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Strategic Initiatives - TBEM

TBEM | Tinplate Promotion Council | Total Productive Maintenance
Total Operational Performance | 6 Sigma | Value Engineering | Quality Circles
HR Initiatives | IMS Certification | Knowledge Management | Benchmarking

Excellence Journey in TCIL

Content

Actions/Initiatives

Vision/ Mission  
  • Evolved in 1998
  • Vision revisited by Senior Leadership Team in 1999- 2000
  • Vision reviewed at the start of every Annual Strategic Planning Exercise
  • Communicated to all employees thru’:
    - Designated Communication Forums
    - Hoarding at strategic locations
    - Distribution of Pocket cards
 
Core Values  
  • Values
    - Ethics
    - Respect for Individuals
    - Competence
    - Responsiveness

    Enshrined in Policies: Quality, TPM, SHE, Whistle Blower, Gift & Sexual Harrassment Prevention Policy and communicated to all employees thru':

    - Designated Communication Forums
    - Hoarding at strategic locations
    - Distribution of Pocket cards
    - Senior/ Junior Dialogue
    - Ladies Dialogue
    - Meeting with Union Committee Member/ Union Management Meeting
    - Communication
    - Joint Departmental Council / Joint Consultative Council of Management
    - Works Committee Meetings
 
Tata Code of Conduct (CoC)  
  • Formal adoption & appointment of Ethics Counselor in Apr 2000 and Divisional Ethics Co-ordinators
  • 'E' Level: Training and Signing of CoC, Communication - Hindi / English Poster Display
  • 'O' Level and New Entrants: Training and Signing of CoC, Communication: Quiz Competition, awareness thru' Domestic Management Program
  • Pocket card for employees, In-house magazine, Presentatations/ skits/ discussions in JDCs, appointment of Divisionsl Ethics Co- ordinators, Introduction of CoC deployment process. CoC presentation to Suppliers, Customers & Consignment Agents.
  • Union Officials: Training & signing of CoC, Communication: Quiz Competition, awareness thru’ Domestic Management program, E & I of CoC deployment process
  • Installation of 4 Drop Boxes
  • Insider Trading Issues Focused, Shareholder perception measured
  • Employees survey on ethics introduced
  • Perception of 60% employees measured thru' Ethics Survey action taken on feedback: perception of half-yearly suppliers measured thru’ half yearly suppliers meet.
  • Awareness program for aided school and Tata Power (Jsr).
  • Review Mechanism Structure within Ethics Group to assess deployment
  • Gift policy circulated across organization in April, 2005. Session for all women employees in TCIL conducted on Sexual Harassment- its prevention and redressal, TCIL web- site Corporate Governance link designed & developed, declaration on compliance to the Code signed by all Union officials in Kolkata, Joint Dialogue by MD/ Ethics officer highlighted concerns raised & resolved, action plans on feedback of MBE Assurance survey; Sexual Harassment Prevention Policy introduced.
 
Strategic Goals & KEPs  
  • Strategic goals aligned to Vision identified
  • Strategic objectives identified against strategic goals.
  • Deployment thru’ BSC methodology

    Cascading of MD’s BSC for deployment & organizational alignment

  • Short Term / Long Term Action Planning in line with Strategic Objectives
  • Key Enterprise Processes (KEPs) identified with Key Performance Measures (KPMs)
 
Quality Management Structure  
  • Business Council comprising of Sr.Leaders & led by MD.
  • TBEM Category Team led by Functional / Divisional heads.
  • Business Sub-Council comprising of Divisional / Departmental Heads.
  • TBEM Assessors: 58 Internal Assessors / 36 nos. of External Assessors and 5 SAP Participants, CII Assessors: 16 External Assessors.
  • Awareness training on TBEM organized for Executives since 1999 onwards (All Executives have been covered thru' TBEM 'O' Module and BEAM Programs)
 
Balanced Score Card   In order to achieve Strategic Objectives which address Strategic Challenges, TCIL develops Long term and Short term action plans with measures and targets during SPP using MOAC. The action plans are deployed using the BSC methodology. Corporate BSC is cascaded to 7 Functional BSC and further cascaded to KRAs of Executives and KPIs for Operating units using the KPM tree. Corporate BSC measures are reviewed at Business Council and various performance review forums and action plan changes are documented.
 
