Green Co MCR

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Green Co Rating System CertificationParameter 6 Material Conservation, Recycling & Recyclability (MCR) Achieved optimum inventory (RM + WIP) of 3.42 Cr. in Q4 with all present product lines , which includes KS3/KU3,KS4/KU4,KS6to 9.

Implemented SAP Kanban, for smooth material flow.

Various CFTs are working for cost reduction, material conservation and system improvements.

This is a proprietary document of Kirloskar Brothers Limited#1Leadership & Strategy (Credit 1): MCR Credit 1.1: CII Code for Ecologically Sustainable Business Growth

This is a proprietary document of Kirloskar Brothers Limited#Kirloskar Brothers LimitedSmall Pumps BusinessDewas, Coimbatore & Ahmedabad

Environmental, Health, Safety & Energy Policy

We at Kirloskar Brothers Limited engaged in the business of wide range of Pumps, Motors, Valves, Alternators and related accessories are committed for continual improvement in our environmental, occupational health, Safety & Energy performance and enhance the sustainable development.

In pursuit of above, we shall :Conserve non renewable resources and encourage use of renewable resources.Monitor carbon and water footprint and explore areas of its reduction.Use of energy efficient processes and equipment.Eliminate pollution and manage waste effectively through reduction, reuse and recycling.Educate stakeholders towards EHS and energy conservation.Eliminate occupational hazards by adopting best practices, processes and techniques.Strive to enhance the EHS and energy performance of products.Initiate actions towards sustainability through out the product life cycle.Inculcate EHS awareness and communicate this policy to all employees, customers and those working under the control of the organization.Ensure effective employee participation at all levels, in EHS and energy conservation activities.Strive to go beyond legal and other requirements related to EHS and energy, wherever applicable.

This policy shall be made available to all the interested parties. Issue No: 08 Subodh ShrivastavaDate of Issue: 09.05.2014 Vice President & Business Head Date of next review: 09.05.2015 Leadership & Strategy (Credit 1): MCR Credit 1.1: A part of Environmental, Health, Safety & Energy PolicyThis is a proprietary document of Kirloskar Brothers Limited#Material Conservation (Credit1) - Leadership & StrategyReducing consumption of virgin material :--

1.Reducing raw material consumption

2. Reducing consumption of consumables

3. Reducing Packing material consumption

4. Increasing recycled content / bio-degradable content in the product This is a proprietary document of Kirloskar Brothers Limited#4Environmental Management System at Sanand

Material Conservation (Credit1) - Leadership & StrategyThis is a proprietary document of Kirloskar Brothers Limited#5Material Conservation (Credit1) - Leadership & Strategy

This is a proprietary document of Kirloskar Brothers Limited#6Integrated supplier lead times and delivery schedules

Flows from suppliers pulled by customer demand (using tact time, load leveling, line balancing, single piece flow)

Minimized inventory through all tiers of the supply chain

On-time supplier delivery to point of use

Minimal source or incoming inspection

Effective two-way communication links to coordinate production & delivery schedules

Striving for zero quality defects essential to success

Greater efficiency and profitability throughout the supplier networkMaterial Conservation (Credit1) - Leadership & StrategyThis is a proprietary document of Kirloskar Brothers Limited#Material Conservation (Credit1) - Leadership & StrategyMCR (Credit 1.2) - Short & long term targets and allocation of resourcesSr. No.InitiativesUnit Target 14-15 Target 15-16Target 16-17Target 17-181 Reduction in (RM+WIP)Cr.4.64.243.82 Reduction in weight of runner models Ton751001251503 Cost Reduction Through various methodsCr.1.71.92.12.34 Reduce the inbound logistic costMn0.250.350.40.455 Reduce the transportation/No. of supplier reduceNo.12010090806 Procurement of paper will reduceNo. of bundle2502001801607 Increase procurement of wind & Solar PowerKW152025308 Development of 5 star rated modelsNos.90354045This is a proprietary document of Kirloskar Brothers Limited#Study the consumption pattern of componentIdentification Projects align with MCRStudy the Lead time of component.Decide the KANBAN Qty, and no.of KANBANCalculate and monitor total inventory of RM+ WIPReview the result of inventory for further improvementMonitoring of KANBAN through SAPMaterial Conservation (Credit1) - Leadership & StrategyMCR (Credit 1.2) - Reduction in (RM+WIP) Action planCommunication with VendorResponsibility : Materials Head Start Date: 01/04/2014Review Date :31/12/2014

This is a proprietary document of Kirloskar Brothers Limited#Material Conservation (Credit 2) - Employee Involvement & Capacity BuildingMCR (Credit 2.1) - Strategies adopted for awareness creation and employee involvementTeams working towards Lean & Green Procurement Practices:--

