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Submitted for the partial fulfillment of Post Graduate Diploma in Industrial Engineering
(PGDIE)
Under the Guidance of
Mr. Dhanaraj N
Pundir
HOD (DS/PUQ-SDT1-IN)
Placements
Bosch Limited
Mumbai
Prof. A.K.
Dean,
NITIE,
Submitted by
Sudhir Kumar
Roll No. 101, Class of 2012
This is to certify that the project work titled Development of Suppliers through Lean
Principles has been successfully completed at BOSCH Group by Sudhir Kumar under
my guidance, in partial fulfillment of Post Graduate Diploma in Industrial Engineering at
National Institute of Industrial Engineering (NITIE), Mumbai.
Faculty Guide
Prof. A.K. PUNDIR
Associate Dean, Placement
NITIE, Mumbai
ACKNOWLEDGEMENT
No academic endeavour can be single handedly accomplished. This work is no exception.
Summer Internship gives an opportunity to apply the theoretical knowledge in the actual
working conditions.
I take the opportunity to extend my thanks to Bosch Limited, Bangalore for offering me
platform to gain exposure and garner knowledge in the field of Operation Management and
Supply Chain Management. At the outset I would like to record my gratitude to Mr. Syed
Ehtesham Ahmed, Assistant Manager (HR) for initiating me in this training. I wish to
extend my sincere and heartfelt gratitude to my project guide Mr. Dhanraj. N, HOD
(DS/PUQ-SDT1-IN) for having made my summer training a great learning experience by
their constant guidance, encouragement and extreme support. I would also like to thank Mr.
Karthik B.S., Sr. Engineer (DS/PUQ-SDT1-IN) who helped me at all stages during this
project and whose suggestions were indispensable all through my training and played a
great role in making this a useful project. I would like to express my deep sense of gratitude
to Mr. Raghuvendra, Sr. Engineer (DS/PUQ-SDT1-IN), Mr. Nikhil, Sr. Engineer (DS/PUQSDT1-IN) and Mr. Biswajit Swain Sr. Engineer (DS/PUQ-SDT1-IN) for their cooperation,
valuable guidance and time to time consultation without which I couldnt have completed my
project. I have been extremely benefited by prestigious association as a summer intern with
BOSCH Group.
I also take immense pleasure in extending my thanks to my faculty guide Prof. A.K. Pundir,
Associate Dean, Placement, NITIE, Mumbai for providing the valuable insight during the
project and for inspiring me to complete the project successfully. Finally, I would also like to
acknowledge Bosch and its business associates for their support.
Sudhir Kumar
Executive Summary
Daimler India Commercial Vehicle Pvt. Ltd. Is going to launch new commercial vehicle in
two plateform HDT and LDT from mid of 2012. For any commercial vehicle, Frame
Assembly is important and critical part. For smooth execution of frame assembly, I did
gap analysis in frame assembly activities up to C-Sample (Its a type of sample product in
new product development cycle) delivery. Currently supplier is located in Mumbai and
before D-Sample (Its also sample product before start of production) delivery supplier
will stabilize a new frame assembly plant near DICV plant at Chennai.
In Gap analysis DICV Goal should be specific and measurable. In this case, I have
mapped the whole PSSM activities by data flow modeling tool with proper input, output,
controller and mechanism. Analysis includes CFT, supplier, DICV schedule and review of
business documents as well as interviews with team members in various departments.
Once all information has been gathered, I mapped whole activities in IDEF (integration
definition) model and compared with standard activities along with time schedule of DICV
to find the gaps and impacts. Also analyzed the gaps impact in the form of time, cost and
quality by survey. By the priority of gap impacts, generated the ideas by brainstorming
exercise and evaluated each idea on the basis of cost, risk, return and effectiveness.
Approximate 2 yrs remaining for SOP (start of production) and there are so many
activities remaining and for these activities different depts. will be involved in different
level as RASIC form. So prepared the roles and responsibilities in the form of matrix to
avoid any kind of ambiguity, and by this way company can save time, cost and also can
deal with supplier in better manner. I did backward scheduling of all activities from
supplier to all DICV depts.
