRDAK,Tower %100 % 90929694 92 7FG Inventory Day s Online (Hand to mouth) Two days 11210 8WIP Inventory Day s Online (Hand to mouth) Two days 04 03 01 9Raw Material Day s 157108 08 M 1010 Kaizens No of kaizen / employee /month Nos.0.61 0.450.520.58 0.40 5 KK Targets 18

20. Loss Capturing Press shop Sr. No. Loss Press shop loss in hours BMJan’14Feb’14Mar’14Apr’14May’14 1 Brekdown / Equipment failure losses 34 4835313918 2 Setup & Adjestment losses 128 119146123143111 3 Inspection & Adjustment loss 7 65788 4 Management loss 36 3325513932 Total 206211212229169 19

21. Loss Prioritization- Press Shop 20

22. OEE 21

23. Quality 22

24. Q-Customer Complaints Status Plant wise 23

25. Quality – Customer Complaints (Occurrences) Customer Part No.Part DescriptionJan’14Feb’14Mar’14Apr’14 May’14 KIRDAK AUTOCOMP PVT LTD. WALUJ 1 FGS00089CORE PACK 3 WAY BOXER 2 FGS00096CORE PACK ASSLY-K3 1 3 FGS00092CORE PACK ASSEMBLY-2(DI) 4 FGS00091CORE PACK ASSEMBLY-1(RE) 5 FGS01640CORE PACK GL 6 FGS01704CORE PACK ASSLY AURA 1 7 FGS00093 CORE PACK ASSLY JA (COLLAR TYPE) SUNITI ELECTRICALS CHAKAN PUNE 8 FGS00093 CORE PACK ASSLY JA (COLLAR TYPE) 9 FGS01786 CORE PACK KTM JU (B) ( 0209830174 ) 211 TOWER MECH. WALUJ 10 FGS00096CORE PACK ASSLY-K3 11 FGS00089CORE PACK 3 WAY BOXER 1 12 FGS00093 CORE PACK ASSLY JA (COLLAR TYPE) 13 FGS01799CORE PACK GL 11 14 FGS01704CORE PACK ASSLY AURA

26. Quality – Customer Complaints (Occurrences) Customer Part No.Part DescriptionJan’14Feb’14Mar’14Apr’14May’14 TOWER MECH. RUDRAPUR 15 FGS00089CORE PACK ASSLY -K70 16 FGS01704CORE PACK ASSLY AURA 17 FGS01799CORE PACK GL RIETER INDIA PVT. LTD. SATARA 18 FGS00199DISTRBUTOR BEHIND -10713902 19 FGS00200DISTRBUTOR IN FRONT -107141630 1 20 FGS00203PRESS LEVER -10714167 21 FGS00201PRESS SADDLE T70 -10714165 22 FGS00202PRESSURE SADDLE -10713851 23 FGS00204CLOSING LEVER -10713854 24 FGS00205U-BEAM FS 160 P3-1 -10713853 25 FGS00206 AGJUSTING SEGMENT BOTTOM PART - 10713862 26 FGS00207 ADJUSTING SEGMENT TOP PART- 10714172

27. Quality – Customer Complaints (Occurrences) Customer Part No.Part DescriptionJan’14Feb’14Mar’14Apr’14May’14 DHANANJAY AUTO PARTS WALUJ 27 WIL00161BOXER PLATE BLANK 28 WIL00164PLATE ST. CL.MODIFIED-FORMED 29 WIL00465WIPER CORE PACK-15 131 00500 30 WIL00528 PLATE CUSH GEAR FOR NAITDRING 31 WIL00486HINGE-STERIO RIVET 32 WIP00186STIFFNER PLATE 1 DHANANJAY ENTERPRISES – 1 33 WIL00025 DRIVEN PLATE-BLANK M&M FOR NITRIDING 34 WIL00287 PLATE CLUTCH 3W4S-BLANK FOR PANASHINING 35 WIP00265 PLATE CLUTCH K-70/BR100 BLANKS DHANANJAY METAL CRAFT PVT. LDT. II 36 WIP00165 PLATE ST. CL.MODIFIED- BLANKS(UG3) 37 WIP00270 PLATE ST. CL.MODIFIED- BLANKS(UG4) 38 FGS00207 ADJUSTING SEGMENT TOP PART- 10714172 TOTAL 52121

