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They had a vision…
Tata Cummins Limited
�First to market
� Customer Led
� World class processes
� Progressive work culture
� Lowest cost producer
2
� 50:50 JV
� Inauguration: 4th July 1995
� Power range: 80 hp to 235hp.
� Capacity: 1.20,000 engines per year.
� Application : Automotive, Industrial
& Power Generation
� Customers : Tata Motors & Cummins
� First BHARAT IV Engine in India for M & HCV
� Ready with Engine with BS V norms
2010
Vision:“Making people’s lives better by
unleashing the power of
Cummins” Mission• Motivating people to act like owners working together
• Exceeding customer expectations by always being first to market with
the best products
• Partnering with our customers to make sure they succeed
Cummins Confidential
Personality:• Decisive
• Driven To Win
•Agile
• Passionate
• Caring
Values:• Integrity
• Innovation
• Delivering Superior Results
• Corporate Responsibility
• Diversity
• Global Involvement
Skills/Knowledge/Abilities
•Demanding that everything we do leads to a Cleaner,
Healthier and Safer environment
• Creating wealth for all stakeholders
2013 Highlights….2013 Highlights….
Celebration : Visibility & Awareness
Electrical Safety
Safety Rolling Trophy
Waste Reduction
FIFI :
Web Base Zero Leakage Drive
Health
Great Place to Work – Frame Work.
Great
Place to
Leadership Excellence
Performance Ethics –
CPMS/IDP/ODR
Diversity and Inclusion
Corporate Responsibility
Cummins Operating System
8
Place to
WorkEmployee Engagement Survey and Actions
Employee Communication
Compensation, Benefits & Recognition
Recruitment and
Onboarding
COMMON PROCESSESETHICS
Global Wellness Strategic Foundational Components
Financial Health
Productivity
Healthy Employees
Physical Health
Workplace Health
Emotional Health
Education
Self Awareness
Self Improvement and Maintenance
Financial Health
Physical Health
Workplace Health
Emotional Health
9 Cummins Confidential
Each initiative will touch at least one pillar of the framework and support the business goals of building healthy and productive
workforce.
Source – CMI white paper on Global H&W
Workplace Health
Productivity
Healthy Employees
Physical Health
Emotional Health
Financial Health
Pre- Join HC,
HRA Biometrics,
Onsiite Clinics,
Statutory HC,
Health Fairs,
Employee
Assistance
Programs,
Financial
Education,
Awareness,
Identification
of workplace
Hazards, Roll
Out of initiatives,
Cummins Confidential10
Education
Self Awareness
Self Improvement and Maintenance
Workplace Health
Physical Health
Emotional Health
Financial
Phase wise approach for Effective Implementation
Health Fairs,
Family &
Nutritional , Tie
Ups
Programs,
Support,
Counseling
Awareness,
Counseling
Out of initiatives,
Review and
Improvements
Generic Awareness,
Expert Talks,
Seminars, Fairs etc
Improvement &
Maintenance,
India Health and Wellness Roadmap
• Year 2014• Nutritional Health – cont..• Emotional Health – cont..• Family Health• Workplace Health – cont..• Health Education and Self Awareness - cont.
• Year 2013• Physical Health• Nutritional Health • Emotional Health• Workplace Health• Health Education & Self Awareness
Phase 1
Phase 2
Cummins Confidential11
Phase 3
Phase 4
Year 2016• Improvement & Maintenance – cont..• Financial Health – cont..• Sustenance & Control Process – cont..
Year 2015• Improvement & Maintenance • Family Health• Financial Health• Workplace Health• Sustenance & Control Process
Phase wise approach would help in consolidation, sustenance and focus on administrative processes.
