tata cummins ltd - cii-safetyciiersafety.com/presentations/2014/tata cummins ltd.pdf · tata...

Tata Cummins Ltd. Jamshedpur

They had a vision…

Tata Cummins Limited

�First to market

� Customer Led

� World class processes

� Progressive work culture

� Lowest cost producer

2

� 50:50 JV

� Inauguration: 4th July 1995

� Power range: 80 hp to 235hp.

� Capacity: 1.20,000 engines per year.

� Application : Automotive, Industrial

& Power Generation

� Customers : Tata Motors & Cummins

� First BHARAT IV Engine in India for M & HCV

� Ready with Engine with BS V norms

2010

Vision:“Making people’s lives better by

unleashing the power of

Cummins” Mission• Motivating people to act like owners working together

• Exceeding customer expectations by always being first to market with

the best products

• Partnering with our customers to make sure they succeed

Cummins Confidential

Personality:• Decisive

• Driven To Win

•Agile

• Passionate

• Caring

Values:• Integrity

• Innovation

• Delivering Superior Results

• Corporate Responsibility

• Diversity

• Global Involvement

Skills/Knowledge/Abilities

•Demanding that everything we do leads to a Cleaner,

Healthier and Safer environment

• Creating wealth for all stakeholders

Awards & Achievements

BS OHSAS 18001: 2007 ISO 14001: 2004

Health Safety & Environment

2013 Highlights….2013 Highlights….

Celebration : Visibility & Awareness

Electrical Safety

Safety Rolling Trophy

Waste Reduction

FIFI :

Web Base Zero Leakage Drive

Health

Health & Wellness

Health and Wellness beyond Illness

Great Place to Work – Frame Work.

Great

Place to

Leadership Excellence

Performance Ethics –

CPMS/IDP/ODR

Diversity and Inclusion

Corporate Responsibility

Cummins Operating System

8

Place to

WorkEmployee Engagement Survey and Actions

Employee Communication

Compensation, Benefits & Recognition

Recruitment and

Onboarding

COMMON PROCESSESETHICS

Global Wellness Strategic Foundational Components

Financial Health

Productivity

Healthy Employees

Physical Health

Workplace Health

Emotional Health

Education

Self Awareness

Self Improvement and Maintenance

Financial Health

Physical Health

Workplace Health

Emotional Health

9 Cummins Confidential

Each initiative will touch at least one pillar of the framework and support the business goals of building healthy and productive

workforce.

Source – CMI white paper on Global H&W

Workplace Health

Productivity

Healthy Employees

Physical Health

Emotional Health

Financial Health

Pre- Join HC,

HRA Biometrics,

Onsiite Clinics,

Statutory HC,

Health Fairs,

Employee

Assistance

Programs,

Financial

Education,

Awareness,

Identification

of workplace

Hazards, Roll

Out of initiatives,

Cummins Confidential10

Education

Self Awareness

Self Improvement and Maintenance

Workplace Health

Physical Health

Emotional Health

Financial

Phase wise approach for Effective Implementation

Health Fairs,

Family &

Nutritional , Tie

Ups

Programs,

Support,

Counseling

Awareness,

Counseling

Out of initiatives,

Review and

Improvements

Generic Awareness,

Expert Talks,

Seminars, Fairs etc

Improvement &

Maintenance,

India Health and Wellness Roadmap

• Year 2014• Nutritional Health – cont..• Emotional Health – cont..• Family Health• Workplace Health – cont..• Health Education and Self Awareness - cont.

• Year 2013• Physical Health• Nutritional Health • Emotional Health• Workplace Health• Health Education & Self Awareness

Phase 1

Phase 2

Cummins Confidential11

Phase 3

Phase 4

Year 2016• Improvement & Maintenance – cont..• Financial Health – cont..• Sustenance & Control Process – cont..

Year 2015• Improvement & Maintenance • Family Health• Financial Health• Workplace Health• Sustenance & Control Process

Phase wise approach would help in consolidation, sustenance and focus on administrative processes.

