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Tata Motors's Achivements

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    TBEM Group, Jamshedpur 1

    Treading the path ofexcellence

    at CVBU

    TATA MOTORS

    Treading the path ofexcellence

    at CVBU

    TATA MOTORSParthasarathi Banerjee

    Asst General Manager

    Tata Business Excellence ModelCommercial Vehicle Business Unit

    Tata Motors Ltd

    Jamshedpur

    Software Productivity Conference

    Bangalore 18 February 2006

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    TBEM Group, Jamshedpur 2

    Tata Motors - A Flagship

    Automotive Company of the Tata Group

    Leading the Future

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    TBEM Group, Jamshedpur 3

    Tata Group

    Serving India for 127 years

    93 diversified companies

    A Total Turnover of US$ 17.8 billion (2.8% of Indias GDP)

    Largest Market Cap. - Trusted over by 2 million shareholders

    Account for 5 % of Indias exports

    Strong Brand Equity and Business Values

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    The Tata Group - 7 business sectors

    Engineering Materials Energy Chemicals

    PowerAutomotive andEngineering Products

    ChemicalsMetalsComposites

    Communications & IT Consumer Products Services

    HotelsFinancial Services

    International operationsOther Services

    Telecommunications

    Information Technology

    Consumer goods

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    Tata Motors

    Indias Largest Automotive Company

    Total income of US$ 4.7 billion (2004-05)

    Over 3 million Tata Vehicles plying on Indian Roads

    Indias only full range manufacturer of Passenger Cars & CommercialVehicles

    Product portfolio covers passenger cars, trucks, buses, and defencevehicles

    Currently has four vehicle manufacturing units at Jamshedpur, Pune,Lucknow and Gunsan (S Korea)

    Leading the future of the Indian Automobile Industry

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    Additional Strengths that Tata Motors can leverage

    Tata Group synergy for world class offering

    Tata Cummins for state-of-the-art Engines

    TACO - Collaboration with world class auto component /systemmanufacturers including Johnson controls, Yazaki, Knorr Bremse,Ficosa, Owens Corning, Faurecia,Toyo, etc..

    Tata Steel for HR & CR sheets and other steel inputs

    Telcon - Earth moving plant and machinery - collaboration withHitachi, John Deere, Euclid

    Tata Advance Materials for special materials & composites

    TCS / Tata Technologies for a range of engineering, manufacturingand business system solutions software development

    Fiat s.p.A. for Design, Manufacturing, Sourcing and Distribution of cars

    Hispano Carrocera SA for Innovation in Buses

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    Tata Motors

    Among the top 6 Medium & Heavy Commercial Vehicle Manufacturers in the

    world

    Over 130 models of Vehicles & Automotive Products which include

    Cars & Multi-utility vehicles

    1 ton LCVs to 40 ton HCVs / Tractor Trailers

    Buses from 12 seats to 67 seats

    Tippers to Special Purpose vehicles

    Wide Range of Defence vehicles

    Driven in 70 countries

    Leading the future of the Indian Automobile Industry

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    Tata Motors Product Range : Cars and MUVs

    Cars MUVs

    Indica Safari

    Sumo

    Victa

    SumoSpacio

    Indigo

    Indigo Marina

    T t M t C i l V hi l P d t R

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    Tata Motors - Commercial Vehicles Product Range

    LCVs Medium & Heavy CVs- Trucks

    Tata Mobile207- Pickup

    LPT 1615Truck

    SE 1613 TCTruckSFC 407Cargo Truck

    LPT 407Cargo Truck

    LPO 1613

    Car Carrier

    LPT 709 EContainer

    Truck

    LPT 2515Tanker

    ACEMini-Truck LPT 2516

    Mixers

    T t M t C i l V hi l P d t R

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    Tata Motors - Commercial Vehicles Product Range

    Medium & Heavy CVs Dumpers/ Tippers / Tractor Trailer

    LPS 3015Tractor

    LPK 1615Tipper

    LPS 3516Tractor -Container

    LPK 2516Heavy duty

    Dumper

    LPK 1615Turbo

    Heavy DutyDumper

    LPS 3516

    Tanker

    TATA i t t d l i ti l ti

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    TATA integrated logistics solutions

    T t M t D f & P ilit V hi l

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    Tata Motors- Defence & Paramilitary Vehicles

    Tata SD 1015TC (4X4)Troop Carrier

    Tata 407 SoftTopTroop Carrier

    LPT 1615 TC(4X4)Troop Carrier

    Tata 407 hardtopTroop Carrier

    Tata LPT A713 TC(4X4)Ambulance

    Tata LPT A1621 TC (6X6)High mobility

    (Logistics)

    Tata LPT 709E HardTroop Carrier

    Tata A 1615TC 4X2

    LOC Carrier

    Tata Motors Commercial Vehicles Product Range

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    Tata Motors - Commercial Vehicles Product Range

    Buses

    SFC 407Mini bus

    LPO 1510CNG bus

    LP/LPO1510Euro I

    City Bus

    LP 709EStaff Bus

    LPO 1616

    TCLuxury Bus

    LPO 1615TCLuxury bus

    Tata Daewoo Commercial Vehicle joins the Tata Family

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    Tata Daewoo Commercial Vehicle joins the Tata Family

    First major Overseas acquisition in March 04

    Significant addition to Product Range and manufacturing capabilities

    Access to South Korean Market for MCVs and ICVs

    A step towards International presence

    Tata Daewoo Commercial Vehicle joins the Tata Family

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    Tata Daewoo Commercial Vehicle joins the Tata Family

    Erstwhile DWCV Second largest CV maker in South Korea with a

    market share of around 26 per cent.

