QUALITY CIRCLE FORUM OF INDIAVADODARA CHAPTER

Telephone: 0265-2976242 E-mail: qcfi2000@yahoo.com, qcfivc2015@gmail.com

Changing Business Environment

Challenges for GSFC Marketing Team

CHANGE

IMPACT OF SOFTWARE

Aeroponics is a way of growing plants without soil and with very little water.

Plants are put into special horizontal boards in such a way that the top of the plant, the crown and the roots are suspended in the air.

Cultured meat production claim that from 10 muscle cells of posk or beef they can produce 50,000 tons of corresponding meat.

Raising livestock takes huge toll on the environment, including water and feed that animals consume, the methane and waste they emit. Modern meadow is a 3 year old biotech start up working to develop meat by growing animal cells and not the whole animal.

THE GSFC STORY

GSFC Turnover details of last 5 years

Financials of GSFC (Rs. in Crores)S.No. Particulars 2015-16 2014-15 2013-14 2012-13 2011-12

1 Net Sales 6163.33 5324.57 5412.49 6253.3 5301.832 Other Income 64.21 101.93 157.05 138.09 162.083 Total Revenue 6227.54 5426.5 5569.54 6391.39 5463.914 Less : Operating

Expenses5548.49 4733.92 4883.66 5455.37 4167.19

5 Operating Profit 679.05 692.58 685.88 936.02 1296.726 Profit before taxes 548.12 573.91 495.42 767.72 1113.357 Profit after taxes 379.85 400.51 342.17 518.1 757.57

Last 5 years turnover of some major companies

0

2000

4000

6000

8000

10000

12000

Tata Chemicals RCF Kribhco GSFC Deepak GNFC GACL

Axis

Titl

e

Turnover (in Rs Crs.)

2011-12

2012-13

2013-14

2014-15

2015-16

1. New Companies 2. Importers3. Information era.4. Government Policy

THE GSFC ADVANTAGESACHIEVEMENTS OF GSFC:

•First company to adopt the steam Naphtha Reforming process for manufacture of Ammonia.•GSFC has set up the first DAP fertiliser complex in India, at Sikka, Jamnagar Gujarat.•GSFC is the first company in India to establish a Caprolactum plant. This was in the year 1974. This led to manufacture ofdownstream products like Nylon yarn, tyre cords etc.•GSFC is the first company to recover ARGON gas from purge gas in 1981.•GSFC also has to its credit setting up India’s first Melamine plant.•GSFC has a market presence of 55 years and carved an impeccable image in the Indian Marketing scene.•GSFC has excelled in integration of technologies, brilliant innovative research, having created a product mix ranging from more than 24brands of fertilisers to petrochemicals, chemicals, the industrial gases, plastics, fifers and other products.

• Strong Company with high reputation Expansion Plans. Huge Goodwill • Product acceptability Awareness and Interest.

CHANGES OVER THE YEARS.

MARKETING TEAM• Advantage to be part of GSFC team.

• GSFC selects Cream of talent.

• Qualification, Aptitude and Attitude.

• High level of training Proactive, Modern, practical and effective.

• Marketing : process of planning and executing the conception, pricing, promotion, and distribution of ideas, goods, and services to create exchanges that satisfy individual and organizational goals.

It is indeed a matter of pride for the employee’s to be an integral part of GSFC, and working inthe GSFC family, contributing to the Corporate growth and National growth.

They should as a member of GSFC family to pursue the path of excellence, to deliveraccording to the new challenges and Market scenario. Every member of GSFC family has toraise the performance bar and make a positive and tangible difference to make the organisationto achieve the goals.

CASE STUDIES

Scientifically designed

Related to daily work zone

Related to your knowledge experience and insight

Simple format

Research, compile responses

Opportunity to be creative acknowledged and add to the growth of the company.

Welspun Group

WELSPUN INDIA LIMITED

FACTORY:VILLAGE: MORAI, VAPI, GUJARAT – 396 191

HEAD OFFICE: WELSPUN HOUSE, 6TH FLOOR, SENAPATI BAPAT MARG,LOWER PAREL, MUMBAI – 400 013.