SAFETY

Safety Statistics – Lagging Indicator

13

17

86

3 22

0 1 0 0

0

5

10

15

20Recordable Accident Trend

1.38

1.96

0.92

0.45 0.22 0.12 0.10 0.00 0.07 .01 0.01

0.65 0.650.65 0.650.65 0.65 0.6

0.5 0.4 0.35

0

0.5

1

1.5

2

Incident Rate Trend

Actual Actual Target

First Aid CasesSeverity Day Rate

**115

89

56

9

0

20

40

60

80

100

120

140

First Aid Cases

7.090

13.760

7.6308.590 8.170

4.910

1.310

2.970

0.606 0.05

6 64 3.2 3.2

0.000

2.000

4.000

6.000

8.000

10.000

12.000

14.000

16.000

Incidence Rate –((number of recordable incidents for last 12 months) x200,000)

The total number of hours worked during the year

Severity Day Rate –((number of lost working days for last 12 months) x 200,000)

The total number of hours worked during the year

**$$

$$

Safety Statistics – Leading Indicator

112

3080

13766

7760

2000

4000

6000

8000

10000

12000

14000

16000

Find it Fix it

BSO

26 2832 33

39 41

54

61

50

0

10

20

30

40

50

60

70

Jun-13 Jul-13 Aug-13 Sep-13 Oct-13 Nov-13 Dec-13 Jan-14

BSO Actual BSO Planned

2013 Target : 25 ,

2014 Target : 50

Behavior Safety Observations

Key Safety Initiatives

1

2

LOTO

Forklift

5

6

Contractor

Safety

Lifting Tools

& Tackles


3Driver Safety

4

7

8Machine

Guarding

Behavioral

Safety

PPE Compliance

Contractor Safety

Model for ensuring contractor/supplier safety was developed to ensure all the aspects

are covered for their safety.

� Biometric Attendance monitoring system:

provides a fix head count of number of people in the plant.

� HSE Induction: Right on the day of appointment. After the induction “Safety training provided” seal is marked on the I-card

� HSE Training: Carried out on a daily basis for 60 � HSE Training: Carried out on a daily basis for 60 min on a specific topic. Contractor employees segregated based on their trade.

� Work Permits & Prevention Plan : Work permit system implemented for Hot work, work

at height, confined space etc. Prevention plan mandated for all the work permits. Daily audit

and inspection of all the work permits.

� Equipment's & Tools : All the equipments used by the contractors are inspected for its

integrity & capability

� Contractor Training: Specific training on fire fighting and action they need to take in

case of first aid

Bio Metric SystemBio Metric System Record

Modified I-Card

Contractor Safety

HSE induction & Training

Food hygiene Hoist and CranesInduction First Aid

� BBS Level 1 launched in Nov’2012, 95% non-exempt employees were trained for

BBS Level -1 training.

� After successful completion of BBS Level 1 , BBS Level -2 launched by Mr C K

Kulkarni on 19.02.2013.

� Technique for Behaviour based Observation explained to Managers in this

Programme.

� 90& Managers participated in BBS Level – 2 training which include PLT , Safety

Behavior Based Safety

18

� 90& Managers participated in BBS Level – 2 training which include PLT , Safety

Forum members and line managers ( Period March – May’13)

� More than 200 BSO received and action taken on BSO, during Jun –Dec’13 period


� Electrical Initial survey completed in Sep 2013.

� Data submitted to ETON for Arc Flash Survey, Survey results in 2014 Q1

� Train the Trainer program organized in TCL – J through ETON.

� Authorized level training completed in Oct’13 by ETON for 25 employees.

� Authorized level training planned for all related person in 2014 Q1.

� Awareness level program in progress , Target of 100% awareness by 2014 Q1

� Electrical tool kit will be launch in 2014 Q1

� Permit system for electrical works plan in 2014 Q1

Scope: What is Find It Fix It (FIFI)?

� A behavioral based web tool developed to promote employee ownership to find, fix, and track potential Health, Safety, or Environmental (HSE) issues.

