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SHRIRAM FOUNDRY LTD.MACHINE SHOP. July. 2011. TEAM MEMBER:-. Mr.P.S.ACHARI Mr.P.K.PATIL. Mr.R.R.NERLEKAR. Mr.G.M.SHAIKH Mr.S.B.PATIL. COMPARATIVE PRODUCTION STATUS. PART NAME & NUMBER:- CONMET FRONT HUB - 10001946. ( Rough to finish Component in production.

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SHRIRAM FOUNDRY LTD.MACHINE SHOP

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Shriram foundry ltd machine shop

SHRIRAM FOUNDRY LTD.MACHINE SHOP

July. 2011


Team member

TEAM MEMBER:-

  • Mr.P.S.ACHARI

  • Mr.P.K.PATIL.

  • Mr.R.R.NERLEKAR.

  • Mr.G.M.SHAIKH

  • Mr.S.B.PATIL


Comparative production status

COMPARATIVE PRODUCTION STATUS

PART NAME & NUMBER:- CONMET FRONT HUB - 10001946

( Rough to finish Component in production.

( Rough to finish 44 nos per shift – 1set up s/f & 2 set up finish)

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

Rough to finish trial success, Casting stock – 406,Ready for dispatch – 104)

2 set up rough & 1set up finish per shift 45 no's


Comparative production status2

COMPARATIVE PRODUCTION STATUS

PART NAME & NUMBER:- CONMET HUB 10019727 Spline

After removing the setting 50 nos casting received.

Casting stock – machined, Ready for dispatch – 27 nos.


Comparative production status3

COMPARATIVE PRODUCTION STATUS

PART NAME & NUMBER:- CONMET HUB – 10019716 Spline

Component in production


Comparative production status4

COMPARATIVE PRODUCTION STATUS

PART NAME & NUMBER:- CONMET HUB – 10019736


Comparative production status5

COMPARATIVE PRODUCTION STATUS

PART NAME & NUMBER:- CONMET HUB – 10019759

After removing the setting 74 nos casting received.


Comparative production status6

COMPARATIVE PRODUCTION STATUS

PART NAME & NUMBER:- CONMET HUB – 10019815

After removing the setting 170 nos casting received.


Comparative production status7

COMPARATIVE PRODUCTION STATUS

PART NAME & NUMBER:- CONMET FRONT HUB – 10020463 – High BHN

Productivity increased per shift 22 to 28 nos.


Comparative production status8

COMPARATIVE PRODUCTION STATUS

PART NAME & NUMBER:- Pulley 476.0

Casting late received.

Job in production


Comparative production status9

COMPARATIVE PRODUCTION STATUS

PART NAME & NUMBER:- CLASS PULLEY – 644 800.2

Casting to finish trial success – per shift 21 nos.


Comparative production status10

COMPARATIVE PRODUCTION STATUS

PART NAME & NUMBER:- Pulley 642.0


Comparative production status11

COMPARATIVE PRODUCTION STATUS

PART NAME & NUMBER:- Pulley 413.0

96 nos ready for dispatch


Comparative production status12

COMPARATIVE PRODUCTION STATUS

PART NAME & NUMBER:- Pulley 266.0


Comparative production status13

COMPARATIVE PRODUCTION STATUS

PART NAME & NUMBER:- Pulley 145.0


Comparative production status14

COMPARATIVE PRODUCTION STATUS

PART NAME & NUMBER:- Pulley 771.0

48 nos Ready for dispatch.

Casting to finish trial success – per shift 21 nos.


Comparative production status15

COMPARATIVE PRODUCTION STATUS

PART NAME & NUMBER:- Pulley 189.0


Comparative production status16

COMPARATIVE PRODUCTION STATUS

PART NAME & NUMBER:- Pulley 190.0


Comparative production status17

COMPARATIVE PRODUCTION STATUS

PART NAME & NUMBER:- Nabe 1975457

Component in production.


Cost details itemwise

COST DETAILS(ITEMWISE)

PART NAME & NUMBER:- CONMET HUB 1946

For mnt variable bearing cost is 36020 RS,deduct this amount then cost – 23.16 RS.