    Produced 200-400 horse power range of heavy dutytrucks

    Has over 93 models of cargo trucks, dumpers, mixer

    vehicles and also the capacity to make lightcommercial vehicles.

    Also makes tractors and utility vehicles and has an

    annual production capacity of 20,000 vehicles.

    DWCV makes commercial vehicles in 200-400 BHPrange, while Tata Motors makes trucks up to a

    maximum capacity of 200 BHP.

    Tata Daewoo Commercial Vehicle joins the Tata Family

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    Tata Daewoo Commercial Vehicle joins the Tata Family

    Acquisition of DWCW expected to

    help Tata Motors in its efforts to make the 'truck of the

    future', Enter Southeast Asian markets like South Korea,

    Thailand and Malaysia as well as China, to truly boost

    its presence in foreign markets

    Tie-up with Hispano Carrocera SA yields Starbus and Globus

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    Tie up with Hispano Carrocera SA yields Starbus and Globus

    StarbusSeating capacities from 16 to 67 seats

    Designed for optimum functionality andcomfortOffer unparalleled economy to the operators

    Starbus range includes Standard, Deluxe, LowFloor and Skool bus options - each with acustomised set of features

    GlobusTata Globus Coach designed to transportlong-distance traveller in the very lap of luxury

    Ergonomically designed seatsSpacious leg roomSpecial baggage spacePersonalised climate control vents to quieterengines

    Air-suspension and superior braking systems

    The Business Model

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    The Business Model

    Malcom Baldrige National Quality Award for Business

    Excellence

    European Foundation Quality Model

    many others

    The Tata Group

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    The Tata Group

    1991 the time India was beginning to get

    liberalised. Mr. Ratan N Tata takes over as

    Chairman, Tata Sons 1993 Chairman for over 50 years Mr. JRD

    Tata passes away

    1994 JRD QV Award for Business Excellence

    instituted within the Group in line with MBNQA

    2000 JRD QV BE Model renamed Tata

    Business Excellence Model (TBEM)

    The Goals of TBEM

    The Goals of TBEM

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    The Goals of TBEMThe Goals of TBEM

    Delivery of ever-improving value to customers,

    resulting in marketplace success

    Improvement of overall organizational effectiveness

    and capabilities

    Organisational & Personal Learning

    Ever growing top line

    Ever improving efficienciesand reducing costs

    TBEM Core Values and Concepts

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    TBEM Core Values and Concepts

    Visionary LeadershipVisionary Leadership

    Organizational &Organizational &

    Personal LearningPersonal Learning

    AgilityAgility

    Valuing Employees &Valuing Employees &PartnersPartners Managing for InnovationManaging for Innovation

    CustomerCustomer-- DrivenDriven

    ExcellenceExcellence

    Focus on the FutureFocus on the Future

    Social ResponsibilitySocial Responsibility

    & CitizenshipManagement By FactManagement By Fact

    & Citizenship

    Focus on Results &Focus on Results &

    Creating ValueCreating ValueSystems PerspectiveSystems Perspective

    TBEM Framework: A Systems Perspective

    TBEM Framework: A Systems Perspective

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    TBEM Framework: A Systems PerspectiveTBEM Framework: A Systems PerspectiveTBEM

    90

    85 85

    8585

    125450

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    THE TBEM FRAMEWORK

    Leadership 125

    Strategic Planning 85

    Customer & Market Focus 85

    Measurement, Analysis& KM 90

    Human Resource Focus 85

    Process Management 80

    Business Results 450

    TOTAL 1000

    Business Excellence Awards to CVBU

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    JRD QV Award for Business Excellence 2005JRD QV Award for Business Excellence 2005

    Earlier winners

    TCS (2004)

    Tata Steel (2000)

    CIICII--EximExim Bank Award for Business Excellence 2005Bank Award for Business Excellence 2005Earlier winners

    Infosys (2002)

    Tata Steel (2000)

    Maruti Udyog (1998)

    Hewlett Packard (1997)

    Journey in the Award Process, so far

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    y

    Wins

    JRD QV Award for Business Excellence CII-Exim Bank Award for Business Excellence

    400410 437

    503

    551578

    620

    0

    100

    200

    300

    400

    500

    600

    700

    1998 1999 2000 2001 2002 2003 2004 2005

    Business Excellence Model key elements

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    y

    StrategicLeadership

    ExecutionExcellence

    OrganizationalLearning

    to to Lead the

    organizationManage theorganization

    Improve theorganization

    We work through

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    g

    StrategicLeadership

    ExecutionExcellence

    OrganizationalLearning

    to to Lead the

    organizationManage theorganization

    Improve theorganization

    Strategic Leadership

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    Leadership SystemLeadership System

    Strategic PlanningStrategic Planning Focus on CustomerFocus on Customer

    Strategic Leadership

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    Leadership SystemLeadership System

    Strategic PlanningStrategic Planning Focus on CustomerFocus on Customer

    Leadership Role

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    Set directionSet direction

    OrganiseOrganise and allocate resourcesand allocate resources

    Review to achieve plansReview to achieve plans Develop EmployeesDevelop Employees

