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SHRIRAM FOUNDRY LTD.MACHINE SHOP. MARCH. 2012. TEAM MEMBER:-. Mr. R.R.NERLEKAR.(I/C Pulley line) Mr.S.R.HIREMANI.(I/C Hub Line) Mr.S.M.Patil ( I/C F.A.Support line) Mr.G.M.SHAIKH (Tooling) Mr.Rafiq.Naikawadi ( Quality) Mr.P.P.Patil ( System). COMPARATIVE PRODUCTION STATUS.

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SHRIRAM FOUNDRY LTD.MACHINE SHOP

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Shriram foundry ltd machine shop

SHRIRAM FOUNDRY LTD.MACHINE SHOP

MARCH. 2012


Team member

TEAM MEMBER:-

  • Mr. R.R.NERLEKAR.(I/C Pulley line)

  • Mr.S.R.HIREMANI.(I/C Hub Line)

  • Mr.S.M.Patil ( I/C F.A.Support line)

  • Mr.G.M.SHAIKH (Tooling)

  • Mr.Rafiq.Naikawadi ( Quality)

  • Mr.P.P.Patil ( System)


Comparative production status

COMPARATIVE PRODUCTION STATUS

PART NAME & NUMBER:- Pulley 190.0


Comparative production status1

COMPARATIVE PRODUCTION STATUS

PART NAME & NUMBER:- Pulley 476.0

Component under production


Comparative production status2

COMPARATIVE PRODUCTION STATUS

PART NAME & NUMBER:- Pulley 145.0


Comparative production status3

COMPARATIVE PRODUCTION STATUS

PART NAME & NUMBER:- Pulley 642.0

Component under production.


Comparative production status4

COMPARATIVE PRODUCTION STATUS

PART NAME & NUMBER:- Pulley 266.0

Claas not need this component from next month because drawing has chenged.Whater stock will be dispatched.

Component under production


Comparative production status5

COMPARATIVE PRODUCTION STATUS

PART NAME & NUMBER:- FAIRFILD HOUSING - 619


Comparative production status6

COMPARATIVE PRODUCTION STATUS

PART NAME & NUMBER:- CONMET FRONT HUB - 10014340


Comparative production status7

COMPARATIVE PRODUCTION STATUS

PART NAME & NUMBER:- CONMET HUB - 10004446


Comparative production status8

COMPARATIVE PRODUCTION STATUS

PART NAME & NUMBER:- CONMET HUB – 10019727 (Spline Hub)

Component under production.


Comparative production status9

COMPARATIVE PRODUCTION STATUS

PART NAME & NUMBER:- CONMET ROTTER - 10009996


Comparative production status10

COMPARATIVE PRODUCTION STATUS

PART NAME & NUMBER:- CONMET HUB – 10019736 (335 SERIES)


Comparative production status11

COMPARATIVE PRODUCTION STATUS

PART NAME & NUMBER:- CONMET HUB – 10020463 (HIGH BHN)


Comparative production status12

COMPARATIVE PRODUCTION STATUS

PART NAME & NUMBER:- CUMMINS – Nut Plate(400/100)

No schedule


Comparative production status13

COMPARATIVE PRODUCTION STATUS

PART NAME & NUMBER:- Front Axle support

Prod – SRF – Reg 1332 nos,Mod – SRF – 434,Alka – 70 nos,Axcel – 513 nos.Total – 2453 nos.


Cost details itemwise

COST DETAILS(ITEMWISE)

PART NAME & NUMBER:- CONMET HUB 4446

Note:- To calculate labor cost take 35% overhead on Basic+DA


Cost details itemwise1

COST DETAILS(ITEMWISE)

PART NAME & NUMBER:- CONMET HUB 4340

Note:- To calculate labor cost take 35% overhead on Basic+DA


Cost details itemwise2

COST DETAILS(ITEMWISE)

PART NAME & NUMBER:- CONMET HUB 9736

Note:- To calculate labor cost take 35% overhead on Basic+DA


Cost details itemwise3

COST DETAILS(ITEMWISE)

PART NAME & NUMBER:- CONMET HUB 9717

WTJNL-2525 HOLDER RS. 1200/- Tool Cost Rs. 62.49

Note:- To calculate labor cost take 35% overhead on Basic+DA


Cost details itemwise4

COST DETAILS(ITEMWISE)

PART NAME & NUMBER:- CONMET HUB 9828

Note:- To calculate labor cost take 35% overhead on Basic+DA


Cost details itemwise5

COST DETAILS(ITEMWISE)