Safety Statistics – Lagging Indicator
13
17
86
3 22
0 1 0 0
0
5
10
15
20Recordable Accident Trend
1.38
1.96
0.92
0.45 0.22 0.12 0.10 0.00 0.07 .01 0.01
0.65 0.650.65 0.650.65 0.65 0.6
0.5 0.4 0.35
0
0.5
1
1.5
2
Incident Rate Trend
Actual Actual Target
First Aid CasesSeverity Day Rate
**115
89
56
9
0
20
40
60
80
100
120
140
First Aid Cases
7.090
13.760
7.6308.590 8.170
4.910
1.310
2.970
0.606 0.05
6 64 3.2 3.2
0.000
2.000
4.000
6.000
8.000
10.000
12.000
14.000
16.000
Incidence Rate –((number of recordable incidents for last 12 months) x200,000)
The total number of hours worked during the year
Severity Day Rate –((number of lost working days for last 12 months) x 200,000)
The total number of hours worked during the year
**$$
$$
Safety Statistics – Leading Indicator
112
3080
13766
7760
2000
4000
6000
8000
10000
12000
14000
16000
Find it Fix it
BSO
26 2832 33
39 41
54
61
50
0
10
20
30
40
50
60
70
Jun-13 Jul-13 Aug-13 Sep-13 Oct-13 Nov-13 Dec-13 Jan-14
BSO Actual BSO Planned
2013 Target : 25 ,
2014 Target : 50
Behavior Safety Observations
Key Safety Initiatives
1
2
LOTO
Forklift
5
6
Contractor
Safety
Lifting Tools
& Tackles
Cummins Confidential
3Driver Safety
4
7
8Machine
Guarding
Behavioral
Safety
PPE Compliance
Contractor Safety
Model for ensuring contractor/supplier safety was developed to ensure all the aspects
are covered for their safety.
� Biometric Attendance monitoring system:
provides a fix head count of number of people in the plant.
� HSE Induction: Right on the day of appointment. After the induction “Safety training provided” seal is marked on the I-card
� HSE Training: Carried out on a daily basis for 60 � HSE Training: Carried out on a daily basis for 60 min on a specific topic. Contractor employees segregated based on their trade.
� Work Permits & Prevention Plan : Work permit system implemented for Hot work, work
at height, confined space etc. Prevention plan mandated for all the work permits. Daily audit
and inspection of all the work permits.
� Equipment's & Tools : All the equipments used by the contractors are inspected for its
integrity & capability
� Contractor Training: Specific training on fire fighting and action they need to take in
case of first aid
Bio Metric SystemBio Metric System Record
Modified I-Card
Contractor Safety
HSE induction & Training
Food hygiene Hoist and CranesInduction First Aid
� BBS Level 1 launched in Nov’2012, 95% non-exempt employees were trained for
BBS Level -1 training.
� After successful completion of BBS Level 1 , BBS Level -2 launched by Mr C K
Kulkarni on 19.02.2013.
� Technique for Behaviour based Observation explained to Managers in this
Programme.
� 90& Managers participated in BBS Level – 2 training which include PLT , Safety
Behavior Based Safety
18
� 90& Managers participated in BBS Level – 2 training which include PLT , Safety
Forum members and line managers ( Period March – May’13)
� More than 200 BSO received and action taken on BSO, during Jun –Dec’13 period
Cummins Confidential
� Electrical Initial survey completed in Sep 2013.
� Data submitted to ETON for Arc Flash Survey, Survey results in 2014 Q1
� Train the Trainer program organized in TCL – J through ETON.
� Authorized level training completed in Oct’13 by ETON for 25 employees.
� Authorized level training planned for all related person in 2014 Q1.
� Awareness level program in progress , Target of 100% awareness by 2014 Q1
� Electrical tool kit will be launch in 2014 Q1
� Permit system for electrical works plan in 2014 Q1
Scope: What is Find It Fix It (FIFI)?
� A behavioral based web tool developed to promote employee ownership to find, fix, and track potential Health, Safety, or Environmental (HSE) issues.
Find It Fix It- Example: (at-risk behavior)
� FIND example: An employee exits the cafeteria into the manufacturing environment with no safety glasses on.