28. Quality – Customer Complaints (Occurrences)

29. Quality – Customer Complaints (PPM)

30. Customer Complaint – Defect phenomenon wise Quantity Phenomenon Category (R/N) Type A/B/ C ActionJanFebMarAprMayJunJul 1 Miss-matchRAArst500000 2 Run out moreNAArst2400000 3 RustyNBArst270000 4 Tapping missingNBArst01000 5 Slot MissingNBArst01000 6 Mix-upNN/AArst005000 7 ID UndersizeRBArst0007500 8 Stack Lam. BendNBArst0006300 8 Entrap BurrNBArst00002 Total 31725013802

31. QA/R/06 CORRECTIVE ACTION PLAN IN 6 W - 2H LEGENDS :WHAT - Defect Phenomenon. WHERE - Location ( M/C /Stage ) WHICH - Shop / Cell WHY - Cause Side-Indicate Root cause.WHO - Responsible Person WHEN - Target date for action completion. WHY - Cause Side-Indicate Root cause. WHO - Responsible Person WHEN - Target date for action completion. HOW MUCH - Defective Qty STATUS : C - Completed, B - Work in Progress, A - Under Study. HOW MUCH - Defective Qty STATUS : C - Completed, B - Work in Progress, A - Under Study. HOW TO DO - Indicate What is change in inspection side & Then what is cause side action taken & for sustenance updation in JH / PM / WI format. HOW TO DO - Indicate What is change in inspection side & Then what is cause side action taken & for sustenance updation in JH / PM / WI format. S. N. WHAT WHICH WHERE WHY HOW MUCH HOW TO DO Qty TG T. INSPECTION SIDE BEFOREAFTER 1 1)Entrapped Hair line burr K-3 Core Pack Stacking Pocket piercing scrap stick to punch Magnet to punch Punch not demagnetize after re- sharpening ---2 100% Visual Inspection 2 times visual inspection started HOW TO DO INSPECTION SIDE CAUSE SIDE WHOWHENSTATUSWHOWHEN STAT US Hor. Dep BEFOREAFTER Tgt. Dt. Punch not demagnetize after re- sharpening Punch de-magnetized after re- sharpening and point added in Tool PM/BD check sheet. Mr. Shinde14/05/14Comp.Mr. Pawara 15/05/2 014 Comp.NA Quality – Action on CC

32. Quality – In-House Rejection

33. In-House PPM : Phenomenon/QTY : Phenomenon Category (R/N) Type A/B/ C ActionJanFebMarAprMayJunJul 1 LOOSE STACK B/C 1475 529 786 121230 2 UNDERCUT A 265 439 623 174982 3 BEND B 794 984 411 55184 4 DENT MARK B 161 324 243 78233 5 THICKNESS O/S B 627 115 226 190 6 DAMAGE MARK B 1321 1010 146 94261 7 SCRATCH MARK B 173 255 135 1858 8 HOLE MISSING A 0 0 94 1615 9 ENTRAP BURR B 200 37 88 62181 10 TOOL MARK A 0 0 78 513 11 MISSMATCH A 0 36 50 46131 12 LAMINATION CUT B 47 29 32 1236 13 THICKNESS U/S B 1600 399 17 16109 14 RUSTY A 84 78 12 631 15 RIVET DAMAGE B 0 0 9 10

