The Aditya Birla Group is among India's largest business houses
Operating in the country for over five decades and globally for nearly thirty
years. Its 40 state-of-the-art manufacturing units and sectoral services are
anchored by 72,000 employees. Rajashree Cement (RC) is one of the Unit in
Aditya Birla Group. RC is India's largest cement manufacturing Unit. It is the
only Cement Plant in India which has a capacity of 4.2 millions tpa
WCM Cell:
World Class Manufacturing (WCM) Cell implements the blue print of the WCM
concept that has been adopted by the Aditya Birla Group to usher in
transformation necessary for growing in the globally competitive environment.
The Cell is engaged in education and training, along with research and on-site
facilitation services to implement the customised holistic model which lays
emphasis on all aspects of a business for achieving and sustaining overall
competitiveness within the organisation and across its supply chain.
Existing Process:
Each area in the Unit is divided into different teams. Each Team has to follow
WCM standards. Each team has standard QCDIP (Quality, Cost, Delivery,
Innovation and Productivity) format with relevant parameters. Targets will be
fixed against each team by WCM Cell and they have to submit their scores
(achievements) to WCM Cell for every month.. Along with QCDIP formats, other
standard formats like Kaizen, SOP, MP Design, FI Studies, PM Analysis etc will
be submitted to WCM Cell. Every month WCM Cell conducts internal audits
regarding adherence of standards. Internal Customer Satisfaction level will be
verified by WCM Cell. All these information is entered in MS Excel / MS Word
format and sent to WCM Cell for verification. WCM Cell will verify the scores
and gives rating to each team. Based on ratings/score, the best team will be
recognized.
Drawbacks in existing system
. Users has to enter data on a monthly basis in MS Excel / MS Word format and
send to WCM Cell by mail or by hardcopy.
. WCM Cell has to wait for receiving the data from teams
. No tracking of pending input work of individual teams and has to periodically
monitor wheather they have submitted the relevant inputs for evaluation or not.
. WCM Cell has to check each and every file sent by teams and consolidate the
data which is a very time consuming work.
. Getting Holistic and unified information is a most difficult task.
. Reminders have to be sent manually by mail . Lot of stationary requirements
Solution:
. eSoft has come up with a solution called Quality Management System (QMS) to
overcome the above drawbacks. The main objective of QMS is to automate all WCM
activities and to reduce the human interaction in assessment of teams / plant
performance.
Advantages of QMS
. Creating Motivation to the teams by selecting a best team based on their
performance.
. Available of all standard formats like Kaizen, SOP, MP Design, FI Studies, PM
Analysis
. Analyzing the progress of each parameter in QCDIP (Quality, Cost, Delivery,
Innovative and Production) like Production, Budget etc.
. Monitor Internal customer satisfaction level among the departments with in
the organization.
. Abnormality Management
. Eliminating human intervention and avoiding redundancy of work
. Eliminating paper work
. Automatic generation of reminders to teams
. Generation of various types of reports and graphs helps Sr. Management and
WCM Cell in decision making.
Technologies :
It is a cost effective and web based centralized application.The role based
authentication is enabled to have secured access to individual authenticated
users .The application is highly layered and all the standard practices and
procedures has been adopted in the development.
Achievements
. This is the first product which was developed adhering to WCM Standard
formats and evaluates the teams/plant performance. It was successfully
implemented in Rajashree Cement, Malkhaid which is pioneer in Cement Industry.
. This software is very useful for other manufacturing industries which follow
the WCM Standards / Standard formats and wants to assess the individual / team
/ plant performance.
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