    Innovate and improveInnovate and improve

    Aspire for Vision Mission - Values

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    Core Values

    Integrity

    Customer Focus

    Corporate Citizenship

    Passion forEngineering

    Purpose

    To create

    economic

    assets for road

    transportation for

    the bulk movement of goodsand people and participate in

    managing these over the life

    of assets in order to create

    and capture economic

    value

    Vision

    To be a world class corporate constantly furthering the interests of allits stakeholders

    Mission

    Shareholders :To consistently create shareholder value bygenerating returns in excess of WACC during the upturn and at leastequal to WACC during the downturn of the business cycle

    Customers :To strengthen the Tata brand and create lastingrelationships with customers by working closely with businesspartners to provide superior value for money over the life cycle

    Vendors and Channel Partners: To foster a long term relationshipso as to introduce a broad range of innovative products and services,that would benefit our customers and other stakeholders

    Employees:To create a seamless organisation that incubates andpromotes innovation, excellence and the Tata core values

    Community: To proactively participate in reshaping the countrys

    economic growth and to take a holistic approach towardsenvironmental protection

    Strengthen and leverage the Low Cost base and Offer aworld class Product Range at the most competitive price

    A Unique Value Proposition from Tata

    Leadership System

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    Innovate, Share

    and Learn

    AdapttoNew

    Challenges

    andRaisetheBar

    Develop, Reward and

    Recognise Employees

    Understand Vision,Stakeholder Needs,

    Higher LevelObjectives

    CommunicateandBuild

    Commitment

    Create a Culture ofHigh Performance

    BeaR

    oleMod

    el

    Build,M

    otivate,

    Empo

    wer

    Team

    forAc

    celer

    ated

    Chang

    e

    Organise, Align, and

    Allocate Resources

    Communicate and Involve

    Review and Adjust to

    Achieve Plan

    MissionPartners

    CommunityShareholders

    Employees

    Customers

    Passion for Engineering Customer Focus Corporate CitizenshipIntegrity

    Set Direction and Plan

    Tata Code of Conduct

    Leadership System - Deployment

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    Levels of Leadership

    Innocence

    Awareness

    Commitment World-class

    Self Evaluation Matrix

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    Social Responsibility & Organisational Governance

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    CVBU complies with GlobalCVBU complies with GlobalReporting Initiative (GRI)Reporting Initiative (GRI)

    GuidelinesGuidelines TripleTriple BottomlineBottomlineapproachapproach

    Tata Code of ConductTata Code of Conduct CommunicationCommunication

    Tracking adherenceTracking adherence

    Effectiveness MeasurementEffectiveness Measurement

    Strategic Leadership

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    Leadership SystemLeadership System

    Strategic PlanningStrategic Planning Focus on CustomerFocus on Customer

    Strategic Leadership

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    Leadership SystemLeadership System

    Strategic PlanningStrategic Planning Focus on CustomerFocus on Customer

    Strategic Planning

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    throughthrough

    Balanced ScorecardBalanced Scorecard --Development and DeploymentDevelopment and Deployment

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    I believe that lack of Strategic Planning has a

    profound influence on the position of a BusinessOrganization in the marketplace and most of theproblems of the Organization can usually be traced

    to lack of Planning

    Ratan N. Tata 1996

    Strategic Planning

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    Strategic Planning

    Thi kThi k

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    ThinkThink

    Environment ScanningEnvironment Scanning

    VisioningVisioning

    Strategic ChallengesStrategic Challenges

    Setting Strategic DirectionSetting Strategic Direction DevelopDevelop

    Strategic AnalysisStrategic Analysis

    Strategic Focus/ ObjectivesStrategic Focus/ Objectives

    Target Setting/ Resource AllocationTarget Setting/ Resource Allocation

    DeployDeploy

    Balanced Scorecard DeploymentBalanced Scorecard Deployment

    ReviewReview

    ReviewReview

    Evaluation & ImprovementEvaluation & Improvement

    BSC Four Perspectives

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    FINANCIAL PERSPECTIVEFINANCIAL PERSPECTIVE

    "TO SATISFY OUR SHAREHOLDERS,WHAT FINANCIAL OBJECTIVES MUST

    WE ACCOMPLISH?

    "TO SATISFY OUR CUSTOMERS, ANDSHAREHOLDERS, IN WHICH INTERNAL

    BUSINESS PROCESSES MUST WE

    EXCEL?

    INTERNAL PERSPECTIVEINTERNAL PERSPECTIVE

    "TO ACHIEVE OUR FINANCIALOBJECTIVES, WHAT CUSTOMERNEEDS MUST WE SERVE?

    CUSTOMER PERSPECTIVECUSTOMER PERSPECTIVE

    LEARNING PERSPECTIVELEARNING PERSPECTIVE

    "TO ACHIEVE OUR GOALS, HOWMUST OUR ORGANIZATIONLEARN AND INNOVATE?

