| QualTech Prize for Improvement: Qimpro Convention 2008 |
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Day 1: 7 August 2008 | Focus: Improvement |
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| Keynote Speaker: Mr Navin Agarwal |
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| Leaders in the corporate arena today realized that improvement is a journey, not a destination. |
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| 12 shortlisted organizations competed for the QualTech Prize for Improvement at Qimpro Convention. Three winners declared (in no particular order) by a distinguished panel of judges were: |
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| Godrej & Boyce: Improvement of 'First Pass Yield' by 87% |
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| ‘First Pass Yield’ (FPY) of the Valve Plate Assembly in the compressor assemble department used to result in a drop of FPY, thereby adversely affects the throughput of the compressor manufacturing plant. |
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| Result |
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Improvement in First Pass Yield by 87% (from 51.5% to 95.8%) |
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Savings of Rs 22.5 Lakhs p.a |
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Improvement in customer satisfaction |
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Team work |
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Motivation among employees |
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New learnings (Shainin DOE tools) |
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Knowledge sharing |
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| Team |
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Hitesh Kakkar, Head: Quality (Refrigerator Manufacturing) – Author and Presenter |
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Sunil Parekh, AGM: Quality Engineering Department - Presenter |
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Niraj Sharma, AGM: Quality - Presenter |
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| Larsen and Toubro: Inspection Cycle Time Reduction |
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| Average inspection cycle time of each inspection stage in PPE equipment is 8.05 hours with a standard deviation of 3.9 hours. This slowed the project cycle time |
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| Result |
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The process owner has reduced more than 3% of the number of stages thus impacting the project cycle time. |
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The project has resulted in 17% reduction in inspection stages and 25% reduction in inspection cycle time. |
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Equipment manufacturing cycle time is reduced by approximately 15 – 20 days per project. |
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Sales of 267 crores in 2004 – 05 increased to 1215 crores in 2007 – 08 |
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The ability to maintain the inspection service levels has been sustained despite doubling the manufacturing capacity of the plant over the last three years. |
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| Team |
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B Srinivas Reddy, Manager: TQM Facilitation - Author |
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S P Ghiya, Dy General Manager - Presenter |
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| Reliance Industries: To Increase POY CP10 Yield from 98.5% to 99.2% by April 2007 |
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| The Polyester Yarn yield at the CP10 unit was around 98.50%. Lower yield (98.5%) and higher waste (1.5%) at CP10 due to higher and longer process interruptions resulted in low productivity, inconsistent quality, and poor utilization of resources |
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Result: |
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Recurring gains of 704 lakhs per annum. Financially validated |
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Shift in paradigm: change in mindset |
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Belongingness of people increased |
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Number of people involvement increased is apparent from the number of Kaizen received |
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| Team |
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J N Desai, General Manager: Production (Polyester Plant) – Author and Presenter |
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Qimpro Convention proceedings hold 22 paper summaries (INR 500).
Please click here to purchase a copy of the proceeding. |
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| BestPrax Compass: Qimpro Convention 2008 |
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Day 2: 8 August 2008 | Focus: Innovation |
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| Keynote Speaker: Dr R A Mashelkar |
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| We have an opportunity to start the resurgence of an innovative India today. This will not only entail building new social, legal and economic structures that support innovation, but also making a national symbol of "I" in "India" to stand for "Innovation". |
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| 10 shortlisted organizations competed for the BestPrax Compass on the second day of the convention. Three organizations (in no particular order) who were awarded the BestPrax Compass were: |
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| Kansai Nerolac Paints: 3 Wet Technology - An Innovative Application System for Painting 4-Wheeler Sector in Automobiles |
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| Problem |
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| Cost saving system for painting 4-whelers |
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| Results |
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| This process is an industry benchmark by itself. The customer benefits from reduction in manpower, increase in throughput, saving in power & fuel (baking energy), reduction in material cost, and space saving |
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| Team |
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Shashank D Puro, Chief Manager: Technical – Author |
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Mahesh G Mehrotra, Vice President: Technical - Presenter |
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Ashok Shenoy, Chief Manager: Technical Service - Presenter |
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Laxman Nikam - Presenter |
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| Rallis India: Bhagidari Sabha |
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| Problem |
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| Establishing new capacities for contract manufacturing |
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| Result |
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| The market share grew from 9.5% in 2006 to 10.5% in 2007. The sales growth was 13% v/s the industry’s growth of 4%. The profit improved as well, by 5%. In addition to this, the channel partners benefited with enhanced skills, confidence, pride, and growth in business. There was also an improvement in customer engagement scores |
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| Team |
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Nishant Pahuja, Regional Manager: Marketing – Author |
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Sukhbir Malik, General Manager - Presenter |
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| Sona Group: Attrition and Talent Management in Today's Organizations |
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| Attrition and Talent Management |
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| Approach |
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| Attrition reduced from 12.78% to 8.08% as against the average attrition rate of 23% in the manufacturing industry. This resulted in knowledge retention, skill retention, and retention of employees |
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| Team |
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Hari Nair, Vice President: HR – Author and Presenter |
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Qimpro Convention proceedings hold 22 paper summaries (INR 500).
