SCDL Project report.doc

STUDY

OF

PRODUCTION,

PLANNING

AND

CONTROL IN ASTRA META ME TAL L SYSTEMS SYSTEM S PVT LTD. LTD.

Name

: VASUDEV N BHANAJI

Regise! N".

: #$$%#&'(&

NAME OF THE INSTITUTE: LEARNING, BATCH : #$

%$SYMBIOSIS

CENTRE

FOR

DISTANCE

1

NO OBJECTION CERTIFICATE

This is to certify that Mr Vasudev N Bhanaji is an employee of M/s Astra Metal Systems Pvt. td.! for the past " years.

STUDY OF #e have ave no o$je o$ject ctio ion n for for him to carr carry y out out a proj projec ectt %or& %or& titl titled ed ' STUDY PRODUCTION, PLANNING AND CONTROL IN ASTRA METAL SYSTEMS PVT LTD( in our )r*ani+ation and for su$mittin* the same to the ,irector! S-, as a part of 

fulfilment of the P,BA )perations0 Pro*ram.

#e %ish him him all the success. succe ss.

Si*n Si*nat atur uree of the the comp compete etent nt authority of the of the nstitute / )r*ani+ation

P)a*e: Verna! oa! ndia

Dae: 223,ec32414

2

DECLARATION BY THE LEARNER 

This is to declare that  have carried out this project %or& myself in part fulfilment of the P,BA Pro*ram of S-,.

The %or& is ori*inal! has not $een copied from any%here else and has not $een su$mitted to any other 5niversity 5niversity / nstitute for an a%ard of any ,e*ree / ,iploma. ,iploma.

Dae: 223,ec32414

Sig+a!e:

P)a*e:  Verna! oa

Name: Mr Vasudev N Bhanaji

6

CERTIFICATE OF SUPERVISOR -GUIDE

-ertified that the %or& incorporated in this Project 7eport ' STUDY OF PRODUCTION, PLANNING AND CONTROL IN ASTRA METAL SYSTEMS PVT LTD/  su$mitted

 $y Mr Vasudev N Bhanaji is his ori*inal %or& and completed under my supervision.

Material o$tained from other sources has $een duly ac&no%led*ed in the Project 7eport.

Sig+a!e "0 Gi1e: Name: Mr Pradip A. P. da -osta. A11!ess: Astra Metal Systems Pvt. td.

389! Verna ndl. :state! Verna ; oa <46822 2a)i0i*ai"+: ,ip. Production :n**. Desig+ai"+: ,irector  S3e*ia) Fie)1 "0 4"!5: )perations E63e!ie+*e: Product ,evelopment < years0

Vendor ,evelopment < years0 )perations 1= years0

Dae: 22nd ,ecem$er 2414

P)a*e: Verna ; oa ; ndia <46822

<

1. ntroduction>>>>>>>>>>>>>>>>>>>

= 3 1<

2. )$jectives and Scope>>>>>>>>>>>>>>>

19

6. imitations >>>>>>>>>>>>>>>>>>>.

19

<. Theoretical Perspective>>>>>>>>>>>>>>

19 3 2"

9. Methodolo*y and Procedure of #or& >>>>>>>>

2" 384

=. Analysis of ,ata>>>>>>>>>>>>>>>>>.

81

8. ?indin*s! nferences and 7ecommendations>>>>>>>

82 3 8<

". -onclusion>>>>>>>>>>>>>>>>>>>>

89 38=

@. Summary of the Project 7eport >>>>>>>>>>>

88

ANN:57:S 0 Proposal 0 7eferences >>>>>>>>>>>>>>>>>>>>

88

0 ist of ?i*ures! -harts! ,ia*rams>>>>>>>>>>>

8"

V0 ist of Ta$les >>>>>>>>>>>>>>>>>>

8"

INTRODUCTION As!a Mea) S7sems P8. L1. -AMSPL ! are in field of Precision Sheet Metal

?a$rication ndustry! Manufacturin* and Supplyin* Sheet Metal ?a$ricated Products. AMSP started its operation in 1@@". t is an S) @4413244" -ertified -ompany. t initiated its epansion plan $y settin* up an unit in Sancoale ndustrial :state! %here it can use lar*er space for the purpose of production and also addin* stora*e space. t aims at caterin* to the Sheet ; Metal -omponent / Product needs of 5C! ermany and 5SA $ased 9

customers. t also plans to increase its capacity throu*h epansion. t has $een outsourcin* certain activities and for some activities also provides its o%n infrastructure. ts production is $ased on customer specification. t has no desi*nin* of its o%n. Astra follo%s Statistical Process -ontrol Systems for all $asic manufacturin* processes. The Principles of 9S for  house3&eepin* is an on3*oin* activity %hich Astra $elieve is of utmost importance to its vision to $e a '#orld -lass Manufacturin* -ompany(.

Astra Metal Systems Pvt. td. is strate*ically located at Verna ndustrial :state in oa ;  ndia %hich is in close proimity to the Airport! 7ail Terminus as %ell as the sea port all %ithin ran*e of 19&m $oundary. t has plant area of 1244 sD.mts.

Astra Metal Systems Pvt. td. %as promoted $y < technocrats Mr. Satish A. Shinde! Mr. -harlton -olaco! Mr Pravin . Pai and Mr Pradip A. P. da -osta.

