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HKGJCHFT 46576584 DFG
HKGJCHFT 46576584 DFG
Kevin Noakes
11th February 2015
KG IND Organization Chart
SAIS & CPSI-5 team Noida & Punjab SAIS & CPSI-5 team Pune
Supervisor - 1 (Adarsh Sharma) Supervisor - 1 (Paresh Pednekar)
Inspectors - 7 Inspectors - 7
Total =8 Total =8
( 934SAIS + 226 CPSI-5 Inspections) (1028SAIS + 473 CPSI-5 Inspections)
1. As on 2015: The Quality department will have 91 team members. There will be 79 who will work in the Product Safety dept. (SAIS and CPSI-5).
2. 3 Central TCA Controllers and 3 Regional TCA controllers.
Schindler IND | Kevin Noakes | Quality | 3rd Feb2015| Page 3
3. Target for 2015 is 9310 completions and 4772 CPSI-5 inspections.
Field Quality and Product Safety
VFO - Achievements 2014
Variance
C'2014 % age
Types Key Indicator Measure B 14 (Actual v/s Remarks
Actual Achievement
Budget)
Inspections Units 3000 3033 +33 101% Target completed by inspecting Active(2706) and recovery (327)units.
Certified Units 3000 3029 +33 101% All jobs certified.
CPSI-5 NCs (Including CPSI-1) closed within 24days in 2014 versus
CPSI-5
Inspection F'2014 Units 7764 7307 -457 94% Completions target fell short by 6%.
FPY F'2014 90% %age 90% 94.3% +4.3% 105% branches have achieved 90% FPY target.
FSU F'2014 70% %age 70% 34% -36% 49% Notional target.
TBPS Jun12 to Temporary Building Power Supply (TBPS) target for 2014 was 5%,
TBPS
Feb14 5%. %age 5% 7.5% +2.5% 67% but achieved is 7.5%. Overshoot by 2.5%. But from 23.1% it came
(No. of units= 2420) down to 7.5% i.e reduce to 15.6%. (785 jobs)
Temporary
Certified
Temporary Certified
Total jobs from Jan13 to Feb14= 1008, which is reduce to 278 jobs by
Jan13 to Feb14 5% %age 5% 3.9% -1.1% 128% Dec14 end.
(No. of units=1008)
Quality File Note QFN target for 2014 was 5%, but achieved is 27%%. Overshoot by
QFN
Jan13 to Feb14 5% %age 5% 27% +22% 19% 19%. At the start it was 97% (394 QFN) and from 97% it has came
(No. of Units=394) down to 27% (113 QFN) i.e reduce by 70%.
Inspection
Lead Time
for SAIS
commodity. certified
No. of
Capacity planning
inspectors 25% 38% +13% 152% 15 inspectors are certified in escalators.
SAIS Escalators
certified
due R&D issue 8.4Lacs (4%), > 25K cost of claims, due to law of land
All IND Recovery
92%
INR 92% 67% -25% 73% issue (3.3%), material not received from field 13.62Lacs (6%).
2) COM: PCBAs worth Rs.20Lacs INR (9%) is pending for recovery
Sanmina. This pcb is not able to send due to high duty/ freight cost,
repair cost is more then 90% of pcb cost.
PROCITS ICSS
Units Units
Average Demerit Average 294 out of 823 jobs (36%) failed to achieve average demerit score of
Score < 100 Score
< 100 101 +1 99% <100.
No. of
SAIS Audits 244 244 222 -22 91%
Audits
SAIS Demerit Score Average
60 61 +1 98.3% 69 out 222 jobs (31%) failed to achieved average demerit score of < 60
60 Score
No. of
CPSI-5 Audits 244 244 229 -15 94%
Audits
CPSI-5 Demerit Score Average 12 out 229 jobs (5.2%) failed to achieved average demerit score of <
100 7 -93 1428%
100 Score 100.
DLFI / TC
Achievement factor for Quality Dept. for rating: 4 98%, 3 92%, 2 85% and 0 <
Certified %age 92% 85%
Units NC's Closure Achievement factor for Quality Dept. for rating: 4 25days, 3 25 35days, 2
Days 25 50days and 0 < 50days.
