Shriram foundry ltd machine shop
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SHRIRAM FOUNDRY LTD.MACHINE SHOP. Oct. 2011. TEAM MEMBER:-. Mr. R.R.NERLEKAR.(I/C Pulley line) Mr.S.R.HIREMANI.(I/C Hub Line) Mr.G.M.SHAIKH (Tooling) Mr.S.B.PATIL ( Quality) Mr.P.P.Patil ( System). COMPARATIVE PRODUCTION STATUS. PART NAME & NUMBER:- CONMET FRONT HUB - 10001946.

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SHRIRAM FOUNDRY LTD.MACHINE SHOP

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Shriram foundry ltd machine shop

SHRIRAM FOUNDRY LTD.MACHINE SHOP

Oct. 2011


Team member

TEAM MEMBER:-

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

  • Mr.S.R.HIREMANI.(I/C Hub Line)

  • Mr.G.M.SHAIKH (Tooling)

  • Mr.S.B.PATIL ( Quality)

  • Mr.P.P.Patil ( System)


Comparative production status

COMPARATIVE PRODUCTION STATUS

PART NAME & NUMBER:- CONMET FRONT HUB - 10001946

400 nos casting stock at our end & 144 ready for dispatch.Job in production.


Comparative production status1

COMPARATIVE PRODUCTION STATUS

PART NAME & NUMBER:- CONMET ROTTER - 10009996

Machine utilized for nut plate..


Comparative production status2

COMPARATIVE PRODUCTION STATUS

PART NAME & NUMBER:- CONMET HUB – 10019717 Spline

Total 62 nos CR rejected at 5/8 tapped hole.After remove the setting casting received.


Comparative production status3

COMPARATIVE PRODUCTION STATUS

PART NAME & NUMBER:- CONMET HUB – 100143439Rear Hub)

1st set up 256 jobs machined found 121 nos CR & 7 nos MR. To fulfill the customer schedule again production start.


Comparative production status4

COMPARATIVE PRODUCTION STATUS

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


Comparative production status5

COMPARATIVE PRODUCTION STATUS

PART NAME & NUMBER:- CONMET HUB – 10019759

96 nos ready for dispatch.


Comparative production status6

COMPARATIVE PRODUCTION STATUS

PART NAME & NUMBER:- CONMET FRONT HUB – 10020463(250 BHN)

108 no's CR & 11 no's CR.


Comparative production status7

COMPARATIVE PRODUCTION STATUS

PART NAME & NUMBER:- CONMET FRONT HUB – 10019817(ADB hub)

100 no's ready for dispatch & under production.


Comparative production status8

COMPARATIVE PRODUCTION STATUS

PART NAME & NUMBER:- Pulley 413.0(SG Iron)

32 no's CR.(one day production)


Comparative production status9

COMPARATIVE PRODUCTION STATUS

PART NAME & NUMBER:- Pulley 800.2(Double decker)

CR 57 nos, MR 05 nos.(3day production)

CR 43 nos, MR 05 nos.


Comparative production status10

COMPARATIVE PRODUCTION STATUS

PART NAME & NUMBER:- Pulley 642.0

59 no's CR.


Comparative production status11

COMPARATIVE PRODUCTION STATUS

PART NAME & NUMBER:- Pulley 189.0


Comparative production status12

COMPARATIVE PRODUCTION STATUS

PART NAME & NUMBER:- Nabe 2222845


Cost details itemwise

COST DETAILS(ITEMWISE)

PART NAME & NUMBER:- CONMET HUB 1946

6.5x200 TS DRILL 04 NOS. RS 2600/- TOOL COST RS. 41.24

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


Cost details itemwise1

COST DETAILS(ITEMWISE)

PART NAME & NUMBER:-CONMET ROTTER 9996`

Casting to Finish

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


Cost details itemwise2

COST DETAILS(ITEMWISE)

PART NAME & NUMBER:- CONMET HUB – 9717

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


Cost details itemwise3

COST DETAILS(ITEMWISE)

PART NAME & NUMBER:- CONMET HUB – 9759

Ø16.570 carbide drill Rs. 6500 /- 01 nos Tool Cost Rs. 45.20

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


Cost details itemwise4

COST DETAILS(ITEMWISE)

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

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


Cost details itemwise5

COST DETAILS(ITEMWISE)

PART NAME & NUMBER:- CONMET HUB – 4343

Ø12.57x215 shr/57 01 nos rs. 1271 & SHR/450 01 NOS Rs. 1875 Tool Cost Rs. -50.86

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


Cost details itemwise6

COST DETAILS(ITEMWISE)

PART NAME & NUMBER:- CONMET HUB – Hub 9817

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


Cost details itemwise7

COST DETAILS(ITEMWISE)

PART NAME & NUMBER:- CONMET HUB – 20463

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


Cost details itemwise8

COST DETAILS(ITEMWISE)

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

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


Cost details itemwise9

COST DETAILS(ITEMWISE)

PART NAME & NUMBER:- Pulley 642

Ø13 carbide Drill Rs. 5240 Tool Cost Rs. 40.61

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


Cost details itemwise10

COST DETAILS(ITEMWISE)

PART NAME & NUMBER:- Pulley476

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


Cost details itemwise11

COST DETAILS(ITEMWISE)

PART NAME & NUMBER:- Pulley 413

Rough grooving resharp insert stock complited,new insert under trial cost planned 175 RS per job.

