5A.10.3.6 Result Summary

Chapter 5A
Autonomous Maintenance
5A.10.3.6 Result Summary:KPI
Indicator S.No.
KAI
Actu
Targ
B.M
al
Bette
et
U.O.M
(FTill
r
(F08)
F13
13)
Q1
Minor Stoppage
reduction
Nos./
Year
340
35
S.No.
1.1
Minor flaws removed
Cumm.
Nos.
1.2
Source of
contamination
removed
Cumm.
Nos.
1.3
Nos. of Red Tag

Cleared
1.4
32
CLITA time
reduction
Defects due to Poor

J/H
Number of First Aid
Injuries due to poor
JH
Reduction in
Leakage Points
(Oil,Air,Coolant)
5S score in direct
area (Shop Floor)
No of JH kaizens
U.O.M
B.M
Actual
Bette
Target
(FTill F13
r
(F-13)
08)
Q1
5000
BM
F09
900
BM
F09
22000
19380
3500
3403
Cumm.
Nos.
3835
BM 18000
F09
16881
Nos. of White Tag

Cleared
Cumm.
Nos.
8457
BM 32000
F09
28507
Minutes/
Man/
M/c
60
12
15
2.1
Hard to access area

removed
Cumm.
Nos.
700
BM
F09
2500
2404
Nos./
Month
70
30
25
3.1
Quality defects
sources removed
(dust, dirt &tools)
Cumm.
Nos.
21
BM
F09
60
52
Nos./
Month
143 10
4.1
No. of unsafe places

Cumm.
removed
Nos.
1200
1205
Nos.
650
BM 220
F09
225
5.1
No. of Kaizens done

for no Leakage
Cumm.
Nos.
90
74
50 80
65
6.1
JH One Point
Lessons
implemented
Cumm.
Nos.
1600
1507
7.1
No.of cell members Cumm.

trained for JH
Nos./year
495
476
Nos.
950
BM 2200 2204
(F09
318
BM
F09
35
BM
F09
497
BM
F09
70
BM
F09
Chapter 5A
No. of Tags Put (Red + White)
One Point Lessons
Better
Better
45388 Tags
put
40000
26338
12292
1600
32000
24000
0
F10
F11
F12
1000
800
497
400
200
0
F09
(BM)
F10
1500
1000
2113
950
2204
5000
2000
1800
1400
500
4698
4500
3315
3600
3000
2000
5000
4741
4741
1378
2400
1000
0
F09
F10
F11
F12
Target
F09
(BM)
F13 (
Actual Till
Q1)
Actual
F10
F11
F12
F13
(Actual
Till Q1)
Target
Actual
Minor Stoppage Reduction
Training on JH 4
Better
Better
400
6.8 times
increase
500
400
350
300
450
476
495
450 476
324
200
150
100
144
88%
reduction
340
300
300
250
270
220
200
200
150
100
100
50
100
50
70
F09
(BM)
350
Numbers/Month
600
Cumulative Numbers
Actual
4119
4000
3.4 times
increase
6000
2200
1800
1487
F13
(Actual
Till Q1)
Visuals
Better
Cumulative Numbers
Cumulative Numbers
2000
F12
Target
Genba Kaizens
2.3 times
increase
F11
Actual
Better
2500
1400
1200
1000
600
1507
1600
1182
1099
1200
F13
(Actual
Till Q1)
Target
1456
1400
40000
10000
F09
(BM)
3 times
increase
1800
45388
45000
32659
30000
20000
43194
Cumulative Numbers
Cumulative Numbers
50000
40
0
F10
F11
F12
Target
F13 (Actual
Till Q1)
Actual
F08
(BM)
F09
F10
Target
F11
F12
32
35
32
F13
(Actual
Actual Till Q1)
Chapter 5A
Nos. of White Tag Cleared
Nos. of Red Tag Cleared

Better
Better
5373
3 times
increase
4000
3000
3835
4085
4500
4000
4000
2891
3000
2000
1303
1000
1500
0
F09
(BM)
F10
F11
F12
Target
2500
Cumulative Numbers
F13
(Actual
Till Q1)
2000
1711.33
Better
500
2000
2049
3000
2000
F10
F11
F12
F13
(Actual
Till Q1)
1300
644.1
600
43
40
30
Actual
3.4 times
increase
70
50
45
30
35
21
60
52
52
48
50
20
10
20
0
F09
F10
F11
F12
Target
F09
(BM)
F13 (
Actual Till
Q1)
Actual
6.8 times
increase
1000
1205
1119
1000
850
800
1200
1205
Numbers/Month
1200
845.87
500
682.15
600
400
300
200
318.36
0
F09
(BM)
F10
F11
F12
Target
F11
F12
F13
(Actual
Till Q1)
Actual
No. of kaizens done for no leakage

Better
1400
F10
Target
No. of unsafe places removed

Better
Cumulative Numbers
3430
5000
60
2200
1500
1000
6450
8000
Target
1380.11
1500
9000
3 times
8673
increase
Actual
2262
2.3 times
increase
8457
F09
(BM)
Hard to acces area removed

2438
Better
10000
9000
8000
7000
6000
5000
4000
3000
2000
1000
0
Cumulative Numbers
Cumulative Numbers
5000
Cumulative Numbers
6000
F13 (Actual
Till Q1)
Actual
100
90
80
70
60
50
40
30
20
10
0
88%
reduction
90
54
45
35
63
70
74
74
55
45
30
F09
F10
F11
Target
F12
F13
(Actual
Actual Till Q1)
Chapter 5A
Reduction in leakage point
Defects due to poor JH

Better
80
70
Cumulative Numbers
60
900
3 times
increase
62
70
53
60
50
41
50
40
800
37
40
30
20
25
30
10
0
F09
(BM)
F10
F11
F12
Target
763
600
500
300
350
200
0
F10
F11
Actual
F12
Target
F13
(Actual
Till Q1)
Actual
CLITA Time Reduction

70
70
60
58
70
52
60
44
55
35
50
65
80
30
20
10
0
F09
F10
F11
F12
Target
Better
143
F13 (
Actual Till
Q1)
Actual
First Aid Injuries
140
120
100
80
70
60
61
40
42
40
20
20
18
10
3
0
F09
(BM)
F10
60
60
Minutes/Machine/Shift
80
Cumulative Numbers
225
220
100
F09
(BM)
2.3 times
increase
90
Numbers
377
450
Better
100
160
441
550
5S score in direct area (Shop Floor)
40
554
650
400
F13
(Actual
Till Q1)
Better
50
3 times
increase
700
Cumulative Numbers
Better
F11
Target
F12
Actual
F13 (Actual
Till Q1)
50
50
45
50
40
40
30
30
15
20
20
10
15
15
12
0
F08
(BM)
F09
F10
Target
F11
F12
Actual
F13
(Actual
Till Q1)

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5A.10.3.6 Result Summary

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Chapter 5A

Minor flaws removed

Nos. of Red Tag

Defects due to Poor

Nos. of White Tag

Hard to access area

No. of unsafe places

No. of Kaizens done

No.of cell members Cumm.

One Point Lessons

Minor Stoppage Reduction

Nos. of Red Tag Cleared

No. of kaizens done for no leakage

No. of unsafe places removed

Hard to acces area removed

Defects due to poor JH

CLITA Time Reduction

First Aid Injuries

5S score in direct area (Shop Floor)

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