Monitoring & Review system  

Examples of Measures/ Indicators for monthly reviews by MD and Senior Leaders

Functions
KPMs for ST Plans (Reviewed Daily monthly)
KPM for LT Plan (Review Quarterly / Annually)
Strategic Objective
Marketing & Sales NRs, Collections, Debtors, Despatch, Compliance,Stocks, Order Status, Sales, Exports Customer-Sat Index, No. of new packaging solution Domestic Market Share ,Export as % of Sales Increase engagement across the industry (A2)Build & Promote Competitive products (A3)
Operations Production, Mill Availability, Thru’put, Quality & Material Yield, Downtime, Power & Stores Consumption, Dispatch compliance, R&M cost, Processing cost OEE, ETP Production Increase Scale of Operation (E2), Build & Promote Competitive products (A3), Become Cost Competitive (E3)
Finance WC, Cash Flows, Interest rates EVA+ ,WC Efficiency ,ROCE%, WACC (Enhance Share Holder value)E1, Become Cost competitive (E3)
Supplier –Partner Tin Stock, Inventory, Transporter performance, PR to PO time, GRN Cycle Time, Stock out, compliance on quality Supply compliance for Tin and HRC , Supplier satisfaction Index Long term agreement with suppliers (B1), Enhance Supplier Satisfaction (B2)
HR Training Coverage, Statutory Compliance, Grievance Handling, Absenteeism Training Satisfaction Index, IR Index, CRIEmployee-Sat Index Reducing turnover among officers/ executives in core Functions (C2), Strengthen I.R climate (C3), Move towards Sustainable, renewable community support (D1)
 
People Motivation & Performance Orientation  
  • Adoption of Group HR Guidelines
  • Identification of successors
  • Sending of future leaders to General Management Programs at IIM-A & XLRI
  • Systemic Integration of Company wide improvement initiatives
  • BE Nite Recognitions (Assessors, Individual Excellence, Community Services, Group Award / Team Excellence, Stakeholder Recognition, NGOs for partnering in Community, Bench marking Projects)
  • Performance Bonus (Achievements including beyond immediate portfolio)
  • Quarterly Suggestion Awards (Suggestion Box Schemes for getting Innovative Ideas)
  • Recognizing Diploma Achievers (encouraging on-job individual learning by unionized personnel)
  • Winners of Ethics Month, Business Excellence Month, Gyan Vardhan Month & Safety Month Events
 
Customer Orientation  
  • Bifurcation of Marketing / Sales function.
  • KAM Initiatives, structured visit to customers.
  • Customers visit to plant.
  • Customer Contact Programs.
  • Yearly Customer Satisfaction Survey / Feedback.
  • Marketing Bulletin, Zonal Khabar.
  • Complaint management system.
  • Focus on Product & Market Development and Solution Provider.
  • Tinplate Promotion Council.
  • Interaction with Professional Industry Bodies- Indian Institue of Packaging (IIP), Central Food Technological Research Institute (CFTRI)
 