    CVBU BSC Implementation Structure

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    STEERING COMMITTEESTEERING COMMITTEE

    CVBUCVBU -- BSCBSC

    PLANT / FUNCTIONAL STEERINGPLANT / FUNCTIONAL STEERING

    COMMITTEECOMMITTEE -- BSCBSC

    DIVISIONAL/ CX STEERING COMMITTEEDIVISIONAL/ CX STEERING COMMITTEEBSCBSC

    DEPARTMENTAL STEERING COMMITTEEDEPARTMENTAL STEERING COMMITTEEBSCBSC

    INDIVIDUALINDIVIDUAL MPAsMPAs

    BSC Assessment

    ATTRIBUTES

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    ATTRIBUTES

    QUALITY OF GOALSCustomer Orientation

    Data Sufficiency

    Alignment with next higher level BSCComparative Comparison and/ or Benchmarking

    QUALITY OF PROCESS

    Trend of and Overall Performance

    Quality of Review and Analysis

    Degree of Involvement

    Learning and Sharing

    QUALITY OF PERFORMANCE

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    BSC ASSESSMENT - CONCLUSION

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    LEVELS OF PERFORMANCE

    Level 1: THE BEGINNINGLevel 1: THE BEGINNING

    Level 4: TOWARDS MATURITYLevel 4: TOWARDS MATURITY

    Level 2: EARLY DEVELOPMENTLevel 2: EARLY DEVELOPMENT

    Level 3: EFFECTIVE DEPLOYMENTLevel 3: EFFECTIVE DEPLOYMENT

    Level 5: A WAY OF LIFELevel 5: A WAY OF LIFE

    BSC JOURNEY

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    CVBU BSC evolved first in September 2000

    Concept cascaded to Plants and Functions by 2001

    Assessments to develop maturity initiated in 2003

    Most divisions have matured BSC processes in 2005

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    and A Recognition WE, at CVBU, are

    proud of

    and A Recognition WE, at CVBU, are

    proud of

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    CVBU Tata Motors, the first and the onlyCVBU Tata Motors, the first and the onlyIndian Company, awarded with the BSCIndian Company, awarded with the BSC

    Hall of Fame in 2003 by BalancedHall of Fame in 2003 by BalancedScorecard Collaborative from the creatorsScorecard Collaborative from the creators

    of Balanced Scorecardsof Balanced Scorecards -- Drs. Kaplan andDrs. Kaplan and

    NortonNorton

    Also, we are in the company of only 29Also, we are in the company of only 29other companies in the world who haveother companies in the world who have

    won this awardwon this award

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    warning!!

    The Balanced Scorecard is nota substitute for good

    management- it is only a tool.

    It requires good management!!

    Strategic Leadership

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    Leadership SystemLeadership System

    Strategic PlanningStrategic Planning

    Focus on CustomerFocus on Customer

    Strategic Leadership

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    Leadership SystemLeadership System

    Strategic PlanningStrategic Planning

    Focus on CustomerFocus on Customer

    Focus on Customer

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    Market Development ProcessMarket Development Process

    Customer Touch PointsCustomer Touch Points One every 900 sq. km.One every 900 sq. km.

    Derive MarketingDirection

    Listening &Learning

    Preparation ofAnnual Business

    Plans

    Preparation ofMarketing Plan

    Implementation &Reivew

    Focus on Customer

    Listen and learnListen and learn

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    Listen and learnListen and learn

    Product/Service

    Planning

    BusinessPlanning &

    Development

    Monthly Review of the impact on Business results, in SCMeetings

    Customer Listening& LearningApproaches

    Capture customer & marketinformationas per predetermined

    frequency

    Analyses of data by NPI and LOBs

    Priritisation of key customerrequirements & their relative

    importance in purchasing decisionsbased on inputs from customers

    through surveys

    Competitiveinformation from

    FIBRESBenchmarking

    MarketPlanning

    NetworkPlanning

    Development of the Plans by LOBs/ NPI/ Sales/ Services

    We work through

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    StrategicLeadership

    ExecutionExcellence

    OrganizationalLearning

    to to

    Lead theorganization

    Manage theorganization

    Improve theorganization

    We work through

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    ExecutionExcellence

    StrategicLeadership

    OrganizationalLearning

    to to

    Lead theorganization

    Manage theorganization

    Improve theorganization

    Execution Excellence

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    Customer RelationsCustomer Relations

    HR FocusHR Focus

    Manage ProcessesManage Processes

    Operational ImprovementsOperational Improvements

    Assess and ImproveAssess and Improve

    Execution Excellence

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    Customer RelationsCustomer Relations

    HR FocusHR Focus

    Manage ProcessesManage Processes

    Operational ImprovementsOperational Improvements

    Assess and ImproveAssess and Improve

    Customer Relationships

    Relationship ManagementRelationship Management

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    Relationship ManagementRelationship ManagementCustomers/ Channel MembersInputs through L&L on -

    AccessibilityRecognition for loyaltyGuidance & Assistance

    Benchmarking InformationCustomer Database QFD Information Dealership Network study Best practices in Auto Industry

    Determine contact requirementsNew CRM approaches/ modifyexisting CRM approaches

    CVBU/ LOB SCAnalysis of inputs, Review ofcurrent approaches

    Deployment of CRM approachesthroughout network

    Review of impact on BusinessResults

    Sales Process ImprovementSales Process ImprovementC0 Customer

    (Prospects)C1 Customer

    (Performa Issued)

    C3 CustomerVehicle Delivered

    (TATA Customer)

    C2 CustomerLOI/Token Payment

    Received

    Customer Satisfaction Improvement ProcessCustomer Satisfaction Improvement ProcessCustomer Relationships

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    Qualitative Discovery phase to clarify all issues impacting

    customer satisfaction

    Questionnaire development (positively worded statements,covering above aspects)