A4 SMR Holder Rs. 4500/ Casting Problem CNMA 120412 Insert Breakage Tool Cost Rs. 208.00

A4 SMR Holder Rs. 4500/ Casting Problem CNMA 120412 Insert Breakage Tool Cost Rs. 219.20

Casting Problem CNMA 120412 TT 7310 Insert Breakage Tool Cost Rs. – 150.35

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


Cost details itemwise12

COST DETAILS(ITEMWISE)

PART NAME & NUMBER:- Pulley 145

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


Cost details itemwise13

COST DETAILS(ITEMWISE)

PART NAME & NUMBER:- Pulley 189

4ASMR -2525, 1 HOLDER & Ø11.1 CARBIDE DRILL RS. 8000 TOOL COST RS. 34.89

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


Cost details itemwise14

COST DETAILS(ITEMWISE)

PART NAME & NUMBER:- Pulley 800.2

Rough grooving resharp insert stock complited,new insert under trial cost planned 230 RS per job.

TDT 4 E .04 K-10 Insert New Insert & TTER Holder 1 nos Tool Cost Rs. 328.05

TDT 4 E .04 K-10 Insert New Insert & TTER Holder 3 nos / A4SMR Holder 1 nos Tool Cost Rs. 422.88

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


Machine utilisation in vtl oct 11

MACHINE UTILISATION IN % (VTL – Oct 11)

Pulley

Pulley


Machine utilisation in cnc oct 11

MACHINE UTILISATION IN % (CNC – Oct 11)

HUB

Pulley


Machine utilisation in cnc oct 111

MACHINE UTILISATION IN % (CNC - Oct 11)

ROTTER/NUTPLATE

Pulley


Machine utilisation in vtl vmc oct 11

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

HUB

HUB


Majour losess details whole shop

Majour Losess Details (Whole shop)


Rejection details itemwise in

REJECTION DETAILS(ITEMWISE IN %)

Part Name:- CONMET HUB 4343

PRD- 323 NOS,

IN H MR 2.17% ( 7),

SF MR 0.93 % (3)

PRD- 191 NOS,

IN H MR 6.81% (13),

SF MR 3.14 % (6)

***ACTION ON MAJOR REJECTION CAUSES


Rejection details itemwise in1

REJECTION DETAILS(ITEMWISE IN %)

Part Name:- CONMET HUB 9716

PRD- 131 NOS,

IN H MR-7.63% (10) –( IN THIS 5JOBS ARE REJECT IN HOLE 24.86 WALLSHIFT)

***ACTION ON MAJOR REJECTION CAUSES


Rejection details itemwise in2

REJECTION DETAILS(ITEMWISE IN %)

Part Name:- CONMET HUB 9736

PRD- 443 NOS,

IN H MR- 6.77% (30) ( IN THIS 8 JOBS REJECTED IN FACE OUT CUT & 12 JOBS REJECTED IN OD 159 OBLONG DUE TO TOOLING / HARDNESS PROBLEM

***ACTION ON MAJOR REJECTION CAUSES


Shriram foundry ltd machine shop

REJECTION DETAILS(ITEMWISE IN %)

Part Name:- CONMET 10019817

PRD- 327 NOS,,

IN H MR 4.89 % (16) ( IN THIS REJECTION 3 JOB REJECTED IN 6.52 DRILLING WALLSHIFT & 4JOBS IN HOLE 24.86 SHIFT & TOOL MARK MR)

SF MR 1.53 % (5)

PRD- 200 NOS,,

IN H MR 1.5 % (3)

SF MR 1.5 %( 3)

***ACTION ON MAJOR REJECTION CAUSES


Rejection details itemwise in3

REJECTION DETAILS(ITEMWISE IN %)

Part Name:- CONMET HUB 9815

PRD- 546 NOS,

IN H MR- 2.20% (12) ( IN THIS REJECTION 5JOBS REJECTED IN HOLE 24.86 TOOL MARK & OUT CUT MR)

SF MR - 0.73% (4)

***ACTION ON MAJOR REJECTION CAUSES


Rejection details itemwise in4

REJECTION DETAILS(ITEMWISE IN %)

Part Name:- CONMET ROTOR 9970

PRD- 136 NOS,

IN H MR- 4.41% (6)

***ACTION ON MAJOR REJECTION CAUSES


Rejection details itemwise in5

REJECTION DETAILS(ITEMWISE IN %)

Part Name:- CONMET ROTTER 9996

PRD- 538 NOS,

SF MR 3.53% (19 )

BORE OVERSIZE S.J IRON FOR IST OPERATION,

IN H MR 2.79% (15 )

PRD- 813 NOS,

IN H MR 5.29% (43 )

Due to improper fettling – 10 nos,Due opt neg at spot face,Wall shift 5 nos.