11/03/2014 Cummins Confidential21
manufacturing environment with no safety glasses on.
� FIND category: Safety / Health / environment
� FIND type category: (from drop down) “Lack of personal protective equipment”
� FIX category: Behavior
� Location category: Work (from drop down) “Manufacturing/Production”
Dashboard view:
Last 10 fixes for
employee’s captured
Type your WWID
in here to enter
your Find and Fix.
Click “Go”
Type your WWID
in here to search
fixes.
11/03/2014 Cummins Confidential22
employee’s captured
here.
April / June event
messages or alerts!
Click on “Details” to
see full description
of find and fix.
http://fifi.cummins.com/
Key Environmental Initiatives
• Six Sigma Projects on reduction of GHG Emission
• Main Contribution for GHG emission is electricity
• Electricity conup. reduced by 22%
• Six Sigma for reduction in water consumption
• Water consumption reduced by > 24% in 2013
Water Conservation
GHG Emission
•Focus on reduction through reuse of material
•6 Sigma project completed on Grinding Sludge and Oily cotton waste
• Wooden Engine Skid, Head and Pallet converted to Metallic
• Wooden Block Pallet converted to Plastic
Waste Reduction
Recycle Packaging Project
11/03/2014 Cummins Confidential25
Water Consumption
�STP water used for Cooling tower makeup� ETP / STP output water used for horticulture� Identification of Ghost line & closure of same�Process Wise Water monitoring
Target for 2014
• 2013 : 24% reduction in water consumption in absolute term ( Average per month
consumption reduce from 11004 to 8366 KL )
•2014 Target : Absolute Water Consumption reduce from Average 8366 KL to 7953 KL
per month ( By 5 % of 2013 )
•Sustain Water Balance within 5 %
Reduction in GHG Emission ( TCo2 / Lac ManHrs)
� GHG Emissions at TCL-J is contributed by the following
� Eletricity, Diesel Fuel, refrigeration, fugitive emission etc
� Electricity contributes to 93% of the total GHG emissions
27Cummins Confidential
GHG Status
� Electricity consumption comprises of Fixed and variable
components.
� Fixed Load contributes to approx 63% to the total power
consumption. This varies from 55% - 70% on a monthly basis
depending upon the environmental conditions.
� HV AC contributes to approx 63% to the fixed load
28Cummins Confidential
Electricity Consumption
�6 Sigma for Reduction in GHG Emission � 22% Reduction in Absolute Electricity
Consumption
� Unplugged Challenge : Zero Electricity consumption on holiday / closure
29Cummins Confidential
Target for 2014
• Target to achieve 5 % reduction in GHG Emission in 2014 wrt 2013 level
• ISO 50001 Implementation
Recycle of Hand gloves as Jute:
Use of Recycled Hand gloves as Jute, leads to :Reduction in fresh jute consumption by 50%One Kg of Recycled jute saves a cost of Rs 34 per Kg.
Recycle
WashingCollection of Used
Gloves
Recycle Hand Gloves
as Jute in Line for
Machine Cleaning
to replace Fresh
Jute
Used Hand
Gloves
Washing
Plant Process
Shredding of Hand
Gloves into Jute
Gloves
Grinding Process Grinding Sludge Storage
Grinding Sludge for Co –Processing
( 147 Ton in 2012)
Grinding Process Grinding Sludge StorageBrick / Slab with GRINDING Sludge
Proposed Process:
Existing Process:
Activity Details :a. Sample Bricks made with different formulation (Grinding
Sludge, Lime, Gypsum & Cement)b. Sample Floor Concreting carried out c. Testing and brick and slab for abrasive and compressive
strength completed.