    Customer interviews (recent buyers of CVBU and Competition)

    Analysis of data using Regression analysis, Factor analysis

    Relative importance of eachFactor in customer satisfactionand dissatisfaction

    Satisfaction & Dissatisfactionlevels of CVBU & Competitorson each factor

    Relative rating of CVBU Vs Competition for prioritization

    for improvement

    Action plan development and deployment

    Inputs from

    partners

    Annual review of

    The process

    Changes in

    segments

    Execution Excellence

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    Customer RelationsCustomer Relations

    HR FocusHR Focus

    Manage ProcessesManage Processes

    Operational ImprovementsOperational Improvements

    Assess and ImproveAssess and Improve

    Execution Excellence

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    Customer RelationsCustomer Relations

    HR FocusHR Focus

    Manage ProcessesManage Processes

    Operational ImprovementsOperational Improvements

    Assess and ImproveAssess and Improve

    HR Focus

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    Attract the GOODAttract the GOOD

    Advance the BETTERAdvance the BETTER Retain the BESTRetain the BEST

    HR Vision and Mission

    Enhance and maintain Human Capital which

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    Enhance and maintain Human Capital, which

    will make the Organisation a world class playerand further the interests of all stakeholders

    Source, develop and maintain Human Capital,which will drive the culture of customer focus, highperformance and seamlessness.

    Create, learn and implement best in class HRpractices and processes in pursuit of excellence.

    Retain and attract the talent by improving thebrand through employee delight and loyalty.

    Improve Community friendliness.

    64

    Work Structures

  • 8/8/2019 Tata Motors's Achivements

    65/105

    TBEM Group, Jamshedpur 65

    Concept of Factories and Centres ofExcellence (CX)

    Cross-Functional Teams

    Self-Directed Teams

    65

    Employee Development Focused Leadership Development through

  • 8/8/2019 Tata Motors's Achivements

    66/105

    TBEM Group, Jamshedpur 66

    Fast track schemes

    Development Centres

    Technical Specialist Scheme

    Talent Management Scheme

    Focused Employee Training aligned with BusinessNeeds

    Evaluation of Training Effectiveness

    66

    Employee Welfare

  • 8/8/2019 Tata Motors's Achivements

    67/105

    TBEM Group, Jamshedpur 67

    Policy on Safety, Health, Security &Ergonomics

    Business Risk Management

    Employee Welfare Services

    Employee Satisfaction Surveys

    67

    Execution Excellence

  • 8/8/2019 Tata Motors's Achivements

    68/105

    TBEM Group, Jamshedpur 68

    Customer RelationsCustomer Relations

    HR FocusHR Focus

    Manage ProcessesManage Processes

    Operational ImprovementsOperational Improvements

    Assess and ImproveAssess and Improve

    Execution Excellence

  • 8/8/2019 Tata Motors's Achivements

    69/105

    TBEM Group, Jamshedpur 69

    Customer RelationsCustomer Relations

    HR FocusHR Focus

    Manage ProcessesManage Processes

    Operational ImprovementsOperational Improvements

    Assess and ImproveAssess and Improve

    Enterprise Process Model

    VALUE CREATION PROCESSESm

    en

    t

    t

    Expectations, Statutory Requirements

  • 8/8/2019 Tata Motors's Achivements

    70/105

    TBEM Group, Jamshedpur 70

    MANAGEMENTPROCESSES

    Human Resource Management

    Facilities & Environment

    Management

    Finance & Budgeting

    Information & Knowledge

    Management

    Lea

    ders

    hip&

    Corpora

    teCitiz

    ens

    hip

    Organ

    isa

    tiona

    lGovernance

    Interna

    l&Externa

    lCommunica

    tion

    Strate

    gicPlann

    ing

    Performance

    Improvem

    &Cha

    nge

    Managemen

    t

    C U

    S T

    O M

    E R

    and

    O the

    rS

    tak

    eH

    old e

    rs

    (Em

    ploy

    ee

    s,I

    nves

    tor s

    ,G ov

    t ,S

    ocie

    ty)

    Demand Creation Processes

    Market Development

    Channel Partner Management

    Demand Fulfillment Processes

    New Product

    Introduction

    Services

    Design

    Design Processes

    Sales & Operations

    PlanningVendor Management

    Manufacturing

    Production & DeliveryProcesses

    After SalesService

    Service Processes

    Sales Planning

    Vehicle Financing

    SUPPORT PROCESSES

    EL11-Manufacturing

  • 8/8/2019 Tata Motors's Achivements

    71/105

    TBEM Group, Jamshedpur 71

    EPM Process No:CVBU-EL-11

    Locational Process Chiefs: Locational Manufacturing Heads

    Principal Process Owner: A P Arya - Sr VP (JSR and Lucknow Works)

    Sub_Proc No Sub Process Name Sub_Process Owner

    CVBU-EL-11-01 Material Scheduling & Logistics Head Materials - Pune,JSR, LKO

    CVBU-EL-11-02 Produce Vehicles/Aggregates/Components Factory/Divisional Heads - Pune, JSR,LKO

    CVBU-EL-11-03 Vehicles & Spares despatch'Heads Vehicle Despatch, Exports & CKD, Auto Services -

    Pune, JSR, LKO

    CVBU-EL-11-04 Analyis Of Customer Complaints Heads (QA, CQ, Customer Support) - Pune, JSR, LKO