Score Team Cost Reduction Team

Supplier Self Certification Team On line material supplier team (Quality improvement)

Vendor Portal team:--Paperless communication

KANBAN team:--a) Physical Implementation of KANBAN at Supplier end to reduce inventory b) System (SAP) Implementation at Supplier end to reduce paperInventory reduction team:--Reduce unwanted purchasing and remove non moving

Process improvement team:-- Implementation of lean practices to remove Muda from processes both at in-house and supplier end New product development team:-- To develop cost effective green product

SMDS team:--To improve planning through supply chain to minimize wastes

Improve packaging:-- To minimize waste through improvement in packaging and recycle packaging materialThis is a proprietary document of Kirloskar Brothers Limited#Material Conservation (Credit 2) - Employee Involvement & Capacity BuildingMCR (Credit 2.2) - Training programs and capacity buildingS. NoTraining ProgramFaculty Conducted in yearDuration (Hr.)No of participantsTraining Man-hrs.1Process Audit awarenessSameer Parab2014323692SA 8000 Awareness SessionAntoine201436183SAP KANBANUday Apte201484324Kaizen AwarenessAmit Chakraborty201458405Supplier Quality ManualMr B.D Gaikwad / Milind Phadke 201448326Manufacturing Mission to TKT Hightech casteJeet Trapasiya2014332967Quality issue in field return pumpKeyur Angadiya2014224488ISO 9001 awarenessLaxman Aglawe20131.591136.59EnMS Internal Auditor CourseBVQI - Hitesh Karandikar20131623210Session on Ethical DilemmaSwati Patwardhan & S. Nair 20132.51947.511ISO 9001: 2008 Internal Auditor CourseTUV India Pvt. Ltd.20131634812Advanced CNC ProgrammingBFW Pune20132412413EHS & OHSAS AwarenessRajesh Pandey & Chirag Pandya20131969614Quality ParametersRajesh Pandey201322142This is a proprietary document of Kirloskar Brothers Limited#Material Conservation (Credit 3) - SystemsMCR (Credit 3.1) - Framework for Material ConservationParametersCONVENTIONAL MODEL LEAN MODEL StatusOutsourcingCost-basedStrategicImplementedRelationship focusTransaction-focusedMutually-beneficialImplementedSelection lengthLowest pricePerformance & PriceImplementedContract lengthShort-termLong-termImplementedPricing practicesCompetitive bidsTarget costingimplementedPrice changesUpwardDownwardImplementedQualityInspection-intensiveDesigned-inPartially ImplementedDeliveryLarge quantitiesSmaller quantities (KANBAN LOT)ImplementedInventory buffersLargeMinimized, eliminatedImplementedVendor Self CertificationNo InitiationInitiation startedUnder processCommunicationLimited; task-relatedExtensive; multi-levelImplementedProduction flexibilityLowHighImplementedTechnology sharingVery limited; nonexistentExtensiveImplementedConventional Practices v/s Green Procurement adoption at SanandThis is a proprietary document of Kirloskar Brothers Limited#Result of implementation of Lean procurement practices Material Conservation (Credit 3) - SystemsMCR (Credit 3.2) - Monitoring Plan

S. NoParameterUnit F 12-13F 13-141Cost of quality% of sale1.847.242In house machining rejectionPPM476016793Test bench rejectionPPM1640074084Supplier quality of GRN first pass O.K. % of GRN First pass O.K.99.08%99.08%

Analysis on Slow and Non Moving stock

Inventory Management and control through SAP KANBAN.

Cost of quality shows increasing trend as method of capturing has been changed. Monitoring of material self life and mechanism for monitoring FIFO

This is a proprietary document of Kirloskar Brothers Limited#13Material Conservation Team

This is a proprietary document of Kirloskar Brothers Limited#14Material Conservation TeamMCR (Credit 4) Replacement of Raw materials

Raw material consumption reduction We have planned to reduce the consumption of raw materials through design change with out affecting the performance of the product. In first phase, we have taken SS Impeller, Casting parts In this project, we have reduced the material consumption from Avg. 10 % to 90 % through reduction of same material and changing of material.