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


Cost details itemwise1

COST DETAILS(ITEMWISE)

PART NAME & NUMBER:- CONMET HUB 20463

SOMT 09T306 DT IC908 brokan Rs. 14954 Tool Cost RS. -68.39

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


Cost details itemwise2

COST DETAILS(ITEMWISE)

PART NAME & NUMBER:- CONMET HUB 9716 - Spline

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


Cost details itemwise3

COST DETAILS(ITEMWISE)

PART NAME & NUMBER:- CONMET HUB 9727 - Spline

Total Production 50 nos.

Ø 17 Carbide Drill Tool Cost Rs. 54.84

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


Cost details itemwise4

COST DETAILS(ITEMWISE)

PART NAME & NUMBER:-CONMET ROTTER 9996`

Casting to Finish

For mnt variable bearing cost is 36020 RS,deduct this amount then cost – 23.16 RS.

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


Cost details itemwise5

COST DETAILS(ITEMWISE)

PART NAME & NUMBER:- CONMET HUB – 9815

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


Cost details itemwise6

COST DETAILS(ITEMWISE)

PART NAME & NUMBER:- CONMET HUB – 9759

Ø24 U Drill 1 nos. & SHR/450 4 nos Total Rs. 24925 Tool Cost Rs.-58.90

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


Cost details itemwise7

COST DETAILS(ITEMWISE)

PART NAME & NUMBER:- CONMET HUB – 9736

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


Cost details itemwise8

COST DETAILS(ITEMWISE)

PART NAME & NUMBER:- CONMET HUB – NEB HUB 5457

TCLNR -2525 HOLDER RS-1500 TOOL COST RS.15.55

Only Truning

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


Cost details itemwise9

COST DETAILS(ITEMWISE)

PART NAME & NUMBER:- CONMET HUB – Housing 619

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


Cost details itemwise10

COST DETAILS(ITEMWISE)

PART NAME & NUMBER:- Pulley 771

TTER &A4 SMR Holder Rs. 11947 Tool Cost Rs. 144.74

Casting to Finish TTER -2525 A4SML 2525 HOLDERRs. 9000

Tool Cost Rs. 244.96

TTER &A4 SMR Holder Rs. 11947 Tool Cost Rs. 184.09

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


Cost details itemwise11

COST DETAILS(ITEMWISE)

PART NAME & NUMBER:- Pulley 642

For mnt variable bearing cost is 36020 RS,deduct this amount then cost – 23.16 RS.

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


Cost details itemwise12

COST DETAILS(ITEMWISE)

PART NAME & NUMBER:- Pulley 266

A 4 SMR Holder 3 Nos. Rs. 26945/- Tool Cost Rs. – 104.63

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


Cost details itemwise13

COST DETAILS(ITEMWISE)

PART NAME & NUMBER:- Pulley 145.0

Tool Cost Rs. 106.31

For mnt variable bearing cost is 36020 RS,deduct this amount then cost – 23.16 RS.

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


Cost details itemwise14

COST DETAILS(ITEMWISE)

PART NAME & NUMBER:- Pulley 413

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


Cost details itemwise15

COST DETAILS(ITEMWISE)

PART NAME & NUMBER:- Pulley 476

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


Cost details itemwise16

COST DETAILS(ITEMWISE)

PART NAME & NUMBER:- Pulley 189-190

4ASMR -2525 3 HOLDER & Ø11.1 CARBIDE DRILL RS. 17286 TOOL COST RS. 34.89

For mnt variable bearing cost is 36020 RS,deduct this amount then cost – 23.16 RS.

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


Cost details itemwise17

COST DETAILS(ITEMWISE)

PART NAME & NUMBER:- Pulley 800.2

WTJNL-2525, A4SMR 2525 HOLDER RS. 6200 TOOL COSTRS. 205.86

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


Machine utilisation in cnc

MACHINE UTILISATION IN % (CNC)


Machine utilisation in cnc1

MACHINE UTILISATION IN % (CNC)


Machine utilisation in cnc2

MACHINE UTILISATION IN % (CNC)


Machine utilisation in cnc3

MACHINE UTILISATION IN % (CNC)


Majour losess details whole shop

Majour Losess Details (Whole shop)


Rejection details itemwise in

REJECTION DETAILS(ITEMWISE IN %)

Part Name:- CONMET HUB 1946

PRD-838 NOS,

IN H MR 4.42%( 37)

PRD-427 NOS,

IN H MR-1.87%( 8)

PRD-461 NOS,

IN H MR-1.52%( 7)

SF MR- 0.22% (1)