PART NAME & NUMBER:- CONMET HUB 9727

HFHL -2525 Holder 1qty. & HFPR 4020 INSERT RS-6161/ Tool Cost Rs.87.88

HFHL -2525 Holder 1qty. Rs. 4000/- Tool Cost Rs.60.08

Carbide Drill Ø 14 Rs. 6500/- Tool Cost Rs. 50.11

Note:- To calculate labor cost take 35% overhead on Basic+DA


Cost details itemwise6

COST DETAILS(ITEMWISE)

PART NAME & NUMBER:- CONMET HUB 20142

HFHL -2525 Holder 1qty. & Spot face cutter Rs. 8100/- Tool Cost Rs.80.11

Note:- To calculate labor cost take 35% overhead on Basic+DA


Cost details itemwise7

COST DETAILS(ITEMWISE)

PART NAME & NUMBER:- CONMET HUB 20463

BARNSHING TOOL Rs- 2950 /- Tool Cost Rs.87.02

Note:- To calculate labor cost take 35% overhead on Basic+DA


Cost details itemwise8

COST DETAILS(ITEMWISE)

PART NAME & NUMBER:- Housing 619

Note:- To calculate labor cost take 35% overhead on Basic+DA


Cost details itemwise9

COST DETAILS(ITEMWISE)

PART NAME & NUMBER:-CONMET ROTTER 9996`

Casting to Finish

CNMG INSERT PROBLEM

Casting to Finish

Note:- To calculate labor cost take 35% overhead on Basic+DA


Cost details itemwise10

COST DETAILS(ITEMWISE)

PART NAME & NUMBER:- CUMMINS – NUTPLATE (100/400)

No Sehedule

Note:- To calculate labor cost take 35% overhead on Basic+DA


Cost details itemwise11

COST DETAILS(ITEMWISE)

PART NAME & NUMBER:- CONMET HUB – NEB HUB 2222845

Note:- To calculate labor cost take 35% overhead on Basic+DA


Cost details itemwise12

COST DETAILS(ITEMWISE)

PART NAME & NUMBER:- Pulley 189 /190

Note:- To calculate labor cost take 35% overhead on Basic+DA


Cost details itemwise13

COST DETAILS(ITEMWISE)

PART NAME & NUMBER:- Pulley 800.2

Hard Casting -TTER -2525 Holder 2nos. A4 SMR Holder 1 nos Extra Ins. A4G3mm 10 nos. Total Rs.20947/- Tool Cost Rs. 311.62

Hard Casting -Extra Ins. A4G3mm 7qnt.& TDT 4E 13 qnt. TTER -2525 -1 HOLDER Total Rs. 15237 Tool Cost Rs. 342.75

Note:- To calculate labor cost take 35% overhead on Basic+DA


Cost details itemwise14

COST DETAILS(ITEMWISE)

PART NAME & NUMBER:- Pulley 771

Note:- To calculate labor cost take 35% overhead on Basic+DA


Cost details itemwise15

COST DETAILS(ITEMWISE)

PART NAME & NUMBER:- Pulley 413

A 4SMR-2525 HOLDER Rs. 7447 Tool Cost Rs. Cost 218.02

Note:- To calculate labor cost take 35% overhead on Basic+DA


Cost details itemwise16

COST DETAILS(ITEMWISE)

PART NAME & NUMBER:- Pulley 145

Note:- To calculate labor cost take 35% overhead on Basic+DA


Cost details itemwise17

COST DETAILS(ITEMWISE)

PART NAME & NUMBER:- Pulley 642

Note:- To calculate labor cost take 35% overhead on Basic+DA


Cost details itemwise18

COST DETAILS(ITEMWISE)

PART NAME & NUMBER:- Pulley 476

Note:- To calculate labor cost take 35% overhead on Basic+DA


Cost details itemwise19

COST DETAILS(ITEMWISE)

PART NAME & NUMBER:- Pulley 266

Hard Casting- A4G & TDT INS. Extra 14 nos. Total Rs. 11637 Tool Cost Rs. 135.71

Hard Casting- OD Extra Material CNMG INS. 12 qnt.Extra Use Total Rs. 9729 Tool Cost Rs. 167.00

Note:- To calculate labor cost take 35% overhead on Basic+DA


Cost details itemwise20

COST DETAILS(ITEMWISE)

PART NAME & NUMBER:- Front Axle Support ( JD FAS )

Ø 32 Burnishing Tool/ And Milling CutterT otal Rs. 22725 Tool

Cost Rs. -91.04

Ø 32 Burnishing Tool/QCDA4 Adapter/Milling Cutter/TDC 17.1 /Ø12.2 Carbide Drill Total Rs. 22725 Tool

Cost Rs. -85.61

Note:- To calculate labor cost take 35% overhead on Basic+DA


Machine utilisation in vtl jan 2012

MACHINE UTILISATION IN % (VTL – Jan 2012)