This is a proprietary document of Kirloskar Brothers Limited#15 Material Conservation Team MCR (Credit 4) Raw Material Conservation

Material CodeDescriptionPrevious Wt./ Kg.Present Wt./Kg.Reduction In Wt./Kg.Reduction %Qty ProcuredTotal Wt.Saved in Kg.Cost Saved/Mn01543130Noryl Dol ABCD0.6540.0670.58789.76%38572264.10.12Before Moc: Cast ironAfter Moc: Noryl Plastic Noryl plastic is 100% recyclable

Weight of the component also reduce to 89.76 %This is a proprietary document of Kirloskar Brothers Limited#16 Material Conservation Team MCR (Credit 4) Raw Material Conservation:-

Material CodeDescriptionPrevious Wt./ Kg.Present Wt./Kg.Reduction In Wt./Kg.Reduction %Qty ProcuredTotal Wt.Saved in Kg.Cost Saved/Mn03660160Fixed Thrust Brg.With Teflon Coated1.0750.3750.70065.12%114788034.60.44

Before Moc: Cast iron

After Moc: SS investment casting Weight of the component reduce by 65.12 % with increased life of BearingThis is a proprietary document of Kirloskar Brothers Limited#17 Material Conservation Team MCR (Credit 4) Raw Material Conservation:-

Material CodeDescriptionPrevious Wt./ Kg.Present Wt./Kg.Reduction In Wt./Kg.Reduction %Qty ProcuredTotal Wt.Saved in Kg.Cost Saved/Mn03660170Tilting pad Thrust Brg.With Teflon Coated0.8500.3200.53062.35 %20201070.60.03Before Moc: Cast ironAfter Moc: SS investment casting Weight of the component reduce by 62.35 % with increased life of Bearing


Material CodeDescriptionPrevious Wt./ Kg.Present Wt./Kg.Reduction In Wt./Kg.Reduction %Qty ProcuredTotal Wt.Saved in Kg.Cost Saved/Mn61008411SS Imp For KS6D Pump Clock-wise1.1250.9240.20117.87%95761924.7760.4361008833 61009152IMP For KS6EA Pump Anti Clock-wise1.4161.1200.29620.90%49681470.5280.306100883161009151SS Imp For KS6F Pump Anti Clock-wise1.2481.1070.14111.30%97921380.6720.41 Benefits : Increase Pump efficiency. Power Consumption reduce Reduce product weight and transport cost and Co2 emission


Material CodeDescriptionPrevious Wt./ Kg.Present Wt./Kg.Reduction In Wt./Kg.Reduction %Qty ProcuredTotal Wt.Saved in Kg.Cost Saved/Mn61008841SS Imp For KS6G Pump Clock-wise1.3521.250.1027.54 %4920501.840.1961008851SS Imp KS8P Dia. 140mm2.4002.1930.2078.62 %31565.210.02Benefits : Increase Pump efficiency. Power Consumption reduce Reduce product weight and transport cost and Co2 emission


Material CodeDescriptionPrevious Wt./ Kg.Present Wt./Kg.Reduction In Wt./Kg.Reduction %Qty ProcuredTotal Wt.Saved in Kg.61009121 Impeller SS 100 HHN Series 0.8340.3650.46956.24%1146537.474 Benefits :Weight of the component reduced by 56.24 % Increase Pump efficiency. Power Consumption reduce Reduce product weight and transport cost and Co2 emission

Before Moc: Steel castAfter Moc: SS FabricatedThis is a proprietary document of Kirloskar Brothers Limited#21 Material Conservation Team MCR (Credit 4) Raw Material Conservation