-ompanyEs clientele %ith their product ran*e %hich includesF •

Siemens td. Medical :n*ineerin* ,iv! Verna! oa 3ray housin*s! machine parts and Machine enclosures.0

•

,ie$old ndia Pvt. td. ATM Sheet Metal -omponents0

•

Andre% Telecommunications ndia Pvt. td. Base Antenna Parts G Accessories0

•

,3in& ndia td! Verna! oa. :nclosures G parts for net%or&in* products0

•

Tata -onsultancy Services 3 Tivim oa. Mail / -heDue sortin* machine parts.0

•

il$arco Veeder 7oot ndia Pvt.td. ?uel ,ispensin* Cios&s0

•

Siemens A PT,3Berlin! ermany0 Sheet Metal -omponents for Po%er Sector0.

•

Mceoch Technolo*ies Marines 3 Birmin*ham! 5C Marine li*htin* ?ittin*s 0

•

Pentair #ater Pvt. td. Sheet Metal -omponents G :nclosures for #ater3Treatment0

•

V:S Andover ; Hampshire !5C

Sheet Metal -omponents G :nclosures for Air 

Handlin* systems G controls0 •

Miscellaneous customer

O!ga+i9ai"+a) S!*!e "0 As!a Mea) S7sems P8. L1.

=

Pa*e 1 of <

)r*ani+ational chart continued.... Pa*e 2 of <

8

)r*ani+ational chart continued.... Pa*e 6 of <

"

)r*ani+ational chart continued.... Pa*e < of < @

B!ie0 1eai)s "0 1e3a!me+s i+ As!a a+1 ei! !")es ;Res3"+si
14

I

Punchin*

I

Bendin*

I

nsertin*

# Fa
I

#eldin*

I

,rillin*

I

Sanderin*

( S!0a*e 0i+isi+g

I

Po%der -oatin*

I

Pre3treatment

Se!8i*e De3a!me+s: & Dis3a*

I

Prepares an nvoice -um -hallan

I

Sees to it that the pac&a*in* is done as per customer needs and specifications

I

Arran*es the material to $e dispatched.

# S"!es

I

-lassification of *oods

I

BN card system

I

Maintain N

I

)utsourcin* *oods

( 2a)i7

I

-ompany documentation

I

Monitor G measure productsF ncomin*! n3process G ?inal sta*e.

I

-ontrol of ,ra%in*s

I

-ontrol of non3conformin* products at all sta*es

I

-ali$ration )f :Duipments

I

Vendor authentication

I

Special process validation

' Mai+e+a+*e

I

7educe Machine ,o%ntime

I

Preventive Maintenance

I

Servicin* )f Machinery Accordin* To %ee&ly/monthly/Juarterly/Kearly Plan

I

ive ist )f Spares To Purchase 11

= HR  

I

7ecruitment F :mployee referrals and ne%spaper ads

I

Selection F ntervie% Method

I

)rientationF nformal intro.

I

Trainin* F)n3the3jo$

I

SafetyF Shoes! *loves! mas&s! *o**les! ear *ear 

I

nsuranceF :S! Mediclaim Policy

I

Health G Hy*ieneF ood li*htin* G ventilation! %ater purifier! Shift system

I

ncentives F Monetary form! $onus at festivals

I

:mployee #elfareF Travel G food allo%ance

I

eave of a$senceF -ard system! 14 days in advance! 62 days

% Fi+a+*e

I

Purchase payments

I

,is$ursement of salary

I

Annual financial statement

I

7eserves

I

?ollo% up for receiva$les

> Mae!ia)s

I

nterrelated to PP-

I

Schedulin*

I

7eorder level

I

?indin* out potential suppliers

I

AB- analysis

? Ma!5ei+g

I

Mana*ed $y the M,

I

Meets potential customers

I

Advertisin* throu*h the nternet

@ De8e)"3me+

I

Study the feasi$ility of ne% nDuiry

I

,evelopment of Blan&s for Production

I

,efine Process ?lo% for Production

&$ PPC

I

Transfers information of ra% material to the purchase mana*er.

I

-alculate the timin* for the jo$. 12

I

Ma&e monthly plan for the various departments.

I

Transfer of nformation relatin* to Production.

I

Production control.

I

7elease Production orders planned from sales orders as standard or project.

I

Production Bill of Materials

I

Versions of manufacturin* $ills of materials and routin*s created.

I

Multi3location plannin* throu*h efficient information and material flo%.

I

nteractive action messa*in*Lfor the immediate $alancin* of supply and demand

I

Multiple %or&sheets for revie%in* various production options

I

Su$contractin* $y %or& center or operation

SOT ANALYSIS -As!a Mea) S7sems P8. L1 



S!e+gs



O33"!+iies

I

:perienced staff

I

:pansion

I

#ell defined process

I

?orei*n mar&ets

I

Technolo*y / Sophisticated machinery

I

?or%ard nte*ration of product

I

Technical epertise

I

)%n Product

I

ar*e customer $ase

I

Serve additional customer *roups

ea5+ess



T!eas

I

Small scale operations

I

?luctuation of -ustomer )rders

I

ac& of Vision

I

Ne% :ntrants

I

5nplanned Approach

I

-ustomers *ro%in* $ar*ain po%er  

I

,ependency on &ey human resource

I

)perators/%or&ers non3involvement

Astra Metal Systems Pvt. td.! has identified the process needed and have determined the  process and its interactions as per $elo%F

16

O<e*i8es: Te 3!ima!7 "<e*i8e "0 3!"1*i"+ 3)a++i+g a+1 *"+!") i+ As!a Mea) S7sems P8. L1. is " e+s!e a e 1esi!e1 3!"1*s a!e ma+0a*!e1.