For next 2 yrs DICV & Supplier have mutually agreed project time line for frame
assembly, which time schedule is created on the basis of most likely happening. There
are some activities which are more critical as compared to other activities which can
create over all delay in the project. For next 2 yrs I have prepared optimistic, most likely
and pessimistic schedule and performed risk analysis on the basis of PERT execution. By
this analysis I was able to find probabilistic completion of critical tasks
DICV, PSSM, 14th Jun 2010 Page 7 of 38
Background
Company Profile
a) Bosch GroupThe Bosch Group is a leading global supplier of technology and services. It offers
products in areas of Automotive Technology, Industrial Technology and
Consumer goods & Building Technology. It was founded in 1886 in Germany as a
Workshop for Precision Mechanics and Electrical Engineering by Robert Bosch. The
BOSCH Group today is the largest automotive technology supplier in the world with
presence across six continents. It has more than 350 subsidiaries, associated
companies and 12000 service centers located in over 150 countries.
OwnershipNinety-two percent of the shares in Robert Bosch GmbH are held by the charitable
foundation Robert Bosch Stiftung.
Clients-
Partners-
b)
Bo
ch
s
LimitedRobert BOSCH India was founded in 1951.With more than 22,500 employees RBIN is
the largest manufacturer of diesel fuel injection equipment, auto-electrical, hydraulic
gear pumps fir tractor applications, electric power tools, packaging machines,
Blaupunkt car multimedia systems and security systems.
In India Bosch Group operates with following companies. Robert Bosch GnbH holds
71.8 stakes in Bosch Limited.
Robert Bosch Engineering and Business Solutions Ltd.
Bosch Rexroth India Ltd.
Bosch Chassis Systems India Ltd.
Bosch Automotive Electronic India Pvt. Ltd.
Bosch Electrical Drives India Ltd.
Presence
Location
Since
1951
Bangalore
2.
3.
NaP
NhP
1969
1989
4.
5.
JaP
VraP
1999
2007
Sales Trend
Products
70
60
50
40
30
20
10
0
Years
Sales Trend
70
60
50
40
30
20
10
0
Years
Years
5000
0
Years
4000
2000
0
Years
Americas; 18%
Europe; 59%
Bosch BangaloreThe Company was shifted to Bangalore on 16th November 1953 premature Bosch
was in Chennai. A letter of intent for diversification into auto electrical was received in
the year 1985 and approval for the import of capital goods was also obtained. Added a
number of new machines both at the Bangalore and Nasik factories during 1987 under
the modernization program. Also a fourth generation on-line computer facility was
installed at the Bangalore factory. The Company was awarded the status of Trading
House in the year 1988. The unit added A `Cold Start' facility enabling testing of
engine at temperature as low as -20oc. The Centre was appointed as a Bosch Global
Development Centre with the global responsibility for design and development of small
single cylinder pumps for the entire Bosch Group. Bosch's centre had already
developed a new type of single-cylinder pump for vehicular and stationary
applications. During the year 1991 technical collaboration agreements were entered
for the manufacture of fine horning machines and super finishing machines. In 1992,
The Company introduced certain new items such as halogen bulbs, ignition cells,
Bosch Global
Bosch India
Logo
Type
Industry
Founded
Founder
Headquarters
Clients
Worldwide
Asia, Africa, Europe
Delphi, Johnson Controls, Denso, Delphi, Denso, Siemens
Bridgestone
KLUEH Security GmbH, Kuehne +
Nagel (AG & Co.) KG, Toom
-
VK Viswanathan (MD)
Inline Pumps, PF Pumps,
Common Rail Pumps
6630 Crores (2010)
22,500 (2011)
www.boschindia.com
BauMarkt GmbH
Partners
Key People
Products
Revenue
Employees
Website
Business SectorsThe three business sectors of Bosch are- Automotive Technology, Industrial Technology
and Consumer Goods and Building Technology.