ABOUT QCFI

Welspun India Ltd (Overview)

Inception its journey in 1985 with a small textile unit

Located at - Vapi and Anjar, Gujarat

Global leadership position in Line Pipe and Home Textiles

Largest Home Textiles Player in the World – HTT

Largest Bath Towels Supplier

2nd Largest Bedding Supplier

3th Largest Bath Rugs Supplier

Exports more than 35 countries

Exports contribute 94% of the revenue

Integrated facility from raw cotton to finished product.

Products - Terry Towel, Rugs & Carpet, Bathrobe & Bed Linen

Welspun Corporate Overview

Welspun India Ltd.

Welspun Corp Ltd.

Welspun SyntexLtd.

Welspun Power & Steel Ltd.

Welspun Plate & Coil Mills

Welspun Retail Ltd.

Welspun Tubular LLC

Welspun Natural Resources Ltd.

Welspun Max steel Ltd.

Welspun Global Brands Ltd.

Welspun Investment Ltd.

Welspun Infratech Ltd.

Welspun Energy Ltd.

Our Different Products…

9 Core Values

Adaptability Collaboration Dare to Risk

Customer Centricity Innovation Integrity

Inclusive Growth Technology Speed

REVMAN

OurTop Customers Worldwide

TQM is defined as a continuous effort by the management as well as employees of a particular organization to ensure long term customer

loyalty and customer satisfaction

It is a strategy for continuously improving performance at every level

Effective utilization of time, inventory, space, people and

money

Steps for Continuous improvement…

• Name of Dept.: m/c tufting • Name of Project: Reduction in downgrade due to mending• Name of Project Owner: Mr Kundan kumar/Arvind pandey and

team• Description of project: To minimise mending defective p/c • Benefits of Project internal / External: cost saving

Cost Saving

PROJECT NAME

ACTUAL (PC)

ACTUAL (%) BP Target TARGET

(PC)TARGET

(%)

COST SAVING (IN

INR)

DOWNGRADE DUE TO MENDING

1288 0.14 0.1

511 0.12 158410DURING CURRENT PROJECT

767 0.1 237770POST PROJECT ESTIMATION

PLAN

1. Define the Problem

2.Collect Data

3.Ascertain root cause

Improper mending mending

Improper finishing after mending

PROBLEM IMPACT

1. Effect in Cost2. Order pending 3. Extra planning for shortfall4. Delay in Shipment5. Effect in Quality6. Decrease Customer Satisfaction 7. Effect on Inclusive Growth

Reason Pcs PercentageLining due to mix up of shade lots 21 0.00

back stitch 236 0.05Missing Tuft/ Mending 484 0.10

Design Cut / Short size ( Width less) 16 0.00

loop problem 4 0.00

M/C Tufting Total Target - 0.1% 741 0.16

263

484

21 16 40100200300400500600

Series 1

Series 1

HEAT SETTING & CABLING

MACHINE TUFTING

PP CANVAS GO-DOWNYARN GO-DOWN

GREY WARE CUTTING & STITCHING

COATING

PACKING & DISPATCHDYEING

MC TUFTING PREPAROTORY

Department Flow Diagram

Single Yarn/ Yarn preparation

Tufting preparatory

Tufting

Roll Checking Mending and finishing

Roll preparation

Roll doffing Length Cutting/roll checking

Roll transport to coating

Chenille

Defect

DyeingCut & sew

MAN

Untrained ManpowerOperator negligence

MACHINE

Mending machine not proper

METHOD MATERIAL

No defined SOP forFirst piece checking

Mixed yarn

Improper materialhandlingDowngrade due to

tufting department

Stop motion senor notworking/ Yarn tight endsensor

Knots in Yarn

Damaged tubesNo precautionaryMethod for bottom run out

Actual Vs Target

00.05

0.10.15

0.2

Actual Target

Percentage

Percentage

Aim

0.00

0.10

0.20

Total Mending

Finding the root cause

Percentage

Do

1. Development of Solution

2.Implimentation of Solution

“Reduce down grade and make

awareness in associates regarding

the problem facing & its effects”

