Tata Cummins Ltd.

Jamshedpur
 Tata Cummins Limited
They had a vision…

First to market

Customer Led

World class processes

Progressive work culture

Lowest cost producer

50:50 JV

Inauguration: 4th July 1995

2010

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

Ready2with Engine with BS V norms

 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

• Demanding that everything we do leads to a Cleaner,

Skills/Knowledge/Abilities
Healthier and Safer environment
• Creating wealth for all stakeholders

Personality: Values:
• Decisive • Integrity
• Driven To Win • Innovation
• Agile • Delivering Superior Results
• Passionate • Corporate Responsibility
• Caring • Diversity
Cummins Confidential
• Global Involvement
 Awards & Achievements
BS OHSAS 18001: 2007 ISO 14001: 2004
Health Safety &
Environment
 2013 Highlights….

Safety Rolling
Trophy

Electrical
Safety
Celebration :
Visibility &
Awareness

Health

FIFI :
Web Base Zero Leakage
Drive

Waste
Reduction
Health & Wellness

Health and Wellness beyond Illness

 Great Place to Work – Frame Work.

Leadership
Excellence

Cummins Performance
Operating Ethics –
System CPMS/IDP/ODR

Corporate Great Diversity and

Responsibility Inclusion
Place to
Work
Employee
Recruitment Engagement
and Survey and
Onboarding Actions

Compensation
Employee
, Benefits &
Communication
Recognition

ETHICS COMMON PROCESSES

8
 Global Wellness Strategic Foundational
Components

Productivity
Healthy Employees

Emotional Health

Workplace Health
Financial Health
Physical Health

Education
Self Awareness
Self Improvement and Maintenance

Each initiative will touch at least one pillar of the framework and
support the business goals of building healthy and productive
workforce.
9 Cummins Confidential Source – CMI white paper on Global H&W
 Productivity
Healthy Employees

Pre- Join HC,

Workplace Health
Emotional Health

Financial Health
Physical Health

HRA Biometrics, Identification

Employee
Onsiite Clinics, Financial of workplace
Assistance
Statutory HC, Education, Hazards, Roll
Programs,
Health Fairs, Awareness, Out of initiatives,
Support,
Family & Counseling Review and
Counseling
Nutritional , Tie Improvements
Ups

Education Generic Awareness,

Improvement &
Self Awareness Expert Talks,
Maintenance,
Seminars, Fairs etc
Self Improvement and Maintenance

Phase wise approach for Effective Implementation

10 Cummins Confidential
 India Health and Wellness Roadmap

• Year 2013 • Year 2014

• Physical Health • Nutritional Health – cont..
• Nutritional Health • Emotional Health – cont..
• Emotional Health • Family Health
• Workplace Health • Workplace Health – cont..
• Health Education & Self • Health Education and Self
Awareness Awareness - cont.
Phase Phase
1 2

Phase Phase
4 3 Year 2015
Year 2016 • Improvement & Maintenance
• Improvement & Maintenance • Family Health
– cont.. • Financial Health
• Financial Health – cont.. • Workplace Health
• Sustenance & Control • Sustenance & Control
Process – cont.. Process

Phase wise approach would help in consolidation, sustenance and

focus on administrative processes.
11 Cummins Confidential
SAFETY
 Safety Statistics – Lagging Indicator
20 Recordable Accident Trend Incident Rate Trend
17 1.96
2
15 13 1.38
1.5
0.92
8 1 0.65 0.65 0.65 0.65
10 0.65 0.65 0.6 0.5
6 0.5 0.45 0.22 0.12 0.10 0.4 0.35
0.00 0.07 .01 0.01
5
3 2 0
2 1
0 0 0
0

**
Actual Actual Target

Severity Day Rate First Aid Cases

16.000 13.760 140
115
14.000 120
12.000 100 89
10.000 8.590 8.170
7.090 7.630 80
8.000 56
6.000 6 6 60
4.910 4
4.000 2.970 3.2 3.2 40
2.000 1.310 20 9
0.606 0.05
0.000 0

$$
$$
Severity Day Rate –
((number of lost working days for last 12 months) x 200,000)
** Incidence Rate –
((number of recordable incidents for last 12 months) x200,000)

The total number of hours worked during the year The total number of hours worked during the year
 Safety Statistics – Leading Indicator
Find it Fix it
16000 13766
14000
12000
10000
8000
6000
4000
3080
2000 112 776
0

70
BSO Actual BSO Planned
60
Behavior Safety Observations
BSO 61
54
50 2013 Target : 25 , 50
39 41
2014 Target : 50
40 33
32
26 28
30
20
10
0
Jun-13 Jul-13 Aug-13 Sep-13 Oct-13 Nov-13 Dec-13 Jan-14
 Key Safety Initiatives

Contractor
LOTO 1 5 Safety

Lifting Tools
Forklift 2 6 & Tackles

Behavioral
Driver Safety 3 7 Safety

Machine
Guarding 4 8 PPE Compliance

Cummins Confidential
 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
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
 Contractor Safety

Modified I-Card
Bio Metric System
Bio Metric System Record

Induction Food hygiene Hoist and Cranes First Aid

HSE induction & Training

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

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

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 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.
 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”

21 11/03/2014 Cummins Confidential

Dashboard view: Type your WWID
in here to enter Type your WWID
your Find and Fix. in here to search
Click “Go” fixes.