Find It Fix It- Example: (at-risk behavior)

� FIND example: An employee exits the cafeteria into the manufacturing environment with no safety glasses on.

11/03/2014 Cummins Confidential21

manufacturing environment with no safety glasses on.

� FIND category: Safety / Health / environment

� FIND type category: (from drop down) “Lack of personal protective equipment”

� FIX category: Behavior

� Location category: Work (from drop down) “Manufacturing/Production”

Dashboard view:

Last 10 fixes for

employee’s captured

Type your WWID

in here to enter

your Find and Fix.

Click “Go”

Type your WWID

in here to search

fixes.


employee’s captured

here.

April / June event

messages or alerts!

Click on “Details” to

see full description

of find and fix.

http://fifi.cummins.com/

FIFI Statistics FIFI Statistics –– Jan’14 Jan’14


ENVIRONMENT

Key Environmental Initiatives

• Six Sigma Projects on reduction of GHG Emission

• Main Contribution for GHG emission is electricity

• Electricity conup. reduced by 22%

• Six Sigma for reduction in water consumption

• Water consumption reduced by > 24% in 2013

Water Conservation

GHG Emission

•Focus on reduction through reuse of material

•6 Sigma project completed on Grinding Sludge and Oily cotton waste

• Wooden Engine Skid, Head and Pallet converted to Metallic

• Wooden Block Pallet converted to Plastic

Waste Reduction

Recycle Packaging Project


Water Consumption

�STP water used for Cooling tower makeup� ETP / STP output water used for horticulture� Identification of Ghost line & closure of same�Process Wise Water monitoring

Target for 2014

• 2013 : 24% reduction in water consumption in absolute term ( Average per month

consumption reduce from 11004 to 8366 KL )

•2014 Target : Absolute Water Consumption reduce from Average 8366 KL to 7953 KL

per month ( By 5 % of 2013 )

•Sustain Water Balance within 5 %

Reduction in GHG Emission ( TCo2 / Lac ManHrs)

� GHG Emissions at TCL-J is contributed by the following

� Eletricity, Diesel Fuel, refrigeration, fugitive emission etc

� Electricity contributes to 93% of the total GHG emissions

27Cummins Confidential

GHG Status

� Electricity consumption comprises of Fixed and variable

components.

� Fixed Load contributes to approx 63% to the total power

consumption. This varies from 55% - 70% on a monthly basis

depending upon the environmental conditions.

� HV AC contributes to approx 63% to the fixed load


Electricity Consumption

�6 Sigma for Reduction in GHG Emission � 22% Reduction in Absolute Electricity

Consumption

� Unplugged Challenge : Zero Electricity consumption on holiday / closure


Target for 2014

• Target to achieve 5 % reduction in GHG Emission in 2014 wrt 2013 level

• ISO 50001 Implementation

Waste Reduction

Recycle of Hand gloves as Jute:

Use of Recycled Hand gloves as Jute, leads to :Reduction in fresh jute consumption by 50%One Kg of Recycled jute saves a cost of Rs 34 per Kg.

Recycle

WashingCollection of Used

Gloves

Recycle Hand Gloves

as Jute in Line for

Machine Cleaning

to replace Fresh

Jute

Used Hand

Gloves

Washing

Plant Process

Shredding of Hand

Gloves into Jute

Gloves

Grinding Process Grinding Sludge Storage

Grinding Sludge for Co –Processing

( 147 Ton in 2012)

Grinding Process Grinding Sludge StorageBrick / Slab with GRINDING Sludge

Proposed Process:

Existing Process:

Activity Details :a. Sample Bricks made with different formulation (Grinding

Sludge, Lime, Gypsum & Cement)b. Sample Floor Concreting carried out c. Testing and brick and slab for abrasive and compressive

strength completed.