Pulley

Pulley


Machine utilisation in cnc jan 12

MACHINE UTILISATION IN % (CNC – Jan 12)

HUB

Pulley


Machine utilisation in cnc jan 121

MACHINE UTILISATION IN % (CNC – Jan 12)

ROTTER/NUTPLATE

Pulley


Machine utilisation in vtl vmc jan 12

MACHINE UTILISATION IN % (VTL – VMC – Jan 12)

HUB

HUB


Machine utilisation in vtl vmc dec 11

MACHINE UTILISATION IN % (VTL – VMC –DEC 11)

JD Line


Majour losess details whole shop

Majour Losess Details (Whole shop)


Shriram foundry ltd machine shop

REJECTION DETAILS(ITEMWISE IN %)

Part Name:- CONMET 10019828

PRD- 159 NOS,

IN H MR- 3.14% (5)

PRD- 219 NOS,,

IN H MR 1.37% (3)

***ACTION ON MAJOR REJECTION CAUSES


Rejection details itemwise in

REJECTION DETAILS(ITEMWISE IN %)

Part Name:- CONMET HUB 9727

PRD- 379 NOS,

IN H MR 5.28% (20), IN THIS REJECTION 6JOB REJECTED IN DIA 208.99 3MM UNDERSIZE, 2 JOB REJECTED FOR LENGTH 26.605 TOOL MARK , 2 JOBS REJECTED FOR DIA 149.1 SEMIFINISHF TOOL MARK & 2 JOBS FOR DIA. 149.1 OVERSIZE , 3JOBS REJECTED IN Ddia 123S/F TOOL MARK.

PRD- 763 NOS,

IN H MR 2.23% (17),

SF MR 0.52 % (4)

***ACTION ON MAJOR REJECTION CAUSES


Rejection details itemwise in1

REJECTION DETAILS(ITEMWISE IN %)

Part Name:- CONMET HUB 9717

PRD- 179 NOS,

IN H MR 2.23% (4), ) (IN THIS REJECTION 3 NOS EJECTED FOR HOLE 24.86 TOOL MARK)

SF MR 1.68 % (3)

PRD- 216 NOS,

IN H MR 4.17% (9), ) (IN THIS REJECTION 4 NOS EJECTED FOR DIA 139.988 OVERSIZE)

***ACTION ON MAJOR REJECTION CAUSES


Rejection details itemwise in2

REJECTION DETAILS(ITEMWISE IN %)

Part Name:- CONMET HUB 20142

PRD- 291 NOS,

IN H MR- 5.15% (15) –( IN THIS 4JOBS ARE REJECT IN DIA 123 SEMIFINISH TOO L MARK , 3 JOBS DAMAGE MR & 4 JOBS IN 24.86 TOOL MARK)

SF MR - 0.69 %(2)

***ACTION ON MAJOR REJECTION CAUSES


Rejection details itemwise in3

REJECTION DETAILS(ITEMWISE IN %)

Part Name:- CONMET HUB 4446

PRD- 225 NOS,

IN H MR- 2.22% (5)

***ACTION ON MAJOR REJECTION CAUSES


Rejection details itemwise in4

REJECTION DETAILS(ITEMWISE IN %)

Part Name:- CONMET ROTTER 9996

PRD- 432 NOS,

IN H MR 2.31% (10 ) ( IN THIS REJECTION 6JOB REJECTED IN HOLE 13.47 WALL SHIFT)

PRD- 955 NOS,

IN H MR 0.31% (3 )

SUB CONTRACTOR MR- 01.36% (13 )

( 12 JOBS REJECTED IN HOLE 13.47 WALLSHIFT)

PRD- 1267 NOS,

IN H MR 0.63% (8 )

SF MR 0.79% (10 )

( 8 JOBS REJECTED IN HOLE 13.47 WALLSHIFT)

***ACTION ON MAJOR REJECTION CAUSES


Rejection details itemwise in5

REJECTION DETAILS(ITEMWISE IN %)

Part Name:- PULLEY 800.2

PRD- 315NOS,,

PRD- 68NOS,,

PRD-290 NOS,,

IN H MR 1.03 % (3),

***ACTION ON MAJOR REJECTION CAUSES


Rejection details itemwise in6

REJECTION DETAILS(ITEMWISE IN %)

Part Name:- Pulley 266

PRD- 78 NOS,

IH MR – 1.28 %(1).

PRD- 138 NOS,

IH MR – 0 %(0).