***ACTION ON MAJOR REJECTION CAUSES


Rejection details itemwise in1

REJECTION DETAILS(ITEMWISE IN %)

Part Name:- CONMET ROTTER 9996

PRD- 700 NOS,

SF MR 3.57% (25 ),

IN H MR1.00% (7 )

PRD- 1285 NOS,

SF MR 1.25% (16 ),

IN H MR1.48% (19 )

PRD- 637 NOS,

SF MR 1.73% (11 ),

IN H MR 0.78% (5 )

***ACTION ON MAJOR REJECTION CAUSES


Shriram foundry ltd machine shop

REJECTION DETAILS(ITEMWISE IN %)

Part Name:- CONMET 10020463

PRD- 634 NOS,,

IN H MR 5.04%(32),

SF MR 1.57 % ( 10)

PRD-394 NOS,,

IN H MR 3.05%(12),

***ACTION ON MAJOR REJECTION CAUSES


Shriram foundry ltd machine shop

REJECTION DETAILS(ITEMWISE IN %)

Part Name:- CONMET 10009727

PRD- 214 NOS,,

IN H MR 7.47 %(16)

PRD- 347 NOS,,

IN H MR 1.15 %(4)

***ACTION ON MAJOR REJECTION CAUSES


Rejection details itemwise in2

REJECTION DETAILS(ITEMWISE IN %)

Part Name:- CONMET 10019716

PRD- 88NOS,,

IN H MR 1.14%(1),

***ACTION ON MAJOR REJECTION CAUSES


Rejection details itemwise in3

REJECTION DETAILS(ITEMWISE IN %)

Part Name:- CONMET 10019815

PRD- 237NOS,,

IN H MR 8.44%(20),

PRD- 367NOS,,

IN H MR 6.54%(24),

***ACTION ON MAJOR REJECTION CAUSES


Rejection details itemwise in4

REJECTION DETAILS(ITEMWISE IN %)

Part Name:- CONMET 10019736

PRD- 118NOS,,

IN H MR 5.08%(6),

PRD- 383NOS,,

IN H MR 1.57%(6),

***ACTION ON MAJOR REJECTION CAUSES


Rejection details itemwise in5

REJECTION DETAILS(ITEMWISE IN %)

Part Name:- CONMET 10009759

PRD-499NOS,,

IN H MR 9.02%(45),

PRD-350NOS,,

IN H MR 3.43%(12),

***ACTION ON MAJOR REJECTION CAUSES


Rejection details itemwise in6

REJECTION DETAILS(ITEMWISE IN %)

Part Name:- PULLEY 642.0

PRD- 321OS,,

IN H MR 031 %(1), SF MR 0.62%(2)

PRD- 219NOS,,

IN H MR 0.46 %(1), SF MR 0.46%(1)

PRD- 273NOS,,

IN H MR 1.47 %(4), SF MR 1.47%(4)

***ACTION ON MAJOR REJECTION CAUSES


Rejection details itemwise in7

REJECTION DETAILS(ITEMWISE IN %)

Part Name:- PULLEY 476.0

PRD- 480NOS,,

IN H MR 1.04 %(5),

SF MR 0.21% ( 1)

PRD- 131NOS,,

IN H MR 2.29 %(3),

***ACTION ON MAJOR REJECTION CAUSES


Rejection details itemwise in8

REJECTION DETAILS(ITEMWISE IN %)

Part Name:- Pulley 413

PRD- 121 NOS

IN H MR 1.65 %(2)

.

PRD- 118 NOS

IN H MR 0.85 %(1)

.

***ACTION ON MAJOR REJECTION CAUSES


Rejection details itemwise in9

REJECTION DETAILS(ITEMWISE IN %)

Part Name:- PULLEY 266.1

PRD- 88NOS,,

IN H MR 14.77 %(13), SF MR 1.14%(1)

PRD- 176NOS,,

IN H MR 7.39 %(13), SF MR 0.57%(1)

***ACTION ON MAJOR REJECTION CAUSES


Rejection details itemwise in10

REJECTION DETAILS(ITEMWISE IN %)

Part Name:- Pulley 145.0

PRD- 152 NOS,,

IN H MR 0.66 %(1)

PRD- 192 NOS,,

IN H MR 1.04 %(2)

PRD- 191 NOS,,

IN H MR 0 %(0)