Material CodeDescriptionPrevious Wt./ Kg.Present Wt./Kg.Reduction In Wt./Kg.Reduction %Qty ProcuredTotal Wt.Saved in Kg.13010112S 13010112Rough Machined H.H series Motor Base4.573.950.6213.57%125447777.2814080241SRough Machined UBH 6"Sub Motor 3.0 to 7.5 7.627.40.222.89%1414311.0814090221SRough Machined Lbh 6" Sub Motor 3 to 10 5.24.80.47.69%13865554614090512SRough Machined Lbh 6" Sub Motor 10 to 20 6.456.350.11.55%5982598.2This is a proprietary document of Kirloskar Brothers Limited#22Different projects for Waste reductionMCR Credit 4 Raw Material ConservationSr.noProjectObjectiveTeam1Weighment of Casting used in ProductTo ensure use of casting in product as per defined weight JD,MKP, RP2Value Engineering of KP4 series Bowl 07Simplified Manufacturing process, reduction in product weight and improvement in resources conservation.DR,PPJ,CHD3Optimize the secondary transportationTransportation cost reduceMKP,DR,RC4Study, Review and impalement the packaging material reductionTo minimize the paper consumption used in packingJD, MKP,RM5Implementation of 2 sided printing in FG invoicesTo minimize the A4 paper sheet consumptionDR,RC,MSS6 Re used of Stator end plastic cap and polythen bagTo reduce plastic cap and polythene bag consumption by reusing again and againRM,JC,MKP7Study and implement projects for converting metallic parts to Engineering plastics / Reduction in weights for existing component.Simplified Manufacturing process, reduction in product weight and improvement in resources conservation.DR,MKP,CHDThis is a proprietary document of Kirloskar Brothers Limited# Reduce Paint consumption.MCR Credit 4 Raw Material ConservationS. No ChemicalsType TrendBetter FY 2012-13 FY 2013-14 FY 2014-15 till JulyTotal ConsumptionsNo.Of Pump Kg.Per PumpsTotal ConsumptionsNo.Of Pump Kg.Per PumpsTotal ConsumptionsNo.Of Pump Kg.Per Pumps1Pigment Paste (Kg)Liquid 199.12168200.012388553760.007131323570.0042Emulsion Resin (Kg)Liquid 1253.5168200.0752107.5553760.038675323570.0213Kleenol (Kg)Liquid 151.5168200.009182553760.00373323570.0024Duridine (Kg)Liquid 185.2168200.011426553760.008148.6323570.0055LPG Gas (Kg)Liquid 15696.5168200.93316735553760.3026625323570.2056Flow Additive( Lit)Liquid 151.5168200.009182553760.00329323570.0017Ph Stabliser( Lit)Liquid 185.2168200.011426553760.0086323570.000This is a proprietary document of Kirloskar Brothers Limited# Reuse Craft tube in Stator and Rotor

Slide 25Different projects for Waste reductionMCR Credit 4 Raw Material ConservationStator and Rotor Packing tube re send to supplier for reuse

Previously these tubes sold as Scrap

Year Total packed Stator and Rotor receipt Total Scrap tube back to vendor as reuse % Recycled Material2012-13 206731048950.74%2013-14 222311027046.20%2014-157910605276.51%Total 508142681157.82%This is a proprietary document of Kirloskar Brothers Limited#2526Average cost reduction 36 % through Value Engineering

Selected Model - KS4 Pump Series Twin packing tube to Square Packing Box

Changes incorporated :

Change in design to prevent transit damage.

Packing Box size reduced .

Stacking improve

Space utilizations improved

Weight reduction 6929.81 Kgs. Weight reduction in packing material:-MCR Credit 5 Management of Packaging Material MCR Credit 5.1 Reduction in Packaging Material

Before After

This is a proprietary document of Kirloskar Brothers Limited#27List of Reduction Packaging materialMCR Credit 5 Management of Packaging Material MCR Credit 5.1 Reduction in Packaging MaterialCodeDescrptionPrevious Wt./ Kg.Present Wt./Kg.Reduction In Wt./Kg.Reduction %Purchase qtyTotal Wt.Saved in Kg.06080990Corrugated Box Sq.For KS4 640 mm2.531.7520.77830.75%750583.5006081600Corrugated Box Sq.For KS4 760 mm2.972.0080.96232.39%550529.1006081780Corrugated Box Sq.For KS4 855 mm3.472.2721.19834.52%11101329.7806081800Corrugated Box Sq.For KS4 940 mm3.812.4921.31834.59%9501252.10-KS4 Single Craft Tube4.252.4051.84543.41%14622697.39-KS4 Single Craft Tube4.912.9251.98540.43%271537.94 Total8.08636.02%50936929.81ParticularsDetails Of SavingMaterial Code-DescriptionSq. box with 2 tubeWt. Saved / Kg.8.086Purchased Qty5093Purchase in Kgs.6929.81Conv. Factor per Kg to A Tree.54Number of Trees Saved128

This is a proprietary document of Kirloskar Brothers Limited#28Cost reduction 60 % through Value EngineeringSelected Model - KS4 Pump Series Twin packing tube Cap Weight reduction in packing material:-MCR Credit 5 Management of Packaging Material MCR Credit 5.1 Reduction in Packaging MaterialBefore use 2 Cap in 1 Twine Packing TubeAfter use 4 Cap in 1 Sq. Box Packing tube

CodeDescriptionPrevious Wt./ Kg.(2Pc)Present Wt./Kg. (4 Pc)Reduction In Wt./Kg.Reduction %Purchase qtyTotal Wt.Saved in Kg.06080990Corrugated Box Sq.For KS4 640 mm0.180.0720.10860.00%7508106081600Corrugated Box Sq.For KS4 760 mm0.180.0720.10860.00%55059.406081780Corrugated Box Sq.For KS4 855 mm0.180.0720.10860.00%1110119.8806081800Corrugated Box Sq.For KS4 940 mm0.180.0720.10860.00%950102.6-KS4 Single Craft Tube0.180.0720.10860.00%1462157.896-KS4 Single Craft Tube0.180.0720.10860.00%27129.268Total1.080.4320.64860.00%5093550.044This is a proprietary document of Kirloskar Brothers Limited#29Cost reduction 77 % through Value Engineering