***ACTION ON MAJOR REJECTION CAUSES


Rejection details itemwise in7

REJECTION DETAILS(ITEMWISE IN %)

Part Name:- PULLEY 266.1

PRD- 245NOS, IN H MR 0.41 % (1),

PRD-597 NOS,,

***ACTION ON MAJOR REJECTION CAUSES


Rejection details itemwise in8

REJECTION DETAILS(ITEMWISE IN %)

Part Name:- Pulley 189.0

PRD- 352NOS,

PRD- 366 NOS,

***ACTION ON MAJOR REJECTION CAUSES


Rejection details itemwise in9

REJECTION DETAILS(ITEMWISE IN %)

Part Name:- ECC HUB 790/791/858.1/859.1

PRD- 884 NOS,,

SF MR 3.73% ( 33) REJECTED BY Padmavati Engg.

PRD- 905 NOS,,

IN H MR 0.11 %(1)

SF MR 0.33 % (3)

PRD- 972NOS,,

IN H MR 0.20 %(2)

SF MR 0.10 % (1)

***ACTION ON MAJOR REJECTION CAUSES


Rejection details itemwise in10

REJECTION DETAILS(ITEMWISE IN %)

Part Name:- Pulley 413

PRD- 317 NOS,

IH MR – 0.95 %(3).

PRD- 307 NOS,

IH MR – 0.98 %(3).

***ACTION ON MAJOR REJECTION CAUSES


Rejection details itemwise in11

REJECTION DETAILS(ITEMWISE IN %)

Part Name:- Nabe Hub 2222845 /Nabe hub 5457

PRD-493NOS,

IN H MR 2.64 %(13) ( IN THIS REJECTION 7JOBS OF PART NO 2222845 REJECTED IN DIA. 205 +0.040 OVERSIZE.)

SF MR 2.43%(12) – ( IN SEMIFINISH REJECTION 10 JOBS OF 5457 HAVE RJECTED BY SEMIFINISH PARTY ETEK IN LEGTH 41.9 SEMIFINISH TOOL MARK MR)

PRD- 145 NOS,

SF MR – 1.38 % (2)

PRD- 506NOS,,

IN H MR 0.20 %(1)

SF MR 0.59 (2)

***ACTION ON MAJOR REJECTION CAUSES


Rejection details itemwise in12

REJECTION DETAILS(ITEMWISE IN %)

Part Name:-HOUSING 619

PRD- 280 NOS,

***ACTION ON MAJOR REJECTION CAUSES


Rejection details itemwise in13

REJECTION DETAILS(ITEMWISE IN %)

Part Name:- FRONT AXEL SUPPORT

PRD- SRFM =2453 NOS,

IH MR- 1.42 % (35)

19JOBS ARE REJECTED IN BORE DIA. 32.02 OVERSIZE MR & 3JOB REJECTED IN BORE 32.02 TOOL MARK

PRD- 3080NOS,

IH MR- 2.56 % (79)

( IN THIS REJECTION 18 JOBS REJCTED IN BORE 32.02 O/S & 4 JOBS IN 5.8 HOLE WALL SHIFT & 21 JOBS IN 8.5 HOLE POSITION OEE MR)

PRD- 2004NOS,

IH MR- 1.75 % (35)

( IN THIS REJECTION 7 JOBS REJCTED IN BORE 32.02 STEP DUE TO TOOLING & 5 JOBS IN MILLING STEP MR DUE TO TOOLING )

***ACTION ON MAJOR REJECTION CAUSES


Overall rejection all parts

OVERALL REJECTION (All Parts)

PRD- 7161

IH MR- 2.40% SF MR 0.46%

PRD- 9771

IH MR- 1.80%

SF MR- 0.19%

PRD- 6733

IH MR – 2.82 %

SF MR – 1.23%

PRD- 7773

IH MR- 1.25% SF MR 0.27%


Cost of poor quality

COST OF POOR QUALITY

In-house RS.286199.00

S/F

RS. 21533.0

In-house

RS 369367.00

S/F

RS. 44415.00

In-house RS.221207.00

S/F RS. 29813.0

In-house

RS .128243.00 S/F

RS. 12756.00


Labor efficiency

LABOR EFFICIENCY

LABOR EFFICIENCY=

TOTAL SALRIES + 35% O.H ON (B+DA )+ OUTSIDE SUB.CONTRACTOR BILL TOTAL TURN OVER

LABOR EFFICIENCY= 1151981 +244794 / 3219747

LABOR EFFICIENCY= 0.43

FA support line labour efficiency =336461/1710160

LABOR EFFICIENCY= 0.19

REMARK:-EFFICIENCY :- 0.3 – OK MORE THAN 0.3 - IMPROVEMENT IS REQUIRED LESS THAN 0.3 - GOOD


T h a n k y o u

T H A N K Y O U


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