1<

I

At the ri*ht time!

I

n the ri*ht Duantities!

I

Meetin* Duality specifications! and

I

At minimum cost.

S*"3e: The Project study is limited to production and plannin* department. Limiai"+s: Some of the inter related processes are not analysed in depth in vie% of avoidin* any violation of company rules and re*ulations.

Te"!ei*a) Pe!s3e*i8e: Production Plannin* and -ontrol philosophy isF ' Fi!s 3)a+ 7"! 4"!5, a+1 e+ 4"!5  7"! 3)a+(. Before startin* any %or&! plannin* is necessary for the effective utili+ation of 

availa$le resources.

Production Plannin* is concerned %ith the determination! acDuisition and arran*ement of  all facilities necessary for the future operations! %hereas production control is concerned %ith the implementation of a predetermined Production plan or policy and the control of all aspects of Production accordin* to such a plan or policy.

PP- can $e defined as the process of plannin* the production in advance! settin* the eact route of each item! fiin* the startin* and finishin* date for each item! *ivin* production orders to shop and lastly follo%in* up the pro*ress of products accordin* to orders. t is also called the nerve centerE of the factory.

MAIN FUNCTIONS OF PPC

The follo%in* are the &ey functions of Production Plannin* and -ontrolF a0 7elease orders to the system in accordance %ith the priority plan. Priority means control over the status of jo$s and %or& activities $y specifyin* the order in %hich materials or jo$s are assi*ned to %or& centers.  $0 Assi*n jo$s to specific %or& centers. c0 Provide seDuencin* priorities to specify the order in %hich jo$s are to $e processed. d0 -ontrol the manufacturin* lead time $y trac&in* and epeditin* jo$s if reDuired. 19

e0 Monitor the priority status of jo$s via summary! scrap! re%or&! and other reports. f0 Monitor the capacity status of facilities via input/output reports of %or&load/capacity. *0 ,isplayin* and settin* plannin* file entries manually h0 Maintainin* master data i0 :ecutin* total plannin* run for master schedule items  j0 displayin* availa$ility overvie% for material &0 Processin* $ac&lo*s l0 -onvertin* planned orders into purchase reDuisitions! production orders or process orders m0 :ecutin* mass chan*es of planned orders n0 :ecutin* collective availa$ility chec& for components in the planned order to plan materials that almost plan themselves in the operative flo% o0 to *ain an overvie% of the future reDuirements and stoc& situation and to compare the ,emand plannin* %ith the availa$le capacities.

The production plannin* and control in a company is achieved $y inte*ratin* activities asF I

determinin* product demand!

I

translatin* product demand into feasi$le manufacturin* plans!

I

esta$lishin* detailed plannin* of material flo%s!

I

capacity to support the overall manufacturin* plans!

Te ma"! e)eme+s "0 a PPC a!e:

A. ,emand mana*ement B. A**re*ate production plannin* -. Master production schedulin* ,. 7ou*h3cut capacity plannin* :. Material reDuirement plannin* ?. -apacity plannin* . )rder release H. Shop floor schedulin* and control

1=

A. DEMAND MANAGEMENT:

Since Astra Metal Systems Pvt. td. is $asically o$ shopper! does not have its o%n  product and its production is $ased on customer specification hence plannin* %ith respect to demand mana*ement does not ta&e place instead at Astra Metal Systems Pvt. td. PPinteracts %ith customer for their tentative reDuirement for a Duarter or for su$seDuent 6 month %herein 1st month actual and net t%o months tentative demand. Based on %hich further plannin* processes are initiated. Dema+1 0"!e*asi+g:

I

,emand for products is the drivin* force for any production activity.

I

,emand forecastin* is an important input to production plannin*.

I

?orecastin* is concerned %ith estimatin* future demand or reDuirement0 for  products.

B. AGGREGATE PRODUCTION PLANNING:

Astra Metal Systems Pvt. td. are -ontract 3 Manufacturers and have %ide variety of  customers! produces hi*h3variety! distinct products! as such there is vide fluctuation in demand for product. )n the other end! the resources of the company num$er of machines! num$er of %or&ers! etc.0 remain constant. The $est approach to o$tain feasi$le solution is to a**re*ate the information $ein* processed.

18

?or a**re*ation purposes the product demand is epressed in a common measurement unit such as production hours. Production plannin* is concerned primarily %ith determinin* optimal production! inventory! and %or& force levels to meet demand fluctuation.

Basi* s!aegies 0"))"4e1 " a
I

-urrently Astra Metal Systems Pvt. td. maintain %or& force $ut chan*es the  production rate $y permittin* planned overtime! idle time and su$3contractin*.

I

f needed Astra Metal Systems Pvt. td. chan*es the production rate $y chan*in* the si+e of the %or& force throu*h planned hirin*.

I

:plore the possi$ility of planned $ac&lo*s if customers are %illin* to accept delays in delivery of products.

I

A suita$le com$ination of these strate*ies should $e eplored to develop an optimal a**re*ate production plan.

C. MASTER PRODUCTION SCHEDULE:

The primary use of an a**re*ate production plan is to level the production schedule so that the production costs are minimi+ed. Ho%ever! the output of an a**re*ate plan does not indicate individual product. This means that the a**re*ated plan must $e disa**re*ated into individual product. The result of such a disa**re*ation is %hat is &no%n as master   production schedule.