25 Days
Achievement factor for Quality Dept. for rating: 4 65%, 3 60%, 2 45% and 0 <
FPY F2015 %age 60% 45%.
Achievement factor for Quality Dept. for rating: 4 50%, 3 45%, 2 38% and 0 <
FSU Jan-Jun15 45% %age 45% 38%. From Jan-Jun15
Achievement factor for Quality Dept. for rating: 4 65%, 3 60%, 2 50% and 0 <
FSU Jul-Dec15 60% %age 60% 50%. From Jul-Dec15.
Achievement factor for Quality Dept. for rating: 4 5%, 3 10%, 2 20% and 0 <
%age 5%
5% 20%.
Temporary
Certified
Temporary Certified Achievement factor for Quality Dept. for rating: 4 5%, 3 10%, 2 20% and 0 <
%age 5%
Jan13 to Feb15 5% 20%.
Quality File Note (QFN) Achievement factor for Quality Dept. for rating: 4 5%, 3 10%, 2 20% and 0 <
QFN
%age 5%
Jan13 to Feb15 5% 20%.
Achievement factor for Quality Dept. for rating: 4 < 250, 3 > 250 to 300,
All IND CPTU 250 CPTU 250
CPTU
All IND Recovery Achievement factor for Quality Dept. for rating: 4 80%, 3 70%, 2
80%
INR 80% 60% and 0 < 60%.
PROCITS ICSS
Achievement factor for Quality Dept. for rating: 4 > 75%, 3 < 75% to
PROCITS > 75% %age 75% 60%, 2 < 60 to 51% and 0 < 51%.
No. of
EI Audits 940 940
Compliance Audit
Units
Technical
%age
93%, 2 85% and 0 < 85%.
Achievement factor for Quality Dept. for rating: 4 98%, 3
All IND TC 98% %age 98%
93%, 2 85% and 0 < 85%.
80
Percentage(%)
60
91 94 96 98 97 98 96 96 96 95 94
40 80 81 85
76
56
20
80
91
60 93.6 92.1 76.7
98.8 97.2 95.7 95.4 95.2 95.2 95 94.5 94.5 93.8 94.3
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Schindler IND | Kevin Noakes | Quality | 11th Feb2015| Page 11
CPSI Month-wise Defect Per Unit (DPU) CY2014
Month-wise Average DPU
3 2.79
2.46 2.41
3
2.04 2.08
2 1.79
Average DPU
Monthwise
1.98
Average DPU
2 1.76 1.79
1.54 1.53 1.49 1.4 1.28
1.13 1.11
1 0.72 0.66
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Months
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40 34.7
27 29.6 26.6 24.8 23.9 24.3
30 23.7 21.4 20.9 18.3 17.8
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Status of closure open points which were observed during TAP Audit Total 22% units out of 117 units are inspected and certified as per Follow up action
(Audit done by CPS Auditors: Wayne Dawber & Joerg Nabulon) no 2
200 182
170 161
159 157 149
150 139 133 132 132
100 87
50
200 Avg. CPSI 1 Score Avg. FI/TC Score Avg. PQR Score Overall Target'14 No Of Audits 700
71 35
600
No of Audits
150 8
150 500
29
54 400
100 110 15
53 29 28
60 5 43 30 36 31 15 300
14 5
79 82 6 7 78 19
13 3 73 10 68 200
50 63 63
54 57 82 56 51
38 24 40 53 69 59 46 100
7 159 14
10 82 91 110 51
0 0
Branches
Branch wise Indicators C2014 (EI) Target <= 100 (Excluding PQR Points)
120 823 900
FI/TC & CPSI 1 Score
800
100
Avg. CPSI 1 Score Avg. FI/TC Score Overall Target'14 No Of Audits 700
Average Demerit Score
80 600
No of Audits