34. 33 Cost of Poor Quality…

35. Details (Top 5)Proposed SolutionWhoWhen 1 Problem: Loose stack Same height of notching punch to be maintained,. Mr. Pawar Feb’14 Root Cause: Notching punch height variation 2 Problem: Damage Mark 1. Material to be cleaned properly after vibro 2. die cleaning after 10- 15 parts. Mr. Gawali Mar-14 Root Cause: Vibro ceramic stick to die 3 Problem : Thickness u/s & o/s Micrometers and thickness gauges provided on machines to check RM thickness by operator. Mr. Shinde Feb-14 Root cause: Raw material thickness variation In-House PPM : Action Plan

36. Cost 35

37. Power Cost 36 Power Cost : in Lac.

38. Rework Cost 37 Rework Cost : in Lac.

39. Consumable cost 38 Consumable Cost : in Lac.

40. ActivityKKJHQMPMSHOTPMDMET Result AreaPQCDSM Defect Type Shop:M/C:Reg. No: Kaizen Theme: Kaizen Idea Problem/Present Status:Countermeasure: Bench Mark Target 0 Kaizen Start Kaizen Finish 05/10/2012 Team Members: Benefits: Scope and Plan for HD Analysis:Result: NoM/CT/dateResStatu s Sustenance of Kaizen What to do: How to do: Kaizen idea sheets 39

41. Delivery 40

42. Delivery Adherence 41

43. On Time Delivery 42

44. Safety 43

45. Accident Major & Minor Status 44

46. Moral 45

47. No. Of Kaizens/employee/month 46

48. Sr. No.Training Subject No. of People covered No of people balance Remark 11S~2SAll EmployeesNil Training Freq. every months 2 time 2Customer Complaints All Supervisors, Inspectors and operators Nil Training freq. Every month 2 time 3A B C DefectsAll operatorsNil Training freq. Every month 2 time 4InspectionFinal InspectorsNil Training freq. – Every month 2 time 5Material HandlingAll zone membersNil Training freq. – every month 2 time 6SafetyAll EmployeesNil Training freq. – every month 2 time 7Kaizen Training Supervisors, inspectors and operators Nil Training freq. – every month 2 time Education Training Workman - 80 Staff - 55 Total Employees - 135 47

49. Education Training Sr. No.Training Subject No. of People covered No of people balance Remark 9 Jisshu Hozen JHAll operatorsNil Training Freq. every months 2 time 10Kobetsu Kaizen KKAll operatorsNil Training Freq. every months 2 time 11 Planned Maintenance PM All Zone leader Nil Training Freq. after one months 2 time 12Office TPM All Zone leader Nil Training Freq. after one months 2 time 13 Safety, Health and Environment All EmployeesNil Training Freq. every week 2 time 48

50. Education Training Sr. N0.Training ProgramWhy Training needed?No. of PeopleBatches Training Hours 11S~2STo update KnowledgeAll Employeesweekly4 Min. 2 Customer Complaints Zero customer complaintsAll zone members31 hours 3A B C Defects To control in house Rejections All operatorsweekly4 Min. 4Inspection To minimize rejection in house and at customer end. Final InspectionDaily1 hours 5Material HandlingTo update KnowledgeAll zone membersweekly4 Min. 6SafetyBetter working conditionAll zone membersweekly4 Min. 7Kaizen Training To minimize rejection & customer complaint Supervisors and operators. weekly4 Min. 85S ActivitiesTo update KnowledgeAll zone membersweekly4 Min. 49

51. Education Training Sr. No.Training Program Why Training needed? No. of PeopleBatches Training Hours 9 Jisshu Hozen JH Autonomous 7 steps & CLIT All operators21 hours 10Kobetsu Kaizen KK16 losses & OEEAll Employees21 hours 11 Planned Maintenance PM Breakdowns & DefectsAll operators21 hours 12Office TPMZero line stoppagesAll zone members130 Min. 13 Safety, Health and Environment Zero accident & safe & Unsafe condition All EmployeesWeekly 215 Min 50