Selected Model - Big Flow Pump Series Twin packing tube to Square Packing Box

Supplier packing box reuse as internal packing of product

Changes incorporated : Change in design to prevent transit damage. Packing Box size reduced . Stacking improve Space utilizations improved Weight reduction 13259 Kgs. Weight reduction in packing material:-MCR Credit 5 Management of Packaging Material MCR Credit 5.1 Reduction in Packaging Material

Before

AfterSupplier BoxFinish ProductThis is a proprietary document of Kirloskar Brothers Limited#30Weight reduction in packing materialMCR Credit 5 Management of Packaging Material MCR Credit 5.1 Reduction in Packaging MaterialCodeDescriptionPrevious Wt./ Kg.Present Wt./Kg.Reduction In Wt./Kg.Reduction %Purchase qtyTotal Wt.Saved in Kg.06089490Corr. Box Sq. Big Flow2.530.5811.94977.04%680313259.05ParticularsDetails Of SavingMaterial Code06089490DescriptionCorr.Box Sq.Big flow 3Ply X 570 X 225 X130 mmWt. Saved / Kg.1.949Purchased Qty6803Purchase in Kgs.13259.05Conv. Factor per Kg to A Tree.54Number of Trees Saved246

This is a proprietary document of Kirloskar Brothers Limited#31Cost reduction 100 % through Value EngineeringSelected Model - Big Flow Pump Series Twine packing tube Cap Weight reduction in packing material:-MCR Credit 5 Management of Packaging Material MCR Credit 5.1 Reduction in Packaging MaterialBefore use 2 Cap in 1 Twine Packing Tube

CodeDescriptionPrevious Wt./ Kg.(2Pc)Present Wt./Kg. Reduction In Wt./Kg.Reduction %Purchase qtyTotal Wt.Saved in Kg.06003320Twin Packing KS4 640 mm Length0.180.000.18100.00%68031224.54After Plastic Cap Eliminated Plastic Cap EliminatedPlastic Cap EliminatedThis is a proprietary document of Kirloskar Brothers Limited#32Average cost reduction 66 % through Value Engineering

Selected Model - KS3 Pump Series

Supplier packing box reuse as internal packing of product

Changes incorporated : Packing Box size reduced . Stacking improve Space utilizations improved Weight reduction 19709.06 Kgs.

Weight reduction in packing material:-MCR Credit 5 Management of Packaging Material MCR Credit 5.1 Reduction in Packaging Material

Supplier Box AfterFinish Product

Before This is a proprietary document of Kirloskar Brothers Limited#33Weight reduction in packing material:-MCR Credit 5 Management of Packaging Material MCR Credit 5.1 Reduction in Packaging MaterialCodeDescrptionPrevious Wt./ Kg.Present Wt./Kg.Reduction In Wt./Kg.Reduction %Purchase qtyTotal Wt.Saved in Kg.06085330CORRUGATED BOX SQ. FOR KS3 735x180x102MM1.530.590.9461.45%53875066.5406085320CORRUGATED BOX SQ. FOR KS3 660x180x102MM1.530.550.9864.06%422413.7806085340CORRUGATED BOX SQ. FOR KS3 810x180x102MM1.530.620.9159.49%1065969.70Total4.78165.51%687419709.06ParticularsDetails Of SavingMaterial CodeDescriptionSq. box with 2 tubeWt. Saved / Kg.4.781Purchased Qty12612Purchase in Kgs.18739.00Conv. Factor per Kg to A Tree.54Number of Trees Saved347

This is a proprietary document of Kirloskar Brothers Limited#34Elimination of Packing material in stator Rotor incoming from Duke Plasto TechniqueMCR Credit 5 Management of Packaging Material MCR Credit 5.1 Reduction in Packaging MaterialTargeted Elimination 100% through Value Engineering.

Selected Vendor- Duke Plasto Technique

Previous Weight - 0.86 Kg/Pc

New Weight - 0.00 Kg/Pc

Reduction in Weight 0.86 Kg /Pc

Changes incorporated : Use MS pallet for incoming material of Stator and rotor

Individual packing eliminated

Result : Saving of Kraft paper 10860 Kgs.