Total Jobs Total Jobs Percentage of
Activity Total Jobs Pass
71 Done -2014 Fail Job Pass 500
60 EI 823 286 537 65%
400
40 7 53 300
60 159 69 82
35 54 43 91 51 200
20 40 30 31 110
36 46 14 28
29 38 24 15 82 29 100
10 14 15 19
8 13 6 7 10 5
0 5 3 1 0
Branches
Schindler IND | Kevin Noakes | Quality | 11th Feb2015| Page 18
Branch wise Indicators C2014 (SAIS) Target <= 60
140 Branchwise SAIS Score 222
250
120 Avg. SAIS Score Avg. FI/TC Score Avg. PQR Score Overall Target'14 No Of Audits
Average Demerit Score
200
100 43
46
No Of Audits
80 150
7
60 72 69 69 13 12 8 11 100
56 12 54 16 55 8 3 1
40 44 44 45 44
41 43 31 50
23 26 36
20 14 11 17 12 12 17 48
4 8 40 7
0 0
Avg. SAIS Score Avg. FI/TC Score Overall Target'14 No Of Audits 200
60
Average Demerit Score
150
No Of Audits
Total Jobs Total Jobs Total Jobs Percentage of Job
Activity
Done-2014 Fail Pass Pass
40 SAIS 222 69 153 69%
100
43
46
20 8 40
12 31 50
23 26
14 11 17 12 12 17
4 13 16 7 11
7 12 8 8
0 3 1 0
120 250
229
Average CPSI 5 Demerit Score Demerit Target No. of audits
100
200
150
CPSI 229 18 211 92%
60
100
83
40
54
45
50
20 12 21 21
14 15 15
6 25 8 4 6 8
5 7 7 4 5 4 7
0 0 0 0 0 0 0
1 C Raghu Bangalore 0 5
2 Sarathlal V P Navimumbai 0 3
3 Vineet Gupta Noida 0 4
4 Sunil Surve Pune 0 8
5 Abhishek Katare Mumbai 0 5
6 Sunil Shettigar Mumbai 0 5
7 Satish Shete Navimumbai 0 4
8 S Ganesan Ahmedabad 0 1
9 Raghavendra Bangalore 0 5
10 Dinesh Kawale Pune 0 2
11 Simon Santhosh Bangalore 0 1
12 Srivatsan ST Chennai 0 4
13 Anil Patil Navimumbai 0 4
14 Madhukar Waghmare Pune 0 4
15 Nilesh Mohol Pune 0 4
16 Rahul Tekawade Pune 0 4
17 Praveen Kumar Delhi 1 0 4
18 Vijay Pandey Delhi 1 0 7
19 Rakesh Thakur Delhi 2 0 7
20 Mukesh Kundra Delhi 2 0 5
21 Dalip Singh Punjab 0 4
22 Jomy Thomas Mumbai 0 7
23 Souvik Ghosh Kolkata 0 4
24 Mirza Begg Kolkata 0 4
25 Manoj Karmakar Kolkata 0 4
26 Mahesh Nadar Mumbai 0 6
27 K Balamurugan Hyderabad 0 2
28 Balwinder Singh Delhi 1 0 4
29 Kailash Singh Noida 0 4
1500
1192
1200
900
630 648 683
588 619
600 488 468 502
358 393
298 290 269 265
300 176 183 171 200
109 123
70 48 59 66 41
76 59 40 81 60 49 21 24 31 51
0
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C C C C C C 20 20 20 20 20 20 20 20 20 20 20 20 C
Months
1500
1192
1200
952
900
630 630 592 560
488 531 499
600 428 390 393
298 358 290
363 340 297 228 222 188 114
300 176 109 70 123 94 113 70
48 64 52 35 64 43 54 24 24 39 41 16 51
0
Branches
Sr. Number of
Claim Analysis Calculation
No. claims
1 Total number of Claims raised in 2014 (All claims) 9415
RM CLAIMS
2.a Total number of RM claims raised in 2014 6192
2.b Number of RM claims for which cost is borne by the customer 3618
2.c RM claim for which Schindler has borne the cost (MDC error, salesman 2.a - 2.b 2574
error, material out of warranty, etc.)