Master production schedule does not present an eecuta$le manufacturin* plan! $ecause the capacities and the inventories have not $een considered in this sta*e. Therefore! further  analysis for the material and capacity reDuirements are reDuired to develop an eecuta$le manufacturin* plan.

The MPS translates the Sales G )perations Plan S)P0 into a plan for producin* specific  products in the future. -urrently said activity is done usin* 'n( of ecel files of different customers. The MPS is the translation of the S)P into produci$le products that ma&e up the output of a production plan.

D. ROUGHCUT CAPACITY PLAN:

The o$jective of rou*h3cut capacity plannin* is to ensure that the master production schedule is feasi$le. ?or each product family the avera*e amount of %or& needed and &ey 1"

%or& centers unit can $e calculated from each temEs Bill of Materials and from production routin*s process plannin* sheets0.

The availa$le resources are compared %ith the resource reDuirements profile o$tained for  all the %or& centers considerin* all the product families. f the availa$le resources are less than reDuired! then decisions related to overtime! su$contractin*! hirin* %or&ers are ta&en.

-onsider t%o families of Sin*le Tan& Housin*s t%o of the items reDuired $y customer for  t%o different final products0 developed in standard hours of resources per 12 units as follo%sF #or& -enter

Sin*le Tan& MM2.9

Sin*le Tan&s MM14

Total resources

Standard time in Mins0

Standard time in Mins0

reDuired for all

 per 12 5nits0

 per 12 5nits0

families

Punchin*

1=

21

68

,e$urrin*

9<

==

124

Bendin*

<2

<2

"<

#eldin*

"4<

1424

1"2<

Sanderin*

1"=

644

<"=

,rillin*! tappin*

21=

21=

<62

Pre3treatment

8"

8"

19=

Mas&in*

124

124

2<4

Po%der -oatin*

11<

124

26<

,e3mas&in*/ead

6=4

6=4

824

Varnishin*

612

6=4

=82

T"a) Time -i+

#($#

#>$(

=$$=

Res"!*e 0"!

(?

'=

?(

Res"!*e 0"!

=

%

&&

E. MATERIAL RE2UIREMENTS PLANNING:

I

The material reDuirements plannin* system is essentially an information system consistin* of lo*ical procedure for mana*in* inventories of component assem$lies! su$assem$lies! parts! and ra% materials in a manufacturin* environment.

I

The primary o$jective of an M7P system is to determine ho% many of each item in the  $ill of materials must $e manufactured or purchased and %hen.

1@

The &ey concept used in determinin* material reDuirements areF a0 Product structure and $ill of materials  $0 ndependent versus dependent demand c0 Parts eplosion d0 ross reDuirement e0 -ommon3use items f0 Scheduled receipts/)n3hand inventories/Net reDuirements *0 Plant order releases h0 ead time

a0 Product structure and Bill of MaterialsF Product is the sin*le most important identity in an or*ani+ation. A product may $e made from one or more assem$lies! su$assem$lies and components. A
-ontrol of product li&eF ,ra%in* No! 7ev No! 7ev ,ate.

•

7outin* F ProcessOs and Process SeDuence

•

ocation of processOs out of 6 units %hich location %ill do %hich process0F i.e location of Punchin* / aser! Bendin*! ?a$! Surface ?inish Po%der coatin* / Platin*0

•

Time estimate of processOs li&eF No. of Setup for $endin*! No of Bends! No of ,rills / -.S.C! No of Taps! No )f Spots! Area for surface finish etc..

?or e.* Specimen of Bill of Material for one of the Cios& since data cannot fit its $ro&en in 6 part. S!. N". $ &

Re8 Le8e)s

N"

Dae

D!a4i+g N"

1

:

4<.4".14

B@1<<9

Pa! N". PB@$@@? B@1<<9

&

G :

&&.&#.$@ [email protected]"

GB@&''> B81<@@

GB@&''> B81<@@

BASE ASLYSLIM MONO BAS: 3 M:MB:7SM M)N)



64.11.4@

B81961

A

[email protected]"

B81966

B)4944@9 B81961 B)4944@9 B)4944@= B81966

#:, N5T M" BAS: K3M:MB:73M)N) S::C   #:, N5T M" #:, N5T M14 M)T)7 MT. M:MB:73S::C M)N)

$

2 6 2 6 6 2

Des*!i3i"+ HPCL SLEE MONO IOS   C)SC ASS:MBK B)T:,

24

6 2 2 2

4 4 4

64.4=.4= [email protected]" 19.12.48

=49<6 PB844@9 B8196<

A

$%.&&.$@

PB>$&>&

6 & & & & &

# (

P!"*. Se. >>

T"a) 27 & 1

UOM NOS N)S

& 2

N"s Nos

< 2 " " 2 < < 2 1 < 2 2 2 ' ''

Nos Nos Nos Nos Nos Nos Nos Nos Nos Nos  Nos  Nos  Nos N"s N"s

((,(@,'%,'@ 11!1=!66

11!1=!66

11!1=!66 M/11!1= 11!1=!66

&&,&%

B)4944@9 B)414128 PB844@9 B8196< B)4944@= B)4941=1 B)4941<8

#:, N5T M" ocatin* Pin #elded0 BAS: S,: S5PP)7T AN:F SP7NT 7:S:NT S5PP)7T B7A-C:T #:, N5T M14 -arria*e Bolt 6"mm 7) H,! 9/"BS# SJ5A7: N5T 9/"O BS# QKP PAN #ASH:7 , 24.86  ), 6".6  2.= MM

B)49416= PB>$&>& PM$($$#&

THC. e73a1 C)am3 EP FOAM ITH GUM -&=$  &#$  =MM TH

S!0a*e

TYPE FG ASS:MBK

PURE POLYESTER BLAC -GLOSSY P57: P)K:ST:7 BA-C )SSK0

P57: P)K:ST:7 BA-C )SSK0

P57: P)K:ST:7 BA-C )SSK0

P57: P)K:ST:7 BA-C )SSK0 P57: P)K:ST:7 BA-C )SSK0 QKP QKP QKP PURE POLYESTER BLAC -GLOSSY

Ma).