Before AfterThis is a proprietary document of Kirloskar Brothers Limited#35Elimination of Packing material in stator Rotor incoming from Duke Plasto TechniqueMCR Credit 5 Management of Packaging Material MCR Credit 5.1 Reduction in Packaging MaterialCodeDescriptionPrevious Wt./ Kg.Present Wt./Kg.Reduction In Wt./Kg.Reduction %Purchase qtyTotal Wt.Saved in Kg.-St_Rt Craft Tube0.8600.86100.00%1262910860.94ParticularsDetails Of SavingMaterial Code-DescriptionSt_Rt TubeWt. Saved / Kg.0.86Purchased Qty12629Purchase in Kgs.10860.94Conv. Factor per Kg to A Tree.54Number of Trees Saved201

This is a proprietary document of Kirloskar Brothers Limited#36Elimination of Packing material in stator Rotor incoming from Duke Plasto Technique ( Tube Cap )MCR Credit 5 Management of Packaging Material MCR Credit 5.1 Reduction in Packaging MaterialTarget Elimination100% through Value Engineering..

Selected Vendor- Duke Plasto Technique

Previous Weight - 0.013 Kg/Pc

New Weight - 0.00 Kg/Pc

Reduction in Weight 0.013 Kg /Pc

Changes incorporated :

Use MS Pallet

Individual packing eliminated

Result : Saving of Plastic 834 Kgs.

This is a proprietary document of Kirloskar Brothers Limited#MCR Credit 5.2 Recycled content in Packaging MaterialMCR Credit 5 Management of Packaging Material All of our packaging products are 100% recyclable/reusable - The list of material used in our packaging products are 100% recyclable/reusable. The details of one of the product sample is given below.

Sr. No.Material UsedMaterial Recyclable in %Material Reusable in %1Corrugated boxes/sheets100%100%2MS strip100%100%3BOPP tape100%100%4Plywood Boxes/sheets100%5Polypropylene strip100%6M.S Nail100%7Polythine 40 micron100%8Wooden Boxes100%This is a proprietary document of Kirloskar Brothers Limited#MCR Credit 6 Recyclability and / Biodegradability of the productAll of our products are 100% recyclable- The list of material used in our products are 100% recyclable. The details of one of the product sample is given below.

This is a proprietary document of Kirloskar Brothers Limited#THANK YOU

This is a proprietary document of Kirloskar Brothers Limited#Sheet1 StrategyMethodology

Supplier QCD Improvement ProgramImprovement in input of Direct Ok material at KBlSupplier capacity enhancement to meet the increased plan as per KBl vision 2012Supplier rationalisationoptimization of cost of Purchased Items.On line evalution of Supplier performanceTo Covert Transactional relationship into Partnership relationshipment Periodical audit at supplier end for quality system & process specific rrequirment & support to supplier for correctiveaction / improvementsProcesses,gaps and timeline finalized for casting; machining and windings Consolidation of supplier base to create value in supply chainSupport in finalizing input costs to suppliers and using group purchasing stategy for beeter ratesVendor process audit and inspection at vendor's place prior to dispatch intiative to improve FTR supply

Sheet2

List Of Green procurement Team

Plant Coordinator

Mr. Mangesh Pantoji ( Manager )

Core TeamPurchase Mr. Dinesh Rajput ( Asst.Manager )

Implementation team

Purchase Mr. Jignesh Dhakecha ( Asst.Manager ) Maintenance Purchase Mr. Amit Chakroborty ( Associate Mgr.)

Maintenance Purchase Mr. Sushant Khaladkar (Asst. Mgr.)PDM Mr. Amit Panse ( Associate Manager )

HRM & CMr. Parvez Pasta ( Associate Mgr. )

S/C MaterialMr. Rajesh Mungre ( Associate Mgr. )

Finance Mr. Shino Joseph ( Associate Mgr. )

S/C MaterialMr. Jitendra Chaurey ( Asst. Manager )

Sheet3Material CodeDescriptionPrevious WtPresent WtReduction In WtReduction %Qty ProcuredCost Saved/Mn11543121DIS.OUTLET KS4A,B,C,D,E,F SERIES0.6540.0670.58789.76%38570.1277.8230.82

Material CodeDescriptionPrevious WtPresent WtReduction In WtReduction %Qty ProcuredCost Saved/Mn03660160FIXED THRU BRG WITH TEF COATED THRU PL1.080.3750.70065.12%114780.4403660170MITCHETHRU BRG WITH TEF COATED THRU0.850.320.53062.35%20200.0338437113

