Deepak Pathania

Mohammed Mukit Momin

Rock Ford Company

INDEX INTRODUCTION

CURRENT SITUATION OF COMPANY

MISSION, VISSION & STRATEGY

SWOT ANALYSIS

STRATEGIC + BUSINESS – FRUGAL INNOVATION & ENGINEERING

CIM

ISHIKAWA DIAGRAMS

ISO

GT & BP REENGINEERING

THEORY OF CONSTRAINTS & SMED

TPM, JIT, MRP II & SMED

IMPLEMENTATION OF TQM

RISK ANALYSIS

CONCLUSIONS

INTRODUCTION

The enterprise Rockford Motor System was created in 1970,

Initially employing 80 workers. The aim of this company was

produced driving axles for Rambler.

In 1980, the company increased the number of employees to

135 and diversified the enterprise's production by camshafts

that were being made for Chevrolet, Ford and Rambler. Six

years after, in 1986 the employment structures up to 250

workers.

SWOT

FRUGAL INTRODUCTION

More companies are looking to tap into

next billion customers

As, such competition is heating up

EXAMPLES OF PRODUCTS

STRATEGY + BUSINESS - FRUGAL IMPACT OF FRUGAL GLOBALLY - Even global companies

uninterested in the growth offered by the world’s lowest-income consumers will have to pay attention to the lessons of frugal engineering: Products developed with this approach are beginning to compete with goods sold in developed countries, a trend that’s likely to continue.

Deere & Company, for example, designed and sold small, lower-powered tractors in the Indian market, but didn’t begin selling such models in the U.S. until an Indian company, Mahindra & Mahindra Ltd., beat them to it. Mahindra & Mahindra has proven an able competitor to Deere in larger tractors as well.

General Electric (GE), on the other hand, has been more proactive; for example, it has sold a revolutionary new low-cost handheld ultrasound scanner in developed markets by incorporating frugal engineering lessons learned in its Indian medical research and development lab.

A low-cost GE electrocardiogram machine, developed at the same Indian lab for the local markets, is now being sold in the United States and Europe as well.

Meeting all these challenges will require a change in corporate culture. Some companies will be up to it; others companies will not. A successful approach to frugal engineering involves new ways of thinking about customers, innovation, and organization.

BENEFITS OF FRUGAL

Proposal & Suggestion for Rockford Motor Systems

Our purpose was to describe about Frugal and Benefits of

implementation was that even during crisis or recession when

people lose their buying powers on any kind products including

automobile, Home appliances manufacturing market etc.

Companies can focus on the basics needs or components of the

product can meet their customer expectations at lower price.

Through this approach companies can do innovation about new

aspects or can make a new revolution in market and can compete

with their rivals very effectively. Rockford motor systems should

implement similar approach and can come up with an idea of

economical car which people can buy at reasonable price and feel

the association with brand.

Conclusion - Frugal

STRATEGIC SCORECARD

STRATEGIC SCORECARD

STRATEGIC SCORECARD MAP

Marketing strategy Gaining more orders by expanding the marketing strategy in the

current market.

Taking over control low buying power customers by implementing Frugal.

Provide festive offers on new innovative products.

Promotion of brand between middle class of people through auto events and by introducing less expensive cars.

Continuous improvement in manufacturing and management sector

Different attention paying policies for employees and clients

Internal Strategy

Implement quality management system in one year

Implementation of new management system in a company during the year

Realization of obligatory and efficiency employment program

Applying lean manufacturing policy step by step in next 3 years

Establishing a database of information about products, materials, machines and employees.

Purchasing of modern machines and replacing old ones

Reducing the employees

Assembling a new means of production in a line in next 2 years

Implementation of and promote frugal innovation and engineering in company.

INEFFECTIVENESS PRIORIZATION, CAUSE-EFFECT

(ISHIKAWA’S) DIAGRAMS

THE MAIN MODEL USED FOR CONTINUOUS

IMPROVEMENT IS THE FOUR STEPS "PLAN-DO-

CHECK-ACT".

THE MAIN MODEL USED FOR CONTINUOUS IMPROVEMENT

With continuous improvement management in enterprises a set of methods, tools and philosophies are regarding the changes which would have continuous character which could be identified by controlling the several processes. Due to the different kind of difficulties and problems ,which are conducting the enterprise to failures, Problems could be solved by applying these methods:

ISO standards,

Kaizen,

TPM,

SMED

TOC

JIT and GT.