SHEET METAL SH::T M:TA

B/) SH::T M:TA B/) B/) SH::T M:TA B/) B/) SH::T M:TA SH::T M:TA B/) B)/A3H B)/A3H B)/A3H SHEET METAL BO;AH

-7-A 7A,: , -7-A 7A,: ,

-7-A 7A,: ,

-7-A 7A,: , -7-A 7A,: ,

CRCA GRADE D

Basi* P!"*ess )"*ai"+

  +    i   a   s   e   !      m    A    )      a   s       "    T

  3   ,       e    S    0   "  .   "    N

     .    S    0  .   "   C   "   ;   s    N   )    )    i   !    D

  s   3   a    T    0   "   "    N

  s       "   3    S    0    O   "    N

   ;   g   +   !    i   e    :   *   s   a   +   L   ,    P

  +   "    i       a   *    i   !    <   a    F

  s       m   +    i    :        1    i    

  s       m   +    i    :       g   +   e    L

$

$

$

$

$

$

$

$

#?

$

6

4.21@

4.949

4.<<2

1

<

"

4

4

4

As!a

As!a

As!a

6

4.129

4.68@

4.1@

1

1

#

4

4

4

As!a

As!a

As!a

6

4.1

4.2"

4.112

1

1

#

4

4

4

As!a

As!a

1

4."1

4.92

1.="9

1

1

#

4

4

4

As!a

As!a

6

4.186

4.68@

4.161

1

2

#

4

4

4

As!a

As!a

   5    :    T  

  s    1   +   e    B

  s    1   +   e    B    )   a       "    T

  g   +    i    1   +   e    B

   :   s    i   +    i    F   e   *   a    0   !   ,    S

  7    )    <   m   e   s   s    A As!a

As!a

As!a

Re5 

Re5 

21

2

4.46

4.419

4.44<

1

<

1=

4

4

4

Re5

As!a

As!a

 $0 ndependent versus ,ependent ,emandF The demand for the end item ori*inates from customer order and customer forecasts. Such a demand for end items and spare parts is called i+1e3e+1e+ 1ema+1. The demand  $y a parent item for its components is called 1e3e+1e+ 1ema+1. :.*

 R independent demand num$er of end item0 K R num$er of components for each end item K Rdependent demand num$er of su$assem$ly demanded0

c0 Parts :plosionF The process of determinin* *ross reDuirements for component items i.e reDuirements for  su$assem$lies! components! and ra% materials for a *iven num$er of end3item units is &no%n as parts eplosion. Part eplosion represents the eplosion of parents into their  components.

d0 ross 7eDuirements of -omponent temsF ross reDuirement of component items is the total num$er of component items reDuired to manufacture the end products. ross reDuirement of component items is computed $y usin* the information from the product information and the $ill of materials.

e.* f the demand for end3item :1 is 94! than *ross reDuirements for the item components. ,emand of S1 R 1  demand of :1 R 94 units ,emand of S2 R 2  demand of :1 R 144 units ,emand of -1 R 1  demand of S1 R 94 units ,emand of -2 R 2  demand of S1 R 144 units ,emand of -6 R 2  demand of S2 R 244 units ,emand of -< R 6  demand of S2 R 644 units 22

,emand of -9 R 1  demand of S2 R 144 units e0 -om -ommon3 mon35s 5see tems temsFF They are the component items %hich are used in different su$assem$lies of different end3  products. These items must $e added to have more more economic purchasin*. purchasin*.

f0 )n3Hand )n3Hand nven nventory tory!! Schedul Scheduled ed 7eceipts 7eceipts!! and Net 7eDuirem 7eDuirementsF entsF O+a+1 i+8e+"!7 is the availa$le availa$le items in stoc& from the previous period. S*e1)e1 !e*ei3 is the items already $een ordered $ut not $een received from the vendors yet. Ne !ei!eme+ is found $y su$tractin* the "+-a+1 i+8e+"!7  and s*e1)e1 !e*ei3s  from

the g!"ss !ei!eme+s .

*0 Plan Planned ned )rder )rder 7elea 7eleaseF seF P)a++e1 "!1e! !e)eases  refer to the process of releasin* a lot of every component item for 

 production or purchase. ,etermination ,etermination of lot si+e is an economic issue. The trade off is  $et%een e i+8e+"!7 ")1i+g *"ss  and the se 3 *"ss. ot si+es in M7P system are determined for component items for each sta*e seDuentially startin* %ith level 1! then level 2 and so on.

h0 ead Tim Timee and ead ead Tim Timee )ffsett )ffsettin* in*FF The )ea1 ime is the time it ta&es to produce or to purchase a part. The lead time depends onF  ;

setup time

 ;

production time

 ;

lot si+e

 ;

seDuence of machin machines es on %hich %hich operations are performed

 ; 

Dueuin* delays

The 3!*asi+g )ea1 ime is the time $et%een placin* an order %ith a vendor and receipt of the order. The manufactu manufacture re or purchase purchase of component component items must $e offset offset $y at least their )ea1 imes to ensure availa$ility of these items for assem$ly into their parent items at the desired

time.

