Bharat Forge - BFL Excellence System

BFL Excellence System is about developing and strengthening the
management systems and processes of the organization, to improve
performance and create value for stakeholders.

BFL Excellence is much more than having a quality system in place. BFL Excellence is about achieving excellence in everything we do (including leadership, strategy, customer focus, information management, people and processes) and most importantly achieving superior business results.

The important Tools and Techniques included in BFL Excellence System

DMAIC (Define, Measure, Analyse, Improve and Control) methodology in problem solving

Value Stream Mapping to identify & eliminate the wastage in the entire value chain
Design-Gate Review for achieving First-Time-Right in New Product Development

Standardized work to ensure smooth
work flow
Integrating Health, Safety, Environment and Sustainability (including Energy Management)

Display of gallery in each plant to improve internal communication, transparency, & employee motivation

BFL Excellence System Pillars

1 People Engagement

Problem Solving/ DMAIC/ Six Sigma
Lessons learnt
Kaizen & Continuous improvement
Skill up gradation / Multi skilling
Ideation Process

2 Performance Management System

Business Plan
Operations Plan & Monitoring
Management Review meetings
Communication meetings/ Accountability Meeting- shop floor
Layered Audits
Team centres – Communication boards/ PIC

3 Operating System

5S/ workplace organization – Swachhata Abhiyan
Value Stream Mapping/ Maki-Gami analysis – Industry 4.0
Standardized work
Fast response
TPM/ Office TPM
Mistake proofing
SMED
Visual Management
Lean Logistics/ Inventory Management
Health, Safety, Environment & Sustainability
-VeSM
-Green Initiative
Ergonomics
Quality System

4 Engineering System

Change Management – 4 M
Flawless NPD/ Gate Review System
Product Reliability
Bill of Processes
Technology development/ New facility development

5 Customer Satisfaction Management

Voice of the Customer (Q,C,L,D,M)