Last 10 fixes for

employee’s captured
here.
Click on “Details” to
see full description
of find and fix.

April / June event http://fifi.cummins.com/

messages or alerts!
22 11/03/2014 Cummins Confidential
FIFI Statistics – Jan’14

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ENVIRONMENT
Key Environmental Initiatives
• Six Sigma for • Six Sigma Projects
reduction in water on reduction of
consumption GHG Emission

• Water consumption • Main Contribution

reduced by > 24% in for GHG emission
2013 is electricity
• Electricity conup.
reduced by 22%
Water GHG
Conservation Emission

Recycle
Waste
Packaging
Reduction
Project

• Wooden Engine •Focus on reduction

Skid, Head and Pallet through reuse of
converted to Metallic material
•6 Sigma project
completed on Grinding
• Wooden Block Pallet Sludge and Oily cotton
converted to Plastic waste

25 11/03/2014 Cummins Confidential

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

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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

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 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

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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

Collection of Used
Gloves Washing

Plant Process
Used Hand
Gloves

Recycle Hand Gloves Shredding of Hand

as Jute in Line for Gloves into Jute
Machine Cleaning
to replace Fresh
Jute
Use of Grinding Sludge for bricks and Concreting slab
Existing Process:
Grinding Sludge for Co –
Grinding Process Grinding Sludge Storage Processing
( 147 Ton in 2012)
Proposed Process:
Brick / Slab with
Grinding Process Grinding Sludge Storage
GRINDING Sludge

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.
d. Floor Concreting carried out using grinding sludge

Organic Waste Convertor Installation

Food Waste Compost

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Organic Waste Converter
Waste

• 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
33
Green Supply Chain
Designing strategy for returnable packaging implementation
Project Background Selection methodology

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

59% Materials being

Returnable packaging received in recyclable

initiatives packaging.

The waste hierarchy

Cummins Confidential
Green Supply Chain: Wood Reduction Engine Skid
Before:-
FIP Packaging Wooden

Before-
After-Plastic After:-
Cardboard
Metallic

Block Pallet Head Pallet

Before:- After:- Before:- After:-

Wooden Plastic Wooden Metallic
People Involvement
 Zero Leak Drive
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 Day Leak Identification Action Plan of Leak

Kick of by Plant Head
Commitment Fugai Tag identified

Recognize &
Leak Control Audit on Zero Leak Day
Sustenance Plan

• Quarter wise Best BU/FU

• Audit done by Plant
Award
Manager and team
• Zero Leakage on shop floor
• Independent Audit in all
three shift • Action plan for identified points

• All Manufacturing • Monitoring and closure of leak

points in Tracker
department cover
• Reviewing the consumption of
• Points shared with auditee
Oil.

Benefits Results
853 Leak Points Identified and 735 of them are Leakage Identification & Closed Consumption/Engine (In Litre)
closed.

Reduction in Coolant, Oil and Process Water

Consumption

High Level of housekeeping

Reduction in Slip trip fall hazard

 National Safety Week Celebration 2013
Flag Hoisting and Pledge Team Commitment

Safety Anamneses Test

PPE , Fire Extinguisher and PPE maintenance Camp

Safety Quiz
 April Safety Awareness Challenge
Kick Off by Plant Head Team Commitment

Training on Fire-Fighting
Tool Box Talk Update Find it ‘n’ Fix It Drive

Poster Competition
 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
 June Environment Awareness Month
Kick Off by Plant Head Tree Plantation

CR :Paper Bags Making

Poster Competition Zero Leak Drive

Low Vehicle Day

 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
 The Result…

Gold Level in 2012 &

2013
( For 2,000,000 Hrs
CII best practices award 2010-11 CII best practices award 2012-13
without recordable)
For Safety, Health and Environment For Safety, Health and Environment

CII 2nd Award in

20111 -12 for SHE
GREENTECH Award GREENTECH Award 2012
SAFETY Environment
2012 -13 & 2013 -14 2012 -13 & 2013 -14
 HSE Budgeting (Mn USD)….

1.00 800
0.90 0.92
658 668 700
0.80
0.80 600
0.70
0.66
0.60 0.54 458 500

0.50 361 400

0.40 300
0.30
200
0.20
0.10 100

0.00 0
2011 2012 2013 2014
Turnover / Plan Safety Budget / Expense
44