    CVBU-EL-11-05 Implementation of Design Modifications Head (TS/STDs I) - Pune, JSR, LKO

    CVBU-EL-11-06 MaintenanceHead (maintenance): Respective Maintenance Heads/ CX

    Heads in Factory/division, CX, Department

    Manufacturing

    MV Raja Rao, VP (Mfg)

    EL11-02 Produce Vehicles/ Aggregates/ Components

    Inputs

    B/O materials aggregates and OutputsKey Steps in - Produce

  • 8/8/2019 Tata Motors's Achivements

    72/105

    TBEM Group, Jamshedpur 72

    B/O materials, aggregates and

    components In-house materials, aggregates

    and components

    Production schedule

    Estimate sheets/routings

    Support from other functions

    Quality plan/work

    instructions/Control Plans Resources manpower, direct

    material, Indirect material/tools,

    machines, equipments and

    vehicles.

    Outputs

    Vehicle, aggregate,

    component as per quality

    norms and S&OP

    Key Steps in ProduceVehicles/Aggregates/Components

    1.Prepare production schedule

    2.Allocate manpower

    3.Ensure availability of material, tooling,

    equipment

    4.Production of parts, aggregates and

    vehicles

    5.Monitoring of quality, productivity, safety

    and cost

    CLIP Score

    Index

    %

    Rs./ Unit

    %

    %

    %

    Index

    Effectiveness

    S&OP Schedule Adherence

    Quality Index

    First Shot OK (Aggregate/ Assy Line Level)

    COPQ

    Process Capability Improvement (Machining) Ppk > 1.67 for identifiedprocesses

    Process Capability Improvement (Non-measurable) % Conformance > 99.73

    Process Capability Improvement (Tightening) Ppk > 1.33

    Safety index (SR & FR)

    Ratio

    Rs./ Unit

    Efficiency

    Eq. Unit./ Man/ Year

    Variable Conversion Cost / Unit

    UnitPerformance Measure

    How, it operates (Methods/ Practices)

    1. Prepare production schedule Based on vehicle production/dispatch schedule and spare parts call up

    each factory/shop works out Production Schedule.

    2. Allocate manpower

    Each factory/shop works out its manpower requirement on the basis of

    production plan and productivity targets and redistribute manpower and

    communicate net shortage/excess to HR.

    3. Ensure availability of materials, tooling, equipment

    Respective factory/shop co-ordinates with concerned agencies to ensure

    on time availability of material, tools, machines etc.4. Production of parts and aggregates

    Production activities are carried out as per estimate sheets / routings.

    Operatives carry out in process inspections/checks as per quality plan/

    work instructions. Central QA performs audit checks to ensure that laid

    down system is being followed.

    5. Monitoring of quality, productivity, safety and cost

    Factory/Plant management reviews production, productivity, quality and

    cost on daily/monthly basis and takes corrective action as required.

    Sub process : Produce Vehicles/Aggregates/Components

    Sub Process Ref : CVBU-EL-11-02 (version 1.1)Process Owner : Pune -JSR -LKOEPM Linkage CVBU-EL-11 ( Manufacturing )

    Preparation Date : 31/03/04 (updated 05/02/05)

    Execution Excellence

  • 8/8/2019 Tata Motors's Achivements

    73/105

    TBEM Group, Jamshedpur 73

    Customer RelationsCustomer Relations

    HR FocusHR Focus

    Manage ProcessesManage Processes

    Operational ImprovementsOperational Improvements

    Assess and ImproveAssess and Improve

    Execution Excellence

  • 8/8/2019 Tata Motors's Achivements

    74/105

    TBEM Group, Jamshedpur 74

    Customer RelationsCustomer Relations

    HR FocusHR Focus

    Manage ProcessesManage Processes

    Operational ImprovementsOperational Improvements

    Assess and ImproveAssess and Improve

    Operational Improvements

  • 8/8/2019 Tata Motors's Achivements

    75/105

    TBEM Group, Jamshedpur 75

    Achieved through Achieved through

    55--SS TPMTPM

    PokaPoka YokeYoke

    KaizenKaizen

    Execution Excellence

  • 8/8/2019 Tata Motors's Achivements

    76/105

    TBEM Group, Jamshedpur 76

    Customer RelationsCustomer Relations

    HR FocusHR Focus

    Manage ProcessesManage Processes

    Operational ImprovementsOperational Improvements

    Assess and ImproveAssess and Improve

    Execution Excellence

  • 8/8/2019 Tata Motors's Achivements

    77/105

    TBEM Group, Jamshedpur 77

    Customer RelationsCustomer Relations

    HR FocusHR Focus

    Manage ProcessesManage Processes

    Operational ImprovementsOperational Improvements

    Assess and ImproveAssess and Improve

    Assess and Improve

    CVBU Internal Assessment Process

  • 8/8/2019 Tata Motors's Achivements

    78/105

    TBEM Group, Jamshedpur 78

    PurposePurpose Divisions/ Functions as Profit/ Cost Centres

    Align the function for breakthrough performances

    Improving systems and processes

    Sharing/ adapting best practices

    ProcessProcess

    Application Writing

    Evaluation by certified assessors

    Guided by senior executives as mentors

    Excellence Plan

    InputsInputs

  • 8/8/2019 Tata Motors's Achivements

    79/105

    TBEM Group, Jamshedpur 79

    TBEM Assessment Feedback ReportTBEM Assessment Feedback Report CIICII--EximExim Bank Award Assessment FeedbackBank Award Assessment Feedback