F. CAPA CAPACITY CITY PLAN PLANNI NING NG::

26

The output of Material 7esource Plannin* does not produce an eecuta$le manufacturin*  plan! $ecause it contains material reDuirement reDuirement information information only $ut does not contain information a$out the manufacturin* capacity of the plant. -apacity -apacity planni plannin* n* is concerned concerned %ith ensurin ensurin* * the feasi$ feasi$il ility ity of production production plans plans $y determin determinin* in* resources resources such as la$or la$or and eDuipmen eDuipmentt %ith a vie% vie% to developi developin* n* %hat is &no%n as an e6e*a<)e ma+0a*!i+g 3)a+ . The process of capacity plannin* is comple and involves a num$er of decisionsF  ;

:plorin* :plorin* overtime / multiple multiple shifts shifts / su$3contractin* options options

 ;

,evelopin* ,evelopin* alternative alternative process plans plans for effective effective resource utili+ation

 ;

Splittin* Splittin* lots

 ;

ncreasin* or decreasin* employ employment ment levels levels to respond to capacity chan*es chan*es

 ;

nventory options! options! $uffer $uffer stoc&s

 ;

ncreasin* capacity $y $y addin* addin* capital capital eDuipment eDuipment such as machines/eDu machines/eDuipme ipments. nts.

G. ORDE ORDER R RELEA RELEASE SE::

)nce an eecuta$le manufacturin* plan is o$tained! orders are released to the shop floor. )rder release documents includeF includeF  ;

Part No ! Jty to $e produced of each item.

 ;

B)M is also also referred as 7outin* sheets sheets havin* havin* informati information on onF I

oper operat atio ion n seD seDuences nces!!

I

%or& centers!

 ;

Standard machine machine time time allo%ed allo%ed for each operation! etc.

 ;

Appropriate shop floor floor records such as cards! move cards! and part lists for assem$l assem$ly y  jo$s B)M is is referred0.

The "!1e! !e)ease tri**ers a num$er num$er of activities at the shop floorF I

Schedu Scheduli lin* n* of jo$ jo$ order orderss on on the the %or& %or& center centers. s.

I

SeDu SeDuen enci cin* n* of jo$ jo$ss on on a %or %or& & cent center er..

I

Allo Alloca cati tion on of ji*s ji*s and and fi fitu ture re..

I

oadin* oadin* of %or& %or& centers centers consider considerin* in* optimal optimal process conditio conditions. ns.

I

-oordinati -oordination on of materia materiall hand handlin lin*! *! stora*e! stora*e! %arehousi %arehousin*! n*! and and machi machine ne tools.

H. SHOP FLOOR FLOOR SCHEDULING SCHEDULING AND AND CONTROL: CONTROL:

2<

#hen the planned orders are released to the shop floor for manufacturin*! the primary o$jective is to deliver deliver the product. I

at the ri ri*ht time!

I

in the the ri* ri*ht ht Duan Duanti titi ties es!!

I

Meetin* Duality specifications.

But some unepected event machine $rea&do%n for eample0 eample0 may cause delays! the up to date information from shop floor is send to mana*ement via $rea& do%n memo. n order to ta&e action for e.* chan*in* the schedulin*0! up to date information from the shop floor is sent to the mana*ement. mana*ement.

A num$er of methods are used for data collection in Astra Metal Systems Pvt. td. areF I

Han Hand %rit %ritte ten n rep reports orts..

I

Manual Manual data data entry termina terminals! ls! for for enterin* enterin* data data in ecel ecel files files called called #P #P file files. s.

The major functions "0 a s"30)""! *"+!") s7sem  follo%ed areF I

Sche Schedu dule le jo$ jo$ orde orders rs on on the the %or& %or& cen center ters! s!

I

SeDue SeDuence nce the jo$s jo$s in order order on a %or& %or& cent center! er!

I

Provi Provide de accur accurate ate and time timely ly order order status status infor informat mation ion..

The %or& order status s tatus information information includesF includesF I

order $a $atch si+es

I

jo$ co completion

I

rema remain iniin* jo$s jo$s and and ope operat ratio ions ns

The %or& order status information information is usedF I

To moni monitor tor the the pro*ress pro*ress of of manu manufa factu cturin rin* * activ activiti ities. es.

I

To determi determine ne priorit priorities ies for schedu schedulin lin* * jo$s jo$s in in the shop shop in respons responsee to chan*es chan*es in jo$ jo$ order status.

I

To main maintai tain n and contro controll %or& %or& in in process process..

I

To provi provide de output output data data for capaci capacity ty contro controll purpo purposes. ses.

)peration schedulin*F There are t%o t %o major activities to $e performed %hen 4"!5 "!1e!s are released to the shop floorF

29

1.

The %or& orders are assi*ned to the %or& centers such that due dates are satisfied. Allocation of jo$s to %or& centers is referred to as ma*i+e )"a1i+g.

2.

The seDuence of each %or& order throu*h each %or& center is determined. This  process is referred to as "< see+*i+g.

The o$jectives of "3e!ai"+ s*e1)i+g  areF  ;

Meetin* due dates.