484

263

21 16 4

61

95 97 99 100

0

20

40

60

80

100

0

100

200

300

400

500

600

Missing Tuft/ mending

back stitch Lining due to mix up of shade lots

Design Cut / Short size ( Width less)

loop problem/mending

Problems

%ag

e

DEVELOPMENT SOLUTION

Root cause 1:- Back stitch due to Improper mending

New mending gun introduced

Rework after mending required

x

Mending gun implemented in all the machines

√

Development of Solution

•Awareness to mender and quality checkup while rolling

•Proper stitching of products for withstanding the dying process forces.

•Handling the products carefully to avoid peeling of coating.

•Placement of coated products in appropriate manner to avoid marks.

Implementation of Solution

MINIMISING DOWN GRADE PC. BY PROCESS IMPROVEMENT

•Awareness to operator & mender by training about quality

requirement

•Improved mending quality and consistency by introducing

mending gun

•Procured mending gun(manual mending & automatic mending

M/C) parts & improve mending performance.

•Made sop to check first pc. swatches. To reduce chances of mix

yarn

ACTION PLAN FOR IMPLEMENTATION THE SOLUTION

Sr. No. Description Responsibility

1 Operator training Mr. Kundan kumar

2 Develop the SOP & Training Modules Mr. Arvind Pandey

3 Procure new mending machine Purchase

4 Implement mending machine All team

Check

1. Compare Before and after data

Comparing the data

0%2%4%6%8%

10%12%14%16%18%

Sep - dec Jan - apr may - aug

Percentage

percentage

Act

1. Documenting the result

2. Standardizing the process

Documenting

Before

During project

After

MONTH 16- TOTAL PC. CHECKED

UTM DEFECTIVE

PC.AVG PC PER DAY TILL DATE %

15-Sep 761600 1066.2 36 0.14%

15-Oct 843174 1602 53 0.19%

15-Nov 680283 1768.7 59 0.26%

15-Dec 696784 696.78 23 0.10%

AVG. 745460.3 1283.4 43 0.17%

16-Jan 680421 996 33 0.15%

16-Feb 643644 708 24 0.11%

16-Mar 654842 700 47 0.11%

16-Apr 675686 706 32 0.10%

AVG. 663648.3 777.5 34 0.12%

16-May 949950 584 19 0.06%

16-Jun 978503 1301 43 0.13%

16-Jul 1288858 1090 35 0.08%

16-Aug 1166340 632 22 0.05%

AVG. 1095912 901.75 29.74 0.08%

Checksheet

Check sheet for M/C Tufting Checked by :-Shift incharge

Date: A Shift B Shift C Shift

S.No.Check point

1 2 3 4 5 6 7 1 2 3 4 5 6 7 1 2 3 4 5 6 7

1

Status of warp stop motion Sensor

2

Mending gun available

3

Operator trained

4

Proper material handling observed

Supervisor signature

Inter-Personal RelationsCommunication skillsProcess Knowledge

Skills Improve Self-confidenceTeam Work

LIVE CASE STUDY

SALE OF GUJCON CRF AND PRF

• CRF/PRF : Total Production Capacity : 297 MTS

• Production in 2016-17 : 36.8 MTS (CRF:28.4 & PRF : 8.4 MTS)

• Sales : 30 MTS (CRF: 27 & PRF : 3 MTS)

TOPIC

Brief

Tasks: ___________________________________________________________________________________________________________________________________________________________________________

• LIVE CASE STUDY

• EVALUATION CRITERIA

• Presentation Skills• Analytical Skills• Data Collection• Use of Statistical Tools• Understanding of The Problem• Originality• Benefits of your Suggestions/ Solutions to GSFC

• BENEFITS

• Certificate, • Credits, • Booklet • Learning• Acknowledgement

WE WELCOME YOUR SUGGESTIONS AND QUERIES