    ReportReport

    ProcessProcess

    Divisions allocated relevantDivisions allocated relevant OFIsOFIs for evolvingfor evolving

    the Excellence Plan as also the implementationthe Excellence Plan as also the implementation

    planplan

    OutputOutput

    TimeplanTimeplan against each Excellence Plan stepsagainst each Excellence Plan steps

    Implementation of Excellence plansImplementation of Excellence plans

    Quality Month

  • 8/8/2019 Tata Motors's Achivements

    80/105

    TBEM Group, Jamshedpur 80

    a Tool fora Tool forAssessmentAssessment

    andandImprovementImprovement

    Quality Month Objectives

  • 8/8/2019 Tata Motors's Achivements

    81/105

    TBEM Group, Jamshedpur 81

    To revisit our approaches and practicesTo revisit our approaches and practices

    To understand the level of theirTo understand the level of theirdeploymentdeployment

    To develop an Improvement Road MapTo develop an Improvement Road Map

    through

  • 8/8/2019 Tata Motors's Achivements

    82/105

    TBEM Group, Jamshedpur 82

    Interactive WorkshopsInteractive Workshops

    InterInter--divisional competition on overalldivisional competition on overall

    Performance Excellence, 5S, Kaizen, TPMPerformance Excellence, 5S, Kaizen, TPM

    Interact with various stakeholders toInteract with various stakeholders to

    seek their expectations afreshseek their expectations afresh

    Theme this year

    Robust DeploymentRobust Deploymentof Enterprise Processesof Enterprise Processes

  • 8/8/2019 Tata Motors's Achivements

    83/105

    TBEM Group, Jamshedpur 83

    RobustRobust

    Powerfully Built, Marked by Richness and Fullness

    DeploymentDeploymentApplication of an organisations approaches.

    Deployment is evaluated on the basis of the breadth and

    depth of application of the approach to relevantprocesses and work units throughout the organisation

    Theme

    Robust Deployment ofRobust Deployment ofEnterprise ProcessesEnterprise Processes

  • 8/8/2019 Tata Motors's Achivements

    84/105

    TBEM Group, Jamshedpur 84

    EnterpriseEnterpriseAn undertaking of some scope, complication, and risk;

    A purposeful or industrious undertaking - one that

    requires effort or boldness

    ProcessesProcessesLinked activities with the purpose of producing a product

    or service for a customer within or outside the

    organisation. It involves combinations of people,machines, tools, techniques, and materials in asystematic series of steps or actions

    Training Workshops and Seminars and Debates

    In areas of

  • 8/8/2019 Tata Motors's Achivements

    85/105

    TBEM Group, Jamshedpur 85

    Business Excellence

    TPM, Kaizen, 5S

    Safety & Health

    Human Values

    Quality in Education

    Operational Quality and the Customer

    Supplier Quality

    Ethics & Governance

    We work through

  • 8/8/2019 Tata Motors's Achivements

    86/105

    TBEM Group, Jamshedpur 86

    StrategicLeadership

    ExecutionExcellence

    OrganizationalLearning

    to to

    Lead theorganization

    Manage theorganization

    Improve theorganization

    We work through

  • 8/8/2019 Tata Motors's Achivements

    87/105

    TBEM Group, Jamshedpur 87

    OrganizationalLearning

    StrategicLeadership

    ExecutionExcellence

    to to

    Lead theorganization

    Manage theorganization

    Improve theorganization

    Organisational Learning

  • 8/8/2019 Tata Motors's Achivements

    88/105

    TBEM Group, Jamshedpur 88

    Training to excelTraining to excel

    Knowledge ManagementKnowledge Management and, Consequent Results and, Consequent Results

    Organisational Learning

  • 8/8/2019 Tata Motors's Achivements

    89/105

    TBEM Group, Jamshedpur 89

    Training to excelTraining to excel

    Knowledge ManagementKnowledge Management

    and, Consequent Results and, Consequent Results

    TBEM Champions

    TBEM Champions are CHANGE AGENTS

  • 8/8/2019 Tata Motors's Achivements

    90/105

    TBEM Group, Jamshedpur 90

    Three-tier Structure:

    Business Excellence Champions

    Business Excellence leaders

    Business Excellence Mentors

    Experts in Business Excellence Concepts

    Coordinate BE activities in their divisions/ work areas

    Leaders/ Members of External Assessment teams

    TBEM Champions

    TBEM coordinators

    in divisions

  • 8/8/2019 Tata Motors's Achivements

    91/105

    TBEM Group, Jamshedpur 91

    in divisions

    526

    7

    39

    19120

    20

    180

    26

    195

    32

    2000 2001 2002 2003 2004 2005

    External

    Internal

    Change Agents todrive BSC,Benchmarking, KM

    and other businessexcellenceinitiatives

    They are also theTBEM InternalAssessors

    Assessors Base 2nd

    only to Tata Steel

    a leading steelmanufacturer

    Organisational Learning

  • 8/8/2019 Tata Motors's Achivements

    92/105

    TBEM Group, Jamshedpur 92

    Training to excelTraining to excel

    Knowledge ManagementKnowledge Management and, Consequent Results and, Consequent Results