***ACTION ON MAJOR REJECTION CAUSES


Rejection details itemwise in11

REJECTION DETAILS(ITEMWISE IN %)

Part Name:- PULLEY 800.2

PRD- 213NOS,,

IN H MR 8.92 %(19),

SF MR 0.47% ( 1)

PRD- 101NOS,,

IN H MR 1.98 %(2),

***ACTION ON MAJOR REJECTION CAUSES


Rejection details itemwise in12

REJECTION DETAILS(ITEMWISE IN %)

Part Name:- Pulley 771.0

PRD- 204NOS,

I H MR 4.41% (9)

PRD- 199 NOS,

I H MR 6.53% (13)

SF MR 0.50% (1)

PRD- 122NOS,

I H MR 5.74% (7)

SF MR 0.82% (1)

***ACTION ON MAJOR REJECTION CAUSES


Rejection details itemwise in13

REJECTION DETAILS(ITEMWISE IN %)

Part Name:- Pulley 189

PRD-91NOS,

IN H MR 2.20 (2),

SF MR 1.10 %(1)

PRD-234NOS,,

IN H MR 0 %(0)

PRD-270NOS,,

SF MR 074 %(2)

***ACTION ON MAJOR REJECTION CAUSES


Rejection details itemwise in14

REJECTION DETAILS(ITEMWISE IN %)

Part Name:- Pulley 190

PRD-204NOS,,

IN H MR 0 %(0)

PRD-287NOS,,

IN H MR 0.70 %(2)

SF MR 0.35%(1)

PRD-169NOS,

***ACTION ON MAJOR REJECTION CAUSES


Rejection details itemwise in15

REJECTION DETAILS(ITEMWISE IN %)

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

PRD-422NOS,,

IN H MR 0.71 %(3)

SF MR 2.60% (11)

PRD-1384NOS,,

IN H MR 0.79 %(11)

PRD-490NOS,,

IN H MR 0.4 %(2)

***ACTION ON MAJOR REJECTION CAUSES


Rejection details itemwise in16

REJECTION DETAILS(ITEMWISE IN %)

Part Name:- Nabe Hub 2222845 /Nabe hub 5457

PRD-266NOS,,

IN H MR 2.63 %(7)

PRD-163NOS,,

IN H MR 2.45 %(4)

SF MR 2.45 % (4)

PRD-278NOS,,

IN H MR 1.08 %(3)

***ACTION ON MAJOR REJECTION CAUSES


Rejection details itemwise in17

REJECTION DETAILS(ITEMWISE IN %)

Part Name:- HOUSING 6500619

PRD-155NOS,,

IN H MR 1.94 %(3)

***ACTION ON MAJOR REJECTION CAUSES


Overall rejection all parts

OVERALL REJECTION (All Parts)

PRD- 6198

IH MR- 3.22% SF MR 0.58%

Conmet – 1 nos Porosity at flange face,800.2 pulley circlief groove problem.

1 job found CR at cup width - conmet

PRD- 4871

IH MR- 3.10% SF MR 0.57%

2 JOBS FOUND OVERSIZED FOR PILOT DIA. 219.760


Cost of poor quality

COST OF POOR QUALITY

In-house RS.209102.00 S/F

RS. 5257.0

In-house RS174828.00 S/F

RS. 90520.0

In-house RS.318312.00

S/F

RS. 18577.0

In-house RS98050.00 S/F

RS. 92238.0


Labor efficiency

LABOR EFFICIENCY

LABOR EFFICIENCY=

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

LABOR EFFICIENCY= 932676 + 148997 / 1875323

LABOR EFFICIENCY= 0.58

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


Rough to finish project

Rough to finish project.

Claas Pulley :

1.Pulley 145 casting to finish.

2.Pulley 413 casting to finish.

3.Pulley 771 rough to finish trial & production per shift achieved norms 7 nos.

4.Pulley 266 casting to finish achived norms per shift 8 nos.

5).Pulley 800.2 casting to finish trial complited & production per shift achived norms 7 nos.

For pulley line rough to finish project is complited,next project is productivity improvement.

Conmet ;

Rotter 9996 rough to finish trial conducted in Classic machine productivity per shift is 40 nos both 1st & 2nd operation,200 nos machined.

Productivity improvement in hub 20463 high BHN per shift 22 nos to 28 nos.


T h a n k y o u

T H A N K Y O U


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