Use of Grinding Sludge for bricks and Concreting slab
32Cummins Confidential
strength completed.d. Floor Concreting carried out using grinding sludge
Organic Waste Convertor Installation
Food Waste
Organic Waste Converter
Compost
Waste Waste
33
• Hazardous waste include: Oil soaked cotton waste, Grinding sludge, Paint Sludge and ETP Sludge
• 6 Sigma completed on Oily cotton Hazardous waste & Grinding Waste
• Overall 53% reduction in hazardous waste disposal quantity in 2013 wrt 2012
Cummins’ commitment towards building a
Sustainable or Green supply chain.
Figuring out ways to reduce the amount of
packaging on products so there isn’t as much waste
Project Background
Designing strategy for returnable packaging implementation
Selection methodology
The waste hierarchy
Cummins Confidential
Returnable packaging initiatives
59% Materials being
received in recyclable
packaging.
Engine Skid
Before:-
Wooden
After:-
Metallic
Green Supply Chain: Wood Reduction
FIP Packaging
Before-
Cardboard After-Plastic
Block Pallet Head Pallet
Before:-
Wooden
Before:-
Wooden
After:-
Plastic
After:-
Metallic
Zero Leak Drive
Kick of by Plant Head
Leak Control
Action Plan of Leak identified
Recognize &
Sustenance Plan
Leak Identification
Fugai Tag
Objective: To involve every one at TCL Jamshedpur for maintaining cleaner environment.
To draw every body’s attention towards environment abuse created by us , awareness about
monetary losses by these leakages and develop system for zero leak culture in our plant.
Zero Leak DayCommitment
Audit on Zero Leak DaySustenance Plan
�853 Leak Points Identified and 735 of them are
closed.
�Reduction in Coolant, Oil and Process Water
Consumption
�High Level of housekeeping
�Reduction in Slip trip fall hazard
Benefits
• Audit done by Plant Manager and team
• Independent Audit in all three shift
• All Manufacturing department cover
• Points shared with auditee
Results
• Quarter wise Best BU/FU Award
• Zero Leakage on shop floor
• Action plan for identified points
• Monitoring and closure of leak points in Tracker
• Reviewing the consumption of Oil.
Leakage Identification & Closed Consumption/Engine (In Litre)
National Safety Week Celebration 2013
Team Commitment
Safety Anamneses Test
Flag Hoisting and Pledge
PPE , Fire Extinguisher and PPE maintenance Camp
Safety Quiz
April Safety Awareness Challenge
Team Commitment
Training on Fire-Fighting
Kick Off by Plant Head
Tool Box Talk Update Find it ‘n’ Fix It Drive
� Event led by Plant head – TCL, Jamshedpur
� 2333 Find It ‘n’ Fix It recorded in Apr-13
� All departments and all levels participation
� Tool Box talk carried out for 20 Topics
� Carried out in all Business Unit and Fictional Units
� Total 395 session covered across plant
� Total 765 attended the sessions
Poster Competition
June Environment Awareness Month
Tree Plantation
CR :Paper Bags Making
Kick Off by Plant Head
Poster Competition Zero Leak Drive
� 5333 Find It ‘n’ Fix It recorded in June’13
� Highest nos. of FIFI in EBU
� 40% FIFI related to environment
� Environment Awareness training carried out for five
environment topic total 465 attended the session.
� Daily Food wastage monitored and displayed in canteen for
THINK. EAT. SAVE
Low Vehicle Day
CII best practices award 2010-11
For Safety, Health and Environment
CII best practices award 2012-13
For Safety, Health and Environment
Gold Level in 2012 &
2013
( For 2,000,000 Hrs
without recordable)
The Result…
GREENTECH Award
SAFETY
2012 -13 & 2013 -14
GREENTECH Award 2012
Environment
2012 -13 & 2013 -14
CII 2nd Award in
20111 -12 for SHE
HSE Budgeting (Mn USD)….
658 668
361
4580.66
0.80
0.54
0.92
400
500
600
700
800
0.50
0.60
0.70
0.80
0.90
1.00
361
0
100
200
300
400
0.00
0.10
0.20
0.30
0.40
0.50
2011 2012 2013 2014
Turnover / Plan Safety Budget / Expense