PRD- 610 NOS,

IN H MR 1.64% (10) (IN THIS REJECTION 5 JOBS REJECTED IN HOLE 13.47 WALLSHIFT)

SF MR 0.33% (2)

***ACTION ON MAJOR REJECTION CAUSES


Rejection details itemwise in6

REJECTION DETAILS(ITEMWISE IN %)

Part Name:- PULLEY 266.1

16.85 %(15),Due PRD- 89NOS,,

IN H MR to improper clamping 3 nos,size variation problem 6 nos.

PRD- 231 NOS,,

IN H MR 0.43 % (1),

***ACTION ON MAJOR REJECTION CAUSES


Rejection details itemwise in7

REJECTION DETAILS(ITEMWISE IN %)

Part Name:- Pulley 190.0

PRD- 421NOS,,

IN H MR 0.48 %(2)

SF MR 0.24% (1)

PRD- 371 NOS,

IH MR 0.27 % (1)

***ACTION ON MAJOR REJECTION CAUSES


Rejection details itemwise in8

REJECTION DETAILS(ITEMWISE IN %)

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

PRD- 684NOS,,

IN H MR 5.40 %(37)

SF MR 0.29 % (2) (36 NOS OF HUB 790.1 rejected in broaching angle fire.)

PRD- 963 NOS,,

IN H MR 0.42 %(4)

SF MR 3.95% ( 38) REJECTED BY Padmavati Engg.

PRD- 1129NOS,

IN H MR 0.62 %(7)

SF MR 1.06% (12)

***ACTION ON MAJOR REJECTION CAUSES


Rejection details itemwise in9

REJECTION DETAILS(ITEMWISE IN %)

Part Name:- Pulley 771.0

PRD- 340NOS,

***ACTION ON MAJOR REJECTION CAUSES


Rejection details itemwise in10

REJECTION DETAILS(ITEMWISE IN %)

Part Name:- Pulley 145.3

PRD- 436 NOS,,

IN H MR 1.61%(7)

PRD- 372 NOS,,

***ACTION ON MAJOR REJECTION CAUSES


Rejection details itemwise in11

REJECTION DETAILS(ITEMWISE IN %)

Part Name:- housing 650 0619

PRD- 135 NOS,,

IN H MR 1.48 % (2)

PRD- 115 NOS,,

IN H MR 1.74 % (2)

***ACTION ON MAJOR REJECTION CAUSES


Rejection details itemwise in12

REJECTION DETAILS(ITEMWISE IN %)

Part Name:- Nabe Hub 2222845 /Nabe hub 5457

PRD- 418NOS,

IN H MR 2.39 %(10)

SF MR 1.44 % (6)

PRD-208NOS,

IN H MR 1.44 %(3)

SF MR 0.96%(2)

PRD- 116NOS,,

IN H MR 1.72 %(2)

***ACTION ON MAJOR REJECTION CAUSES


Rejection details itemwise in13

REJECTION DETAILS(ITEMWISE IN %)

Part Name:- Nut plate 398187400/398187100

PRD- 979 NOS,,

IN H MR 6.24 % (66 in this 39 jobs of part no 398187400 & 27jobs of part no 398187100 rejected in development.)

PRD- 223 NOS,

PRD- 1310 NOS,

***ACTION ON MAJOR REJECTION CAUSES


Rejection details itemwise in14

REJECTION DETAILS(ITEMWISE IN %)

Part Name:- FRONT AXEL SUPPORT

PRD- 886NOS,

IH MR- 0.45 % (4)

THESE JOBS ARE REJECTED IN DEVLOPMENT

***ACTION ON MAJOR REJECTION CAUSES


Overall rejection all parts

OVERALL REJECTION (All Parts)

PRD- 6602

IH MR- 2.36%

SF MR- 0.44%

PRD- 6472

IH MR- 2.16% SF MR 0.22%

PRD- 6733

IH MR – 2.82 %

SF MR – 1.23%

PRD- 7161

IH MR- 2.22% SF MR 0.46%


Cost of poor quality

COST OF POOR QUALITY

In-house

RS .237987.00 S/F

RS. 57404.00

In-house RS 1,92,187.00 S/F

RS. 4,787.00

In-house RS.157652.00

S/F

RS. 18691.0

In-house RS.221207.00

S/F RS. 29813.0


Labor efficiency

LABOR EFFICIENCY

LABOR EFFICIENCY=

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

LABOR EFFICIENCY= 1033448 + 204752 / 1593263

LABOR EFFICIENCY= 0.77

LABOR EFFICIENCY= If casting rejection in control.

LABOR EFFICIENCY= 1033448 + 204752 / 1708713

LABOR EFFICIENCY= 0.72

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


Rough to finish project cummins filtration

Rough to finish project – Cummins Filtration.


T h a n k y o u

T H A N K Y O U


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