Use of Grinding Sludge for bricks and Concreting slab


strength completed.d. Floor Concreting carried out using grinding sludge

Organic Waste Convertor Installation

Food Waste

Organic Waste Converter

Compost

Waste Waste

33

• Hazardous waste include: Oil soaked cotton waste, Grinding sludge, Paint Sludge and ETP Sludge

• 6 Sigma completed on Oily cotton Hazardous waste & Grinding Waste

• Overall 53% reduction in hazardous waste disposal quantity in 2013 wrt 2012

Green Supply Chain

Cummins’ commitment towards building a

Sustainable or Green supply chain.

Figuring out ways to reduce the amount of

packaging on products so there isn’t as much waste

Project Background

Designing strategy for returnable packaging implementation

Selection methodology

The waste hierarchy


Returnable packaging initiatives

59% Materials being

received in recyclable

packaging.

Engine Skid

Before:-

Wooden

After:-

Metallic

Green Supply Chain: Wood Reduction

FIP Packaging

Before-

Cardboard After-Plastic

Block Pallet Head Pallet

Before:-

Wooden

Before:-

Wooden

After:-

Plastic

After:-

Metallic

People Involvement

Zero Leak Drive

Kick of by Plant Head

Leak Control

Action Plan of Leak identified

Recognize &

Sustenance Plan

Leak Identification

Fugai Tag

Objective: To involve every one at TCL Jamshedpur for maintaining cleaner environment.

To draw every body’s attention towards environment abuse created by us , awareness about

monetary losses by these leakages and develop system for zero leak culture in our plant.

Zero Leak DayCommitment

Audit on Zero Leak DaySustenance Plan

�853 Leak Points Identified and 735 of them are

closed.

�Reduction in Coolant, Oil and Process Water

Consumption

�High Level of housekeeping

�Reduction in Slip trip fall hazard

Benefits

• Audit done by Plant Manager and team

• Independent Audit in all three shift

• All Manufacturing department cover

• Points shared with auditee

Results

• Quarter wise Best BU/FU Award

• Zero Leakage on shop floor

• Action plan for identified points

• Monitoring and closure of leak points in Tracker

• Reviewing the consumption of Oil.

Leakage Identification & Closed Consumption/Engine (In Litre)

National Safety Week Celebration 2013

Team Commitment

Safety Anamneses Test

Flag Hoisting and Pledge

PPE , Fire Extinguisher and PPE maintenance Camp

Safety Quiz

April Safety Awareness Challenge

Team Commitment

Training on Fire-Fighting

Kick Off by Plant Head

Tool Box Talk Update Find it ‘n’ Fix It Drive

� Event led by Plant head – TCL, Jamshedpur

� 2333 Find It ‘n’ Fix It recorded in Apr-13

� All departments and all levels participation

� Tool Box talk carried out for 20 Topics

� Carried out in all Business Unit and Fictional Units

� Total 395 session covered across plant

� Total 765 attended the sessions

Poster Competition

June Environment Awareness Month

Tree Plantation

CR :Paper Bags Making

Kick Off by Plant Head

Poster Competition Zero Leak Drive

� 5333 Find It ‘n’ Fix It recorded in June’13

� Highest nos. of FIFI in EBU

� 40% FIFI related to environment

� Environment Awareness training carried out for five

environment topic total 465 attended the session.

� Daily Food wastage monitored and displayed in canteen for

THINK. EAT. SAVE

Low Vehicle Day

CII best practices award 2010-11

For Safety, Health and Environment

CII best practices award 2012-13

For Safety, Health and Environment

Gold Level in 2012 &

2013

( For 2,000,000 Hrs

without recordable)

The Result…

GREENTECH Award

SAFETY

2012 -13 & 2013 -14

GREENTECH Award 2012

Environment

2012 -13 & 2013 -14

CII 2nd Award in

20111 -12 for SHE

HSE Budgeting (Mn USD)….

658 668

361

4580.66

0.80

0.54

0.92

400

500

600

700

800

0.50

0.60

0.70

0.80

0.90

1.00

361

0

100

200

300

400

0.00

0.10

0.20

0.30

0.40

0.50

2011 2012 2013 2014

Turnover / Plan Safety Budget / Expense

tata cummins ltd - cii-safetyciiersafety.com/presentations/2014/tata cummins ltd.pdf · tata...

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