Sheet4

Product recycle Chain Sample Model of KS6G+-0804Main components of pumpsMaterial of construction% of Material in pumpMaterial Recyclable in %30.872Suction HsgCI10.37%100%3.2BowlCI44.70%100%13.80ImpellerSteel9.24%100%2.854NRVCI14.90%100%4.6BushLtb-41.04%100%0.322CouplingSteel2.24%100%0.69ShaftSteel3.42%100%1.057HardwareSteel1.68%100%0.52SleeveSteel3.88%100%1.197Rubber partsRubber0.44%20%0.137plastic BushNoryl 0.05%70%0.015Sheet MetalSteel0.74%100%0.227Packing itemsPaper7.36%100%2.27230.891Total100%

Sheet5Chemicals Total Consumptions 2012-13Eq. Pump Per pump consumption in ltrsTotalJigsTotal Consumptions 2013-14Eq. Pump Per pump consumption in ltrsTotalJigsTotal Consumptions Apr14-Jul14TotalJigsTotal consumptions Apr2012 to Jul2014Total Jigs Apr2012 to Jul2014Pigment Paste (Kg)199.12168200.01186597388553760.00700664559964131353071920091Emulsion Resin (Kg)1253.5168200.074565972107.5553760.038058003599646753530403920091Flow Additive( Lit)43.3168200.0026659782553760.0014807859996429353022420091Ph Stabliser( Lit)26.6168200.0016659729.7553760.00053633349964635306820091Kleenol (Kg)151.5168200.00906597182553760.0032866224996473353040520091Duridine (Kg)185.2168200.01106597426553760.00769286339964148.63530766200911859.22168200.113215.2553760.06

Sheet6

Sr. No.InitiativesUnit Actual 12-13 Actual 13-14Target 14-15Target 15-161Reduction in (RM+WIP)Cr.1.63.424.64.22Reduction in weight of runner models TonDNA27751003Cost Reduction Through various methodsCr.0.141.341.71.94Reduce the inbound logistic costMnDNA0.10.25Reduce the transportation/No. of supplier reduceNo.601501201006Procurement of paper will reduceNo. of bundle1402852502007Increase procurement of wind & Solar PowerKW-015208Development of 5 star rated modelsNos.0519035

Sheet1 StrategyMethodology

Supplier QCD Improvement ProgramImprovement in input of Direct Ok material at KBlSupplier capacity enhancement to meet the increased plan as per KBl vision 2012Supplier rationalisationoptimization of cost of Purchased Items.On line evalution of Supplier performanceTo Covert Transactional relationship into Partnership relationshipment Periodical audit at supplier end for quality system & process specific rrequirment & support to supplier for correctiveaction / improvementsProcesses,gaps and timeline finalized for casting; machining and windings Consolidation of supplier base to create value in supply chainSupport in finalizing input costs to suppliers and using group purchasing stategy for beeter ratesVendor process audit and inspection at vendor's place prior to dispatch intiative to improve FTR supply

Sheet2

List Of Member in Material Conservation Team

Plant Coordinator



Implementation team


Maintenance Purchase Mr. Sushant Khaladkar (Asst. Mgr.)PDM Mr. Amit Panse ( Associate Manager)


S/C MaterialMr. Rajesh Mungre ( Associate Mgr.)

FinanceMr. Shino Joseph ( Associate Mgr. )

S/C MaterialMr. Jitendra Chaurey Asst. Manager )

Sheet3

Material CodeDescriptionPrevious Wt./ Kg.Present Wt./Kg.Reduction In Wt./Kg.Reduction %Qty ProcuredTotal Wt.Saved in Kg.Cost Saved/Mn1543130Noryl Dol ABCD0.6540.0670.58789.76%38572264.10.1277.8230.82

Material CodeDescriptionPrevious Wt./ Kg.Present Wt./Kg.Reduction In Wt./Kg.Reduction %Qty ProcuredTotal Wt.Saved in Kg.Cost Saved/Mn03660160FIXED THRU BRG WITH TEF COATED THRU PL1.0750.3750.70065.12%114788034.60.44

Material CodeDescriptionPrevious Wt./ Kg.Present Wt./Kg.Reduction In Wt./Kg.Reduction %Qty ProcuredTotal Wt.Saved in Kg.Cost Saved/Mn03660170Mitchethru BRG WITH TEF COATED THRU0.850.320.53062.35%20201070.60.03