Please click here to purchase a copy of the proceeding. |
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| Award's Evening: Qimpro Convention 2008 |
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| Guest of Honour: Dr J J Irani |
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| “Importance of quality has been drilled into the Indian population – weather it is for products or services. I would like to pay tribute to likes of Suresh who drove that movement.” |
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| Dr J J Irani - one of India’s pioneering leaders, was the Guest of Honour for the Qimpro Convention Awards’ Evening. His relation with Qimpro goes back two decades to the late 80s’. |
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| There was a time when there was an aversion to the ‘Made In India’ tag on exported Indian goods. It was during this scenario, he reminisced, when in 1987, Suresh Lulla (Director, Qimpro and Founder, BestPrax Club) walked into Tata Steel and facilitated the Quality journey in the organization. The employees were convinced of the future of quality and adopted the quality model whole heartedly. Mr Lulla worked step by step with Tata Steel to imbibe quality into the DNA of the organization. |
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| Today quality plays a vital role in India. Dr Irani blames Qimpro and Mr Lulla for bringing about this successful change. “Importance of quality has been drilled into the Indian population – weather it is for products or services. I would like to pay tribute to likes of Suresh who drove that movement.” |
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| With this, Dr Irani went on to felicitate the winners of Qimpro Convention for the QualTech Prize for improvement and BestPrax Compass for innovation. He also awarded the judges and examiners tokens of appreciation for their efforts and support. |
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| Nurturing Talent to Manage Attrition |
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| Attrition is a major worry in most organizations. |
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| Lack in establishing a connect with the work culture, employer-employee relationship, sense of ownership, pride in working in an organization, are amongst the many factors that give rise to attrition. |
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The eighth BestPrax Roundtable on ‘Nurturing Talent to Manage Attrition’, was hosted by Sydenham Institute of Management Studies on 22nd August 2008. |
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| The objective was to allow over 100 students to observe the interactions, and subsequently to participate in multiple concurrent Creativity Labs on challenges emerging from the Roundtable. |
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| To set the stage for the interaction, Dr Aneeta Madhok, Director of ARMS Perspectives and Solutions, summarised the Roundtable. The attrition issues were highlighted by the panellists in the opening segment. |
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| Attrition can be curbed at the basic stage of recruitment, opined Ramola Mahajani, Managing Director of Human Edge Cutting. She spoke of Sona Group’s ‘Behavioural Event Interview’ and ‘Stay Management’ interviews to tackle the issue of attrition at a primary stage. |
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| Nelum Gidwani, Director of BestPrax Club emphasized on treating employees with care and respect. Even dull employees have their shining areas. This will inculcate a sense of belonging towards the organization. |
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| To establish unity amongst its internal customers (employees) and bind them as a family, Eureka Forbes has employees of all levels sing the organization’s anthem. Adil Bhesania, Associate Vice President, HR, amazed the panellists with numerous efforts by his organization to appreciate their sales force – thus giving them their due recognition. |
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Amar Deepika, HR Head of Ashok Piramal Group narrated an incident she encountered while working with Punjab Tractors. Senior management thought it best to bring a change in the organization’s culture for improved performance. With these changes, senior labour of the plant requested the designation of ‘Junior Engineer’. Heeding to this request resulted in excellent outcomes. |
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| The examples shared during the Roundtable discussion left the students hungry for more knowledge. In the limited time available, only a few students could pose questions to the panellists. Anjana Senthilnathan, Shivani Tallur, Rinal Mehta, were amongst the few students who wanted to know more about how organizations today are focussing on the employee’s strengths and growth. |
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In the concluding segment of the Roundtable, Dr Madhok articulated four challenges for the students to address in the Creativity Labs: |
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How to create an organizational culture that nurtures ‘pride’ of belonging? |
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How to manage careers for enhancing retention? |
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How to improve the attraction, selection and recruitment processes to ensure we bring in the right people? |
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How to address the issue of attrition as a problem and an opportunity? |
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| Don’t Let Your Right Brain Sleep |
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| The enthused students of Sydenham Institute of Management Studies worked with one of the many creativity tools - ‘Brainwriting 6-3-5’ - and innovated more than 1000 ideas in a short span of approximately 30 minutes. |
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| During this exercise, BestPrax Club scouted for potential ideators. These students will be imparted professional training to become Certified Ideators for our ‘Ideator’s Panel’ for customized Creativity Labs for client organizations – an external resource for BestPrax Creativity Labs ideation assignments. |
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To request for a quote for a Creativity Lab in your organization, please click here.
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