Leadership  

Evaluation and Improvement

Year
Source (Issues)
Action Taken
01-05 TBEM (Measure social responsibility) Pro-activeness in societal concerns CRI introduced in BSC; Instituted EMS ISO 14001 certified and OHSAS
Leadership / communication effectiveness survey Lotus Notes deployment with access to leadership
Raising CoC concerns (Ethics survey) CoC Implementation Process improved
  1. ESSurvey (In House); JN Tata feedback: leadership effectiveness survey (in House) based on Metric format designed for Tata Steel
  2. TBEM: process for knowledge sharing - early stages
  3. CII Exim feedback: Leadership development / succession planning in view of future business needs
  4. Recognition of Customers /Suppliers
  1. Redefining attributes based on Tata Steel Learning
  2. Re-inforced KM initiatives with the help of KM group Tata Steel; Formation / facilitation of KM communities; Capturing knowledge asset thru’ IT.
  3. Re-organisation w.e.f 1st April’04
  4. Introduced recognition of suppliers & customers in B.E Nite and TPC Award Nite
Re-visiting Strategy & Strategy mapping sessions (thru’ BE Group -Tata Steel) : Measurement of CoC deployment Re-validating 2005-10 strategy with BCG, refining Strategy Map and Corporate + Fnl. BSC’s; MBE Survey on CoC by Metric consultant.
06-07 Re- visiting Strategy alignment process thru MOAC ; Re-visiting Leadership system Aligning Stakeholder requirements and Strategic Challenges with Strategic Objectives, Short term and long term action plans with measures and targets
 
Information Technology  
  • Company has implemented Baan ERP during Oct'2003
  • Fibre Optic LAN at Jamshedpur office/works
  • VPN WAN through leaseline, tataindicom vdata card for non-Jamshedpur locations
  • EVA storage for higher availability of ERP
  • Lotus Notes for effective and faster communication and e-workflows towards less paper organization.
  • Deployment of websites www.tatatinplate.com, www.tpcindia.org and www.tinplatehospital.com for stakeholders
  • Intranet sites for information sharing
  • Implemented Swipe Card attendance system for all Jamshedpur employees to decentralize the time office
  • Web based Knowledge Management Process
  • Information Kiosk for employee information sharing.
  • Video Conferencing facility among Jamshedpur, Kolkata, Mumbai and Delhi for communication.
  • Cisco firewall for network security.
  • Spam Filter for message / mailing security
  • Disater recovery site for ERP.
  • Fire alarm system for IT datacenter security.
 
Participation in BE External Assessment Process  
  • TBEM Assessments
    - 1998 : 129 Points
    - 1999 : 131 Points
    - 2001 : 342 Points
    - 2002 : 443 Points (Highest Delta)
    - 2003 : 508 Points (Award for Active Promotion)
    - 2004 : 539 Points
    - 2005 : 553 Points
    - 2006 : 580 Points
    - 2007 : 605 Points (JRD QV Award)                         
      - 2008 :  614 Points
  • CII EXIM Bank Award Assessments.
    - Commendation for Strong Commitment to TQM (2003)
    - Commendation for Strong Commitment to TQM (2004.
    - Commendation for Strong Commitment to Excel (2004).
    - Commendation for Strong Commitment to Excel (2005).
    - Commendation for Significant achievment Award (2006)                                                                        -   Certification for Significant Achievement (2007)
  • IMC RBNQA Award Assessment.
  • JN Tata Award Assessments.
    - JN Tata Award (2004) - Overall Best Associate Company.
    - JN Tata Award (2005) - Best Associate Company.
    - JN Tata Award (2006) - Best TIS Group of Companies.
 
Improvement Initiative   TPM, Benchmarking Process, New Poduct & Market Development Process

TOP, Six-sigma, TPM deployment, KM site, BM projects, re-introduced practice of overseas technical training, ERP implementation, Interface with CORUS, TBEM process, e-workflows using Lotus Notes , CCHP, ISO Systems (9001, 14001 & 18001) certification, WIN Intervention, BCG, New Product Development and Business Development, Project Management

Examples of Continuous & Breakthrough Improvement

Continuous Improvement
Breakthrough Improvement
  • ETP quality yield (87% to 93%)
  • Processing Cost (Rs 4763 pmt. to Rs4514 pmt.
  • Mill availability of 6 Hi/ETP
  • Improvement in Corporate responsibility index.
  • Improvement in grievance handling cycle time
  • Commissioned DD shear in 4 days against 7 days world record
  • Developed new product –Soft DR
  • Converted Tinplate Hospital into profit centre
  • OTSC & TFS line speed at ETP and 6 Hi first pass, speed
  • HRC material yield saving with Ryerson / Tubes

 

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