38437113

Sheet4


Sheet5Chemicals Total Consumptions 2012-13Eq. Pump Per pump consumption in ltrsTotalJigsTotal Consumptions 2013-14Eq. Pump Per pump consumption in ltrsTotalJigsTotal Consumptions Apr14-Jul14TotalJigsTotal consumptions Apr2012 to Jul2014Total Jigs Apr2012 to Jul2014Pigment Paste (Kg)199.12168200.01186597388553760.0070079964131353071920091Emulsion Resin (Kg)1253.5168200.074565972107.5553760.03805899646753530403920091Kleenol (Kg)151.5168200.00906597182553760.003287996473353040520091Duridine (Kg)185.2168200.01106597426553760.0076939964148.6353076620091LPG Gas (Kg)15696.5168200.9332659716735553760.30220799646625353039056.520091Flow Additive( Lit)151.5168200.00906597182553760.003287996429353022420091Ph Stabliser( Lit)185.2168200.01106597426553760.007693996463530682009117822.52168201.06020446.5553760.37

S. No ChemicalsType TrendFY 2012-13 FY 2013-14 FY 2014-15 till JulyTotal ConsumptionsEq. Pump Sp. ConsumptionTotal ConsumptionsEq. Pump Sp. ConsumptionTotal ConsumptionsEq. Pump Sp. Consumption1Pigment Paste (Kg)Liquid 199.12168200.012388553760.007131323570.0042Emulsion Resin (Kg)Liquid 1253.5168200.0752107.5553760.038675323570.0213Kleenol (Kg)Liquid 151.5168200.009182553760.00373323570.0024Duridine (Kg)Liquid 185.2168200.011426553760.008148.6323570.0055LPG Gas (Kg)Liquid 15696.5168200.93316735553760.3026625323570.2056Flow Additive( Lit)Liquid 151.5168200.009182553760.00329323570.0017Ph Stabliser( Lit)Liquid 185.2168200.011426553760.0086323570.000

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Sr. No.InitiativesUnit Actual 12-13 Actual 13-14Target 14-15Target 15-161Reduction in (RM+WIP)Cr.1.63.424.64.22Reduction in weight of runner models TonDNA27751003Cost Reduction Through various methodsCr.0.141.341.71.94Reduce the inbound logistic costMnDNA0.10.20.35Reduce the transportation/No. of supplier reduceNo.601501201006Procurement of paper will reduceNo. of bundle1402852502007Increase procurement of wind & Solar PowerKW-015208Development of 5 star rated modelsNos.0519035

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S. NoParameterUnitF-12-13F-13-141Cost of quality% of sale1.847.242In house machining rejectionPPM476016793Test bench rejectionPPM1640074084Supplier quality of GRN first pass O.K.% of GRN First pass O.K.99.08%99.06%

Sheet8MODLESMaterial Saved in Kgs.Casting25359.69Steel5343.021

Sheet9Sr.noProjectObjectiveTeam1Correct all Engineering BOMTo know correct product cost resulting correct MSR ratioDR,JD,PPJ,MSS2All machine casting to be weight Difference of weight to be corrected and if found weight differences info-records also updatedJD,MKP, RP3Value Engineering of KP4 series Bowl 07Cost Reduction in product DR,PPJ,CHD4 Transportation cost reduceMKP,DR,RC5Study, Review and impalement the packaging material reductionTo minimize the paper consumption used in packingJD, MKP,RM6Implementation of 2 sided printing in FG invoicesTo minimize the A4 paper sheet consumptionDR,RC,MSS7Re used of Stator end plastic cap and polythen bagTo reduse plastic cap and polythene bag consumption by reusing again and againRM,JC,MKP

Sheet1StrategyMethodology

Supplier QCD Improvement ProgramImprovement in input of Direct Ok material at KBlSupplier capacity enhancement to meet the increased plan as per KBl vision 2012Supplier rationalisationoptimization of cost of Purchased Items.On line evalution of Supplier performanceTo Covert Transactional relationship into Partnership relationshipment

Sheet2

List Of Green procurement Team

Plant Coordinator



Implementation team


Maintenance Purchase Mr. Sushant Khaladkar (Asst. Mgr.)PDM Mr. Amit Panse ( Associate Manager )


S/C MaterialMr. Rajesh Mungre ( Associate Mgr. )

Finance Mr. Shino Joseph ( Associate Mgr. )

S/C MaterialMr. Jitendra Chaurey ( Asst. Manager )

Sheet3Material CodeDescriptionPrevious WtPresent WtReduction In WtReduction %Qty ProcuredCost Saved/Mn11543121DIS.OUTLET KS4A,B,C,D,E,F SERIES0.6540.0670.58789.76%38570.1277.8230.82

Material CodeDescriptionPrevious WtPresent WtReduction In WtReduction %Qty ProcuredCost Saved/Mn03660160FIXED THRU BRG WITH TEF COATED THRU PL1.080.3750.70065.12%114780.4403660170MITCHETHRU BRG WITH TEF COATED THRU0.850.320.53062.35%20200.0338437113

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Documents

Green Co MCR