Main Problems in RMS

Adopted Methods to effectiveness and

Decrease the level of problems

ISO-INTERNATIONAL ORGANIZATION FOR STANDERDS

There are 3 ISO standards

ISO 9000: 2000

ISO 9001: 2008

ISO 9004: 2000

The main objective of ISO 9000 standards are

To develop a common simplified standards to all

firms( small, medium and big entrepreneurship.

Giving more concentration on the documentation

of the organization than result.

Methods to improve effectiveness

RMC QUALITY PROCESS

• Achievement of this policy involves all members of the

company and departments, so everyone’s work is

affected by the adopted measures

• Standardization of process

• To obtain the maximum results

• Partnership, integrity, openness, fluent communication,

optimism and motivation for improvement are required

to achieve the mentioned goals

Business Process Reengineering

KAIZEN

Kaizen is a system of continuous improvement in quality, technology, processes, company culture, productivity, safety and leadership that involves every employee – from “top to bottom”.

The five main elements of kaizen

Management teamwork.

Increased labor responsibilities

Increased management morale.

Quality circles.

Management suggestions for labor improvement

ADOPTED KAIZEN, IMPOROVE THE

SYSTEM

Kaizen Reduces Waste in areas such as inventory, waiting times,

transportation, worker motion, employee skills, over production, excess

quality and in processes.

Kaizen Improves space utilization, product quality, use of capital,

communications, production capacity and employee retention

Kaizen provides immediate results. Instead of focusing on large, capital

intensive improvements, Kaizen focuses on creative investments that

continually solve large numbers of small problems

THEORY OF CONSTRAINTS & HOW TO

IDENTIFY Constraints are anything that prevents the organization from

making progress towards its goal.

The Theory of Constraints uses a process known as the Five

Focusing Steps to identify and eliminate constraints

USE OF SMED IN RMS

BENEFITS OF SMED IN RMS

IMPROVING THE EFFECTIVENESS BY TPM

TOTAL PRODUCTIVE MAINTENANCE(TPM)

TPM is a maintenance process developed for improving productivity by making processes more reliable and less wasteful.

No Breakdowns

No Small Stops or Slow Running

No Defects

No Accidents

Reduces equipment related waste including: downtime ,speed losses, defects, frequent adjustment, breakdowns.

Productivity is improved.

Quality is improved.

Employee ownership-ownership of equipment by operators through autonomous maintenance.

Employee confidence-”zero failure”, “Zero defect” and “ zero accident”.

Increased plant reliability.

TPM leads to high delivery performance and customer satisfaction.

An accurate and practical implementation of TPM increase

productivity within the total organization, where

IMPLMENTATION OF 5S METHOD

IMPLEMENTATION OF ERP

5 steps for success full ERP Implementation

Strategic planning

Procedure Review

Data collection and clean-up

Training and testing

Go live and evaluation

IMPLEMENTATION OF TQM

COMPUTER INTEGRATED

MANUFACTURING

IMPLEMENTATION - JUST IN TIME key elements for JIT implementation are:

Top management commitment

Development of a JIT policy manual

Development of a JIT procedure manual

Development and implement a continuous JIT training program for employees at all level

MRP-II

CONCLUSIONS Finally all tools related to maintenance or set up times of the

machines need to be taken into account that overall work will get more effective and efficient.

After evaluating implementation tools, a determination towards the most suitable approaches has been made.

To achieve specific goals and become competitive on the Asian market, the enterprise should start from improve a ISO 9000 documentation (helps in organization of documentation and indirectly in a communication within a company).

Information flow seems to be poor and impacts of that were considered as one of main problem. The next method to implement in company are TQM, GT and TPM (help in an organization of work, improve quality of products, replace an old type machines and in making a proper analysis).

To conclude the consideration which was discussed in the report about “Rockford Motor Systems” case it can be found that company should face many issues which are evaluated in the SWOT analysis in order to become lean and agile. That technique allows determining some points of the company policy (strategy) which should be continuously developed to constantly meet customers’ needs and demands.

In terms of chosen vision related to distribution of the components to a different Asian market the balanced scorecard was presented and described. This tool is very helpful to implement the vision by pointing operational management goals, which company wants to reach in nearest future. It concerns 4 perspectives: financial, customer, internal business process and the development sectors.

Frugal Engineering, although primarily embraced in developing and emerging economies, is quickly receiving global attention as a new form of disruptive innovation. Venture capital investments crucial to developing and scaling innovations have quadrupled since 2005, and bounced back strongly after the financial crisis. Taken together, these suggest that the future for innovation that is both frugal and sustainable could be very bright.

Thanks for your attention !!