 ;

Minimi+in* manufacturin* throu*hput time.

 ;

Minimi+in* %or&3in3process.

 ;

Maimi+in* %or& center utili+ation.

o$ SeDuencin* and Priority 7ulesF  Normally! the total num$er of jo$s eceeds the num$er of %or& centers. -urrently Astra Metal Systems Pvt. td. uses com$inations of priority rules li&e S"!es 3!"*essi+g ime %herein hi*hest priority is *iven to the jo$ %ith the shortest processin* time. n some cases Ea!)ies 1e 1ae  :,,0 or Leas s)a*5  rule is *iven the hi*hest priority. S)a*5  R time remainin* until due date 3 process time remainin*.

More suita$le priority rule for Astra Metal Systems Pvt. td. &ind of entrepreneurship %ill  $e Fi!s  I+ Fi!s  O  ??)0. This %ill improve performance in plant operations. Since too many chan*es lo%ers productivity and even too many chan*es lo%ers one or other  customerEs service level.

J5ATK ASS57AN-:F n Astra Metal Systems Pvt. td. Juality is maintained in t%o %aysF 1. :ach %or&er monitors his %or& and 2. Periodic inspections are performed $y individuals from the Duality control function

nspection is necessary at several places in the manufacturin* process! includin*F 1. nspection of ra% materials 2. nspection of manufactured productF I

Preprocess

I

n3process 2=

I

Post process

nspection of production process parametersF  ;

Tools

 ;

?itures

 ;

Production machinery

 ;

Verification/cali$rationF 1. nspection fitures 2. nspection *au*es 6. nspection machinery

Juality Assuarnce Process at Astra Metal Systems Pvt. td.

Me"1")"g7 a+1 P!"*e1!e "0 "!5: n Astra Metal Systems Pvt. td. the production of hi*h3Duality parts is the company  policy! production operators inspect the parts durin* the production process to ensure that

28

the process is under control. Some operations involve 144 inspection and some use random samples.

Astra follo%s samplin* $ased inspection %herein randomly a sample is ta&en from a $atch %hich is representative of the entire $atch. Thus! only the sample is inspected in determinin* the Duality of the entire $atch. No of samples to $e inspected depends on $atch si+e. ?or fa$ricated products and $ou*ht out items samplin* plans are desi*ned to avoid non value added activity.

Machine components reDuired for production process are verified at Juality department! as an inspection process M/ced components are inspected under sample plan %ith acceptance Duality limit. The num$ers of inspection samples are eDual to the sample si+e as defined  $elo%. -riteria for acceptin* or rejectin* a lot depends on num$er of non conformin* items! if they are eDual to the acceptance num$er! full lot is accepta$le su$ject to the functional fitment acceptance.

Lot size Quantity in Numbers 2 to 8 9 to 15 1 to 25 2 to 50 51 to 90 91 to 150 151 to 280 281 to 500 501 to 1200 1201 to 3200 3201 to 10000

Sample size

2 3 5 8 13 20 32 50 80 125 200

Acceptan ce

0 0 0 0 0 1 1 2 3 5 "

Rejecti on

1 1 1 1 1 2 2 3 !  8

?or in3process inspection of Product a*ain samplin* plan is follo%ed throu*hout the  production line. The SAMP:31U0 ?irst conform Piece %ill $e :cludin* of Settin* Pieces0. f the settin* pieces found to $e Non3 conformin*! it is transferred to Juality -ustody for further disposition action. Visual characters li&e dent mar&! $o%! punchin* mar&! 7ust! #eld distortion! %eld Juality! tapper $end! po%der shade! po%der pattern! scratch mar&! pin holes and forei*n particle0 are inspected 144.

2"

Batch Si+e

Sample s

Sample31U

Sample32

Sample36

Sample3<

Sample39

33

33

33

33

33

5p to 19

2

?irst -onform Piece

ast Piece

1= 3 <@

6

?irst -onform Piece

94

144

94 and A$ove

9

?irst -onform Piece

29

94

89

144

P!"1*i"+ 3!"*e1!eF -ustomer *ives orders to PP- for re*ular production! for ne%

 parts inDuiry comes throu*h ne% development team to PP- Duotes are sent! on approval of  Duotes! commitment for delivery of proto/samples *iven than samples approval process is follo%ed $efore ta&in* actual production process.

H"4 is P!"1*i"+ P)a++i+g 1"+e:  Production plannin* and control PP-0 department

receives a Production )rder P)0 that consists of client reDuirements such as product type! Duantity! revision status! item rate and delivery date. PP- cross verifies Purchase )rder  terms G conditions a*ainst correspondin* Duotation released $y M, / -:) or Previously a*reed rates as per ?inal Product ist. After revie% of Purchase )rder the same is updated in data$ase pro*ram and ac&no%led*ement sent to the customer if needed.