52. Training Need Identification Sr. No.Name of EmployeeDepartment1S~2S Inspecti on Material Handling Customer complaint s ABC Defects SafetyKaizen 1Visas JadhavQA   2Md. ShafiQA  3Arjun GawaliProduction  4Hanif PathanProduction  5Datta ChamleStore  6Tupe P.B.QA  7Mahesh ShindeQA  8Shingade D.Production  9Tribhuvan DeepakProduction   10YogeshProduction  11Pradeep patilStore  12Deepak KoltameStore  13Ashok RautStore  14Premdas RathodQA  15Dadarao MaliProduction   16Mousin ShaikhQA 51

53. Sr. No. Training Program Faculty Month Jan- 14 Feb- 14 Mar- 14 Apr- 14 May -14 Jun- 14 July -14 Aug -14 11S~2S Mr. Tupe Mr. Trinhuvan 2INSPECTION Mr. Vikas Mr. Shafi 3 MATERIAL HANDLING Mr. Deepak Mr. Arjun 4CUST,COMP Mr. Mahesh Mr. Tupe 5A B C DEFECTSMr. Arjun 6SAFETYMr. Pawara 7 Kaizen idea for In house Rejection Mr. Arjun Mr. Mahesh PlanActual Training Plan 52

54. Sr. No. Training Program Faculty Month Jan- 14 Feb- 14 Mar- 14 Apr- 14 May- 14 Jun- 14 Jul- 14 8 Delivery performance Mr. Deepak 9JH (Jishu Hozen)Mr. Arjun 10 KK ( Kobestu Kaizen) Mr. Tupe 11 PM (Planned Maintenance) Mr. Tukaram 12 E & T (Education & Training) Mr. Mahesh 13 SHE (Safety, Health & Environment ) Mr. Vijay 14 OTPM (Office TPM) Mr. Deepak k Mr. Datta PlanActual Training Plan 53

55. Plant -1 ( DMCPL-1) Mr. Kingaonkar Nitin S. TPM Leader Mr. Shinde Mahesh TPM Coordinator Pillar Chairman Mr.Arjun Gavali Members 1-Mr. Pathan 2-Mr. Shingade 3-Mr. Balu 4-Mr. Tribhuvan JHKKQMPM Pillar Chairman Mr. Tupe P.B. Members 1-Mr. Shinde M. 2-Mr. Jadhav V. 3-Mr. Gavali 4-Mr. Pawara 5-Mr. Dongarkar Pillar Chairman Mr. Vikas Jadhav Members 1-Mr.Kartik 2-Mr.Moseen 3-Mr. Matre 4-Mr.Rathode Pillar Chairman Mr. Dongarkar Members 1-Mr. Deshmukh 2-Mr. Kurhade 3-Mr. Pawara 4-Mr. Jadhav S. 5-Mr. Sonwane 6-Mr. Santosh R. E & T Pillar Chairman Mr. Shinde M.A. Members 1-Mr. Gavali 2-Mr. Dongarkar 3-Mr. Pawara 4-Mr. Bhusare 5-Mr. Tupe OTPM Pillar Chairman Mr. Deepak K Members 1-Mr. Datta 2-Mr. Ashok 3-Mr.Shyam babu 4-Mr. Patil SHE Pillar Chairman Mr. Datta Chamle Members 1-Mr. Shekhar 2-Mr. Jadhav 3-Mr. Tribhuwan 4-Mr. Dongarkar DM Pillar Chairman NA Members 1-Mr. Bhusare 2-Mr. Gorakh Total 08 Pillar Chairman's are defined and 34 employees are involved

56. Total Cells and Cell Owners SR.NO.Cell NameCell OwnerPHOTO 1Auto Feeder lineMr.Arjun Gavali 2 Top Arm Cell & Hyd section Mr.Parmeshwar Tupe 3Quality.Mr. Vikas Jadhav 4Tool RoomMr. Ramesh Bhusare Tool Room

57. 56