3 Total number of claims for which Schindler is responsible 1 - 2.b 5797
4 Total number of RT Claims ( issues due to R&D issue, and FI 557 Mayr 237
brake, FI 647:S5500 service pack, FI 601 CPCUF PCBA, FI 608 Door
lock,
5 Number of claims for which 80% of the reduction needs to be achieved 4-5 5560
Completions Expected The proposed growth of KG IND is 27% in 2015. Hence with this
1 Growth rate of KG IND 2014 = 7307 growth rate is increase in number of installation, It is foreseen the number of
Budgeted =9310 27% claims will also increase by 27%.
1 SMIC Sanmina 82 17 74 15 Problem Desp: The CPLD corruption was observed due to surge in
the 3.3v DC generated from SEM PCBA.
Action: R&D identified the root cause of CPLD corruption to be SEM Dec'14 R&D Closed
PCBA. KA 212276 released for Improved design of SEM PCBA, Feb15
CP237.
April'15 SDI Ongoing
Under industrialization with SDI/supplier.
Problem Desp: Boot software failure reported
Action: Possible root cause of software failure was identified as static 30th SCQ Closed
discharge. Hence Anti Static Wrist Straps provided to field. June'14
Procedures to use the same & calibration circulated to Field through
WI on 12th Jan 2015.
SCPU
2 Sanmina 54 11 38 8 Problem Desp: The Boot software failure was observed due to surge
PCBA's
in the 3.3v DC generated from SEM PCBA.
Action: R&D identified the root cause of CPLD corruption to be SEM Dec'14 R&D Closed
PCBA. KA 212276 released for Improved design of SEM PCBA, Feb15
CP237.
Compone Responsibl
# Supplier 2013 YTD'2014 Action / Comments Target Date Status
nts e
Problem Desc: The ARD operation fails in No load and full load
condition.
There is no output available from the Exista Invertor.
Actions
Exista will complete the redesign and in house testing of 3+3 20th Dec'14 Lorenz +
sample improved design 800 W inverters. Jan'15 R&D IND Open
The samples in Jan15 have failed in Supplier end itself
Plan was that 3 each inverters will be sent to R&D CO EBI (Lead
Office) and R&D CO IND(for System Integration checks). TBD Exista Open
ARD R&D CO EBI will perform required tests , including Stress tests
4 Exista 55 10 33 7
Inverter on the sample 800 W inverters
R&D CO IN will, in parallel or later, perform System Integration
Tests.
1 R&D IND 23 1 22
2 SCQ 11 0 11
3 FQE 9 1 8
4 SDI 9 0 9
5 NSM & FO 1 0 1
Grand Total 53 2 51
-Communication Error
-Display Error
3 PCBA SCCIx 57 0.55 130 1.21 1.76
-Shaft Info Error
-Load Cell error
Local Technical Circular (TC135) for checking the alignment of the STM &
1 Mar12 Completed
MTB
CP233
3 Implementation of Retainer + Completed
Dec14
Retainer +
Schindler | Quality Assurance | Kevin Noakes I Page 37
Update on STM drifting
Total number of Units reported drifting with AWT/N pulleys in 2014 : 140
STM & AWT/N Pulley sent to Ebikon for analysis, as per the analysis report
1 20th Oct'14 Completed
the STM is contaminated with Zinc leading to the STM drifting
FI 652: Zinc coating abrasion on AWT V-Pulley" with Felt solution released .
2 17th Oct'14 Completed
3060 units uploaded in FACT as completed.
3 Release of machines with the sand blasted sheaves done by R&D IND CP 233 Completed
FI 659 Traction media data collection, released for reporting STM corrosion
3 10th Dec14 Ongoing
/ snapping
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