PP- controls su$ units such as schedulin*! routin*! ra% material handlin*! and personnel! etc necessary for the successful completion of the order. #hen a contract affectin* product  parameters is modified! PP- initiate the component Modification process. PP- transmits the order reDuirements to these su$ units electronically in the form of a production reDuest. Based on inputs a$out availa$ility of respective resources from various su$ units! PP $rea&do%ns the P) into production $atches and lots. -ustomer releases purchase orders %hich can $e specific Dty %ith tar*et dates or open order %ith monthly or %ee&ly schedule %hich follo%s from time to time

Mae!ia) De3a!me+:

The material department is responsi$le for material reDuirement plannin* and for providin* materials such as -7-A! H7-A! Hard%are! M/c items! Po%der! chemicals. ,urin* the  process of P) order $rea&do%n! the main role of the Material department is to determine the amount of ra% material reDuired to satisfy the P) and chec& for their availa$ility either  via in3house inventory or an eternal vendor. ,ependin* on the availa$ility of the ra% material reDuired for production or the due dates as to %hen the procurement %ould $e complete! the Material department provides the necessary feed$ac& to the schedulin* department PP-0. 2@

F+*i"+a) A!eas "0 Mae!ia) De3a!me+:

Material department has five primary functionsF I

7a% Material reDuirement computation

I

nventory Mana*ement

I

Vendor Selection

I

o*istics

I

#arehouse Mana*ement

The P)s Production )rders0 arrive on the floor at irre*ular intervals and for various types of products %ith various compositions. The orders are currently processed manually $y a PP- Production! Plannin* and -ontrol0 %ho after innumera$le consultations %ith other  departments $rea&s do%n the order into $atches and fi*ures out the $est %ay to produce the lot %ith the *iven specifications and availa$ility of ra% materials. Since the iterative  process and manual schedulin* of the orders is time consumin* and depends on real time information! it invaria$ly results in a hapha+ard schedulin* and delays in finishin* an order.

-urrently Astra is implementin* :7P module. This module %ill $e inte*rated %ith the overall production order information system at a later sta*e. :pected $enefits of the ne% :7P Module are follo%in*F I

Juic&er cycle time

I

ncreased productivity

I

a$or savin*s

I

:fficient schedulin*

I

:liminate $ottle nec&s and ma&e $etter use of machine time

I

#aste prevention and efficient use of ra% material

I

mproved morale / 7educed stress

:7P Module %ill ena$le Astra Metal Systems Pvt. td. employees toF I

-alculate the amount of ra% material reDuired to complete a P)

I

enerate reports of ra% material inventory across all the 5nits

I

enerate list of approved vendors

I

-ompare different vendors from the list and select vendors $ased on price! lead time! and Duality 64

I

enerate purchase orders to vendors

I

:ffective mana*ement of contractin* process

I

,evelop user *uidelines and policies

I

:nsure secure authori+ed user access

I

Protect vendor and customer information

Astra Metal Systems Pvt. td. follo%s J"< "! +i 3!"1*i"+   of production system %herein production is initiated as per customer specifications! each $atch or order consists of a small lot of products and may $e different from other $atches. t is flei$le and can $e adapted to chan*es in product desi*n and order si+e %ithout much inconvenience. n this system varied products are produced a*ainst specific orders.

Production as a System Production System

nputs nputs

-onversion -onversion Su$system Su$system Su$system

)utputs )utputs

-ontrol -ontrol Su$system Su$system

61

Astra Metal Systems Pvt. td. ?ollo%s  "<
T!a+s0"!mai"+ P!"*ess I+3 Materials Machines Man / %or&ers Money / capital nformation

P!"*ess Manufacturin* Assem$lin* Transportin* Storin* -onsultin*

O3 37ay M/cOs ATM M/cOs Cios&s Services

62

P!"*ess La7" P+*i+g

Assem<)7  Tes

Be+1i+g

P"41e!*"ai+g

Fa
P!"*ess La7"  4"!5 !a8e)s " 1e1i*ae1 3!"*ess *e+e!s

ProcessF A series of activities that ta&es an input adds value to it and produces an output for  a customer 

Production Plannin* and -ontrol PP-0 is a process that comprises the performance of  some critical functions on either side! vi+.! plannin* as %ell as control. ?i*ure PP- Process Production Plannin* and control

66

Production Plannin*

Production -ontrol

Plannin*

,ispatchin*

7outin*

?ollo%in* up

oadin*

nspection

Schedulin*

-orrective

P!"1*i"+ P)a++i+g a+1 C"+!") F+*i"+s

All of the four $asic phases of control of manufacture are easily identified in production  plannin* and control. The plan for the processin* of materials throu*h the plant is esta$lished $y the functions of process plannin*! loadin*! and schedulin*. The function of  dispatchin* puts the plan into effect that is! operations are started in accordance %ith the  plan. Actual performance is then compared to the planned performance! and! %hen reDuired! corrective action is ta&en. n some instances re3plannin* is necessary to ensure the effective utili+ation of the manufacturin* facilities and personnel.

A. P!"1*i"+ P)a++i+g:

Production plannin* may $e defined as the techniDue of foreseein* every step in a lon* series of separate operations! each step to $e ta&en at the ri*ht time and in the ri*ht place and each operation to $e performed in maimum efficiency. t helps to %or& out the Duantity of material manpo%er! machine and money reDuires for producin* predetermined level of output in *iven period of time.

a0 P!"*ess P)a++i+g -R"i+g: The determination of %here each operation on a component part! su$assem$ly! or assem$ly is to $e performed results in a route for the movement of a manufacturin* lot throu*h the factory. Prior determination of these routes is carried out $y ne% product development team. 5nder this! the operations! their path and seDuence are esta$lished. The main aim of routin* is to determine the  $est and cheapest seDuence of operations and to ensure that this seDuence is strictly follo%ed. 7outin* procedure involves follo%in* different activities. 10 An analysis of the article to determine %hat to ma&e and %hat to $uy. 6<

20 To determine the Duality and type of material 60 ,eterminin* the manufacