Business Analytics at TVS Motors
Agenda
• Group introduction
• Why BI
• BI journey at TVS Motors
Group profile
TVS Motor Company
• 3 manufacturing units
• One vehicle rolled-out every 10 seconds
PT TVS Motor Company - Indonesia
• 1.5 lakh vehicle capacity
• In-house designed
Sundaram -Clayton
• Three manufacturing Units
• 8 warehouses in USA and Europe
Wabco TVS
• Three manufacturing Units
Group profile
Harita Seating Systems
• Seats for Two-wheelers to Trains
• 4 manufacturing units
Sundaram Auto Components
• High precision Plastic and Rubber components
• 5 manufacturing units
Harita NTI
• Bio degradable plastics, Petroleum from plastic wastes
• Corrosive preventive applications
Products-Motorcycle
Sold 7 million till March 2010
TVS JIVE
TVS StaR Sport
TVS StaR City
TVS Flame
TVS Apache RTR
5
Products-Scooter
Sold 2.3 million till March 2010
TVS Wego
TVS Scooty Pep+
TVS Wego
TVS Scooty Streak
Products – Mopeds
Sold 6.2 million till March 2009
TVS XL SUPER
TVS XL SUPER HD
7
Evolution of IT in TVS Motor
• Upgrade to ECC 6.0
• Business benefit - 6 times of IT establishment cost
• Enterprise portal
• Web 2.0
PLM
SAP EP
XI, SOLMAN,
Sales on SMS
•SAP BW / HR PAYROLL
• SAP in group companies
DMS/CRM
Intranet
SAP R3
2001
2002
2003
2004
2006
2005
2007
Web 2.0
PMS
Digitized
dashboard
2008-10
TVS Motors BI Journey
ERP
• Year - 2001
• All modules
• Over 600 + users
CRM
• Year - 2004
• ERP for Dealers
• Over 700 +
implementations
BI
• Year-2004
• SAP
• MS
Top 3 Areas – BI Usage
Marketing
Sales
Manufacturing
• Customer buying behavior
• Profiling customer
• Planning
• Supply chain visibility
• Project Planning- New Products
• Operations Monitoring
Simplicity is height of Sophistication
• Browser
• Mobile
• Touch
No training required for ATM and e-mails
Success of BI deployment
Simple
Flexible
Access
anywhere/anytime
Critical Success Factors
Speed
Look and feel
Ease of Use
Insights
What is Business Intelligence ?
People - Passive information receiver to proactive
information seekers and
IT from “transaction automation tool” to “IT as a
Transformation Platform for Business Innovation and
Best in Class Operational Efficiency “
Business Intelligence is an
Analytical tool
Reporting tool
A Decision support tool
A common platform and not restricted to any
particular application
Example : Sales
NEED FOR BI
•
•
•
•
•
SAP data – Complex reporting req
Dealership Data from dealers
CRM info
Dashboards for each user.
Avoid person dependent Reporting
Functionalities reqd. in BI
•
•
•
•
•
Reporting
Broadcasting
Analytics
Alerts
Spend Analysis
BI Journey at TVSM
• Implemented BIW 3.0 in 2004
– Sales and Production modules implemented
– Solution not user friendly and not used widely
BI Journey at TVSM
• Upgrade to BI.7.0 in 2007
– SAP- Sales , Production
– Non SAP –DMS(Oracle) and MSSQL data
integration
– CRM Data
– BeX Reports developed
BI –Journey cont..
• Adoption of Web Application Designer to
make reports more user friendly
• BI analytics – Clustering of Customer data to
understanding the customer usage pattern.
BI –Journey Cont..
• Implementation of Enterprise Portal
• Personalized dashboard for All Employees
– Completed for sales staff
How BI works ??
Data captured, compiled and stored in all the above
mentioned various sources are
Integrated
Centrally stored
Analyzed
Provides output in the required format
For Whom BI will be useful ?
For Sr. Managers (Macro level reports)
For Business Managers and Decision makers
(Micro level and Ad-hoc reports)
When we need BI ?
“One can’t predict the need – any
time for any informed business
decision”
Where the BI can be accessed ?
It can be used thro Internet…..
At any time
At any where
At any place
Advantages of BI
Data access at any place
Updated and accurate data
Graphical view of information
Trend analysis with colour codification
Direct export to excel
Reduce dependency on paper reports
Easy for transmission thro mail
Centralized data storage
Understanding Customer
Customer
Type of
customer
Gender
Income
How he buys
Profession
Trade-in
Hypothecation
Exchange vehicle analysis – DMS Data
HP Company Analysis – DMS data
Clustering of Customer data
Clustering of Customer data
Sales Performance
Sales
Future
Planning
Past Trend
Achievement
Growth
SCM visibility
Quarterly
planning
Employee Personalized Portal
Vehicle Sales Dashboard
•Top 20 dealers
•Bottom 20 Dealers
•Model - wise sales
•Zero Billing dealers
Tracking stock at Dealerships
Opening Stock
Plan
Billing
Retails
Closing stock at dealer
YTD Billing/Retails
Performance and growth dashboard
Month on Month sales dashboards
Planning based on sales trend
Sales and growth indicators
BI in Manufacturing
Manufacturing
Inventory
Red,Grey,
Green
inventory
Vendor stock
visibility
Project
Planning
State of Build
WBS tracking
PRODUCTION BY MODEL REPORT
INVENTORY ANALYSIS REPORT - Month wise
Inventory Not in BOM and No plan
Excess to the maximum Norm
With in Maximum Norm
INVENTORY ANALYSIS REPORT – Week wise
Inventory Not in BOM and No plan
Excess to the maximum Norm
With in Maximum Norm
Inventory dashboard
Business Objectives: Solution
- To reduce inventory by Rs.100
crores in 4 months
- To improve free cash flow
Business Issues:
- Due to recession, conserving cash
very important
- Non availability of a dashboard to
identify to identify low hanging fruits
Key Benefits
- Classification of inventory as
follows
a. Qty & Value as per norms GREEN
b. Qty & value above norms
but usable for existing
products – GREY
c. Items not required for the
current production plan –
RED
- Dashboard developed in SAP BI
with facility to drill down
upto part / buyer
47
- Inventory reduced by Rs.100 crores
- Better inventory maintenance
LINE STOPPAGE REPORT
LINE STOPPAGE REPORT
LINE STOPPAGE REPORT
CUSTOMER COLLECTION REPORT
Customer Collection for the Month of April 2009 for Indonesian
Dealers – Hierarchy wise
Data acquisition system for Production monitoring
Background:
• Manual data recording of
Actions Implemented
• Digital data collected online
from bottleneck machine of the
cell and integrated with DAQ
software
Manufacturing cells’ output
• Delayed availability of production
output data for Managers
Benefits
•
Low cost in house developed
software used for data
capturing
• Accurate hour-wise data
available for analysis and
improvement
• Able to obtain information on
machine utilization
• Patent filed for DAQ
Business Objectives:
Further Improvement
• To leverage IT for live data capturing
directly from bottleneck equipment in
Manufacturing line
To provide dash board for Plant
managers for real time data
monitoring for decision making
Results Achieved
First hour output increased to 90%
100
UOM : %
• Capture cell utilization accurately for
capacity decisions
90
88
84
• To identify opportunity for output
improvement
90 90
Future Plans
84
To implement DAQ for Vehicle
assembly lines
80
70
'07- '08- Apr May Jun Jul Aug Sep Oct Nov Dec Jan Feb Mar
'08 '09
On time correction of customer complaints
complaints
Background:
Benefits
Actions Implemented
•
• Customer complaint capturing
• Implemented alert system thru’ statistical
process cycle 60 days
control limit (Monthly PDCA to Daily PDCA)
• Implemented real time control system to
check for effectiveness of corrective action
• Customer complaint resolution
process cycle 120 days
• Implemented electronic job card based
Model
From
To
% reduction
No. of part-complaints
identified and resolved
XL Super
17.5
4.1
76.6
12
XL Super HD
13.6
3.84
71.8
12
Sport
5.21
1.95
62.6
11
StaR City
8.15
3.41
58.2
13
PEP+
8.02
4
50.1
10
Streak
5.43
3.8
30.0
3
report to identify nagging complaints
Present – Reaction for
Customer complaint
Earlier – Reaction for
Customer complaint
3 months in age trend
0.40
• Daily PDCA to Hourly PDCA (Real
0.42
0.45
time basis) for customer complaints
0.4
Future Plans
0.3
0.2
0.16
Control limit
0.1
Production month
Aug-08
Jun-08
Apr-08
Feb-08
Dec-07
Oct-07
Aug-07
Jun-07
0.0
Apr-07
Business Objectives:
• Reduce customer complaint
resolution time from 120 days to
30 days
Def./100 Veh.
0.5
Further Improvement
• Implement horizontal deployment of
above system in shop floor for all
critical parameters
• Digitization of FTA for all solved
problems
• Reduce defect level by 70%
• Reduce warranty cost by 50%
Results Achieved
• Reliability prediction analysis by using
warranty data
• Establish MTTF / MTBF by using
electronic job card
• Establish transfer function for critical
performance parameters
TVS-M QAD
Jun-10
Warranty returns 3 months in age
Model : XLSuper Series
UOM : Def./100 Veh
20
3M
17.22
18
Implemented IT
support trigger
system
18.26
16.67
16
14
13.61
12.34
9.12
10
8
5.92
6
4.67
4.66
4
3.34
2
Production month
Jun-10
May-10
Apr-10
Mar-10
Feb-10
Jan-10
Dec-09
Nov-09
Oct-09
Sep-09
Aug-09
Jul-09
Jun-09
May-09
Apr-09
Mar-09
Feb-09
Jan-09
Dec-08
Nov-08
Oct-08
Sep-08
Aug-08
Jul-08
Jun-08
May-08
Apr-08
Mar-08
Feb-08
0
Jan-08
Def/100 Veh.
12
TVS-M QAD
Jun-10
Warranty returns 5000 Kilometers in age
Model : 3Wheeler - 2S
UOM : Def./100 Veh
150
125
Implemented IT
support trigger
system
119.15
5000 Kms
106.91
97.69
83.59
77.51
75
68.10
49.10
50
48.41 47.71
46.64
30.07
22.51
25
21.21
Production month
Jun-10
May-10
Apr-10
Mar-10
Feb-10
Jan-10
Dec-09
Nov-09
Oct-09
Sep-09
Aug-09
Jul-09
Jun-09
May-09
Apr-09
Mar-09
Feb-09
Jan-09
0
Dec-08
Def/100 Veh.
100
Project Management
Background:
• Every year,
• Around 25 major NPD projects
implemented.
• Approximately 700 engineering
change projects implemented
• Around 2000 improvement
projects carried out
• Around 500 members are involved in NPD
projects
• Most of the projects are delayed due to
improper planning
• Changes to the project plan is cumbersome
• Project progress tracking is paper based
Actions Implemented
• Implemented SAP project system
and cProjects
• Project templates provided
• Time logging functionality
integrated with project system
• Tracking Reports developed
• Alerts developed
• Training provided to all the
members of NPD functions
Benefits
• Dynamic project management
leading to better control over the
project.
Further Improvement
• Integration of supplier plans with the
NPD project plans
• Make the system user friendly
Future Plans
Business Objectives:
• Provide project management tool to
manage multiple projects & resources and
integrate functional & supplier plans
•
Provide project management dashboard
Results Achieved
•
• Paper based project management
• Innovation process management
eliminated
• Versions & change details available
for analysis
• Tracking of bottleneck activity
• Alerts to all project members for any
pending activity and activities due
for the next 6 weeks
Portfolio and resource management
State Of Build application
Background:
• The NPI process has Alpha, Beta &
QP stages.
• Prototype vehicles to be built as per
planned State Of Build.
• Record is useful in analyzing the
failure modes during Alpha, Beta and
QP.
• The State Of Build information is not
readily available
Actions Implemented
• Dashboard with drill down
provided by
• Collating information
from various
applications
Benefits
-Project team takes timely
decisions on building prototypes
and analysis of the failures.
- Provides visibility of progress
status
Further Improvement –
- Add Quality Status, Ordering
status, PPAP status etc.
- Have Versions State Of Builds at
various stages of NPD
Business Objectives:
• Provide part development dashboard
of status to all project members
• Capture versions of the State Of
Builds at various stages of
development
Results Achieved –
• The State Of Build report made
available to all the project
team members
• The drill down links provided to
know the details
• Improved productivity
Future Plans
Capture the snap shot version of
the State Of Build at various
points of time during the
prototype builds
DR workflow
Background:
• Each project starts with a Product
Development Initiation approval
• There are around 25 major NPDs being
initiated on an average.
• System for Initiating the product
development to cater to the above
• The product initiation process is paper
based
• The comments given in the form of
Post-it-stickers often get lost.
• Cumbersome process to obtain
approval
Actions Implemented –
• Workflow provided for DR0
approval in the intranet
• Flexibility built in to accommodate
2W, 3W and ASEAN approval
• Lead time report for all stages
and each product provided
• The report captures comments
from all the members
Benefits
• Facilitate review online / live
• Elimination of physical movement
of paper from desk to desk
• Transparency of comments &
feedback to all stakeholders
• Timely approval of DR0
Further Improvement –
• Extend DR0 Approval workflows
for exports and institutional sales
requirements
• Concept change approval
workflows
Business Objectives:
• Electronic Workflow to obtain comments
and approval
• Workflows for DR1, DR1A, DR2,
• Should be able to know the progress
Future Plans
status of the approval
DR3, DR4 and DR5 stage gates
Results Achieved –
-The lead time for product initiation
approval reduced
- Paper saving
• Development of workflows for
DR1 to DR5
Dashboard in Dealership Management
Exception Broadcasting
De-grown Customers
Top/Bottom
Customers
Zero
Inventory
Zero Sales
Poor Service
level
MAP Based Sales Info
All India Data
MAP driven Report
Dealer level sales figures
SALES INFORMATION ON MAP
Zone wise, state wise and dealer wise sales info on MAP
Billing Details output - Area Level / Segment wise Drill down
Billing Details output - Model wise Drill down
BI- PLATFORMS UNDER
EVALUATION
BO
COGNOS
MICROSTRATEGY
SAP ACE 2008
For Implementing SAP PLM Solutions
SAP ACE 2007
For innovative use of SAP Netweaver
Thank You