    Organisational Learning

  • 8/8/2019 Tata Motors's Achivements

    93/105

    TBEM Group, Jamshedpur 93

    Training to excelTraining to excel

    Knowledge ManagementKnowledge Management

    and, Consequent Results and, Consequent Results

    Knowledge Management as a process

  • 8/8/2019 Tata Motors's Achivements

    94/105

    TBEM Group, Jamshedpur 94

    UnderstandKnowledge

    Requirements

    1EncourageKnowledge

    Sharing

    2Exchange and

    Use

    Knowledge

    3

    Improve theProcess

    5Build

    KnowledgeRepositories

    4

    Knowledge Management Structure

    KM Focus StakeholdersTransfer Mechanisms

  • 8/8/2019 Tata Motors's Achivements

    95/105

    TBEM Group, Jamshedpur 95

    Strategic

    EPM

    Processes

    Sub

    Processes

    Customers

    Ch

    annelPartners

    Vendors

    Em

    ployees

    Measures:Efficie

    ncyandEffe

    ctiveness

    Role Model for KM Drive Best Practices Breakthroughs

    Use KMProvide KMIdentify process

    Best Practices

    Linkage to BSC

    Mentor KMEnable the use of

    Best PracticesImprove ProcessesMeasure Results

    Experts / CoPs Suggestion Schemes CX, SDT, Work Teams,

    Improvement groups Mentoring, Training

    Review meetings Experts CFT, CLT Knowledge

    Workbook

    (Knowledge given /gained, BP)

    Mentoring, Training

    OC, SC Meetings Review Forums Stakeholder Meets Consultants

    Supported by IT and non IT Knowledge Management tools

    KM for all - documentationKnowledge Workbook

    ProcessesSummary

  • 8/8/2019 Tata Motors's Achivements

    96/105

    TBEM Group, Jamshedpur 96

    Best Practices

    Benchmarks

    Knowledge Given and

    Knowledge GainedKM Workbook[ Best Practice Documentdescribing Benchmarks, BestPractices, Knowledge &information Resources,

    Knowledge Management,Knowledge Sharing for eachEPM Process]

    Performance againstBenchmarks

    Information & Knowledge

    Resources

    Organisational Learning

  • 8/8/2019 Tata Motors's Achivements

    97/105

    TBEM Group, Jamshedpur 97

    Training to excelTraining to excel

    Knowledge ManagementKnowledge Management and, Consequent Results and, Consequent Results

    Organisational Learning

  • 8/8/2019 Tata Motors's Achivements

    98/105

    TBEM Group, Jamshedpur 98

    Training to excelTraining to excel

    Knowledge ManagementKnowledge Management and, Consequent Results and, Consequent Results

  • 8/8/2019 Tata Motors's Achivements

    99/105

    TBEM Group, Jamshedpur 99

    ResultsResults

    Correlation of ResultsGOODBusiness Results 2000-01 2001-02 2002-03 2003-04 2004-05

    Trng Hrs/Empl

  • 8/8/2019 Tata Motors's Achivements

    100/105

    TBEM Group, Jamshedpur 100

    g / p

    ESI

    VA/ Employee

    COQ

    CSI-MHCV Trucks

    Revenue

    EBIDTA/ TO

    MS-MHCV

    TBEM

    Summarising

    Global Image

    Global Image

    Excellent

    751 875 B h k L d

    876 1000: World Class Leader

  • 8/8/2019 Tata Motors's Achivements

    101/105

    TBEM Group, Jamshedpur 101

    ExcellentExcellent

    AverageAverage

    BeginningBeginning

    351 450: Early Improvements

    451 550: Good Performance

    551 650: Emerging Industry Leader

    651 750: Industry Leader

    751 875: Benchmark Leader

    We are

    here

    0 250: Early Development

    251 350: Early Results

    Band Descriptors

    551-650

    Effective, systematic approaches to overall item

  • 8/8/2019 Tata Motors's Achivements

    102/105

    TBEM Group, Jamshedpur 102

    Effective, systematic approaches to overall itemrequirements and to key organisational needs

    Fact-based, systematic evaluation and improvement

    process resulting in overall organisational learning.

    No major gaps in deployment.

    Improvement trends and/ or good performance arereported for most areas of importance.

    Results address most key customer/ stakeholder,

    market and process requirements and demonstratearea of strength.

    Band Descriptors

    651-750

    Refined approaches, including key measures

  • 8/8/2019 Tata Motors's Achivements

    103/105

    TBEM Group, Jamshedpur 103

    pp , g yGood deployment in most Areas

    Very good results in most Areas

    Organisation alignment, learning, and sharing are keymanagement tools

    Some outstanding activities and results address mostkey customer/ stakeholder, market, process andaction plan requirements.

    Industry* leader in most areas

    Refers to other organisations performing substantially the same functions, thereby

    facilitating direct comparisons

    Way Forward

    Leadership System Deployment

    Alignment and Integration of BSCs

  • 8/8/2019 Tata Motors's Achivements

    104/105

    TBEM Group, Jamshedpur 104

    Alignment and Integration of BSCs

    Customer from SATISFACTION to DELIGHT

    Knowledge Management as a Strategic Tool

    Business HR alignment

    Institutionalised EPM

    Continuous Learning through Results

  • 8/8/2019 Tata Motors's Achivements

    105/105

    TBEM Group, Jamshedpur 105

    THANK YOUTHANK YOU


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