i) Automotive Technology
Automotive Aftermarket
Diesel Systems
Gasoline Systems
Diesel and Gasoline ECQ Systems
Starter Motors and Generators
ii) Industrial Technology
Special Purpose Machines
Packaging Technology
iii) Consumer Goods and Building Technology
Power Tools
Security Systems
Diesel SystemsBosch in India is committed to develop diesel fuel injection products and provide
services to meet the stringent emission norms of the future. For instance, Boschs inline fuel injection pumps could cater the full spectrum of diesel systems till BS-II. They
are used in arrange of engines starting from small fixed installations to large earth
movers. By increasing pressure capability, improving timing control along with
combustion optimization, the in-line pump is able to meet the next level of emission
norms of BS-III in major part of country, thereby reducing CO emission by 50%.
With the proposed introduction of BS-IV in 13 cities across India, requirement of
reduced emissions are quieter engines are making greater demand on the engine and
the fuel-injection systems. These demands can be met by common rail fuel injection
system that delivers fuel at a high pressure, precise quantity, precise timing and split
into multiple injections. Moreover, electronic control in the common rail diesel fuel
injection system increases flexibility making the system less polluting, more fuel
efficient & capable of meeting future emission norms.
B.
Need and the Significance of the Project WorkMajor products procured by the Bosch India are steels, castings, forgings, turned
and machined parts, sintered components, fasteners, springs, bearings, assemblies,
sub-assemblies, packing materials, logistic services and capital goods.
To cover the full spectrum of Diesel Systems Bosch is committed to develop
diesel fuel injection products that deliver the fuel at high pressure, with precise
Problem Definition
C. MethodologyTo accomplish that challenge the company has set the following guidelines.
Customer Satisfaction
Quality ( Zero defect)
Supplier Development (training and development)
Fairness and Openness
International Activities
Systems Network
Market and Products
Environmental Responsibility
Continuous Improvement
Associate Development
As Bosch India procures large assortments it felt the need of dividing the
purchasing department into two divisions. They are corporate logistics and
purchase (CLP) and plant logistics and purchase (PLP). Corporate logistics and
purchase division sources raw materials, standard components, trade goods and
capital goods. They also ensure proper logistics contracts and customs
clearance. The plant purchase department is responsible for plant specific parts,
machined components, mechanical subassemblies and capital goods.
Any company that wishes to become supply chain member of Bosch India
should fulfill following criteria:
1. All suppliers should be QS 9000 certified manufacturers.
2. The supplier should get A rating from the company. The rating methodology is
given below
S. No.
1.
2.
3.
4.
Audit Score
90 to 100
80 to less than 90
60 to less than 80
Less than 60
Ranking
A
AB
B
C
Meaning
Full Compliance
Mainly Complaint
Conditionally Complaint
Not Complaint
Implementation
3.
Academic Scope
A. Management Techniques / Methodologies Likely to be UsedValue Stream Mapping, Value Stream Design, Vision, System CIP, 5S, Visual
Management, TPM, Poka Yoke, Leveling, Response System, Point CIP, Flow
Oriented Layout, FIFO, Cellular Manufacturing, Standardized Work, MOST,
MTM, SMED, Consumption Control, Capacity Planning, System CIP, Point CIP
B. Functional Areas/Subjects Expected to be spanned by Project Assignment
1. System Efficiency and
Improvement Techniques
2. Work System Design-I & II
3. Industrial Engineering
4. Ergonomics
5. Materials Management
6.
7.
8.
9.
10.
4. Work Plan
11.
A. Identify the Distinguishable Stages / Milestones
12.
13.
14.
VSD / VSM
15.
16.
Vision, Metric
17.
18.
19.
20.
21.
22.
23.
24. Value Stream Design,
25. Key Figures,
26. Vision,
27. System CIP
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
CIP
Production Leveling
Process Stabilization, Visualization
Flow
Lot Size Production
Visual Management,
TPM, Poka Yoke, 5S,
Leveling, Response
System, Point CIP
Full Production
42.
43.
44.
45.
46.
47.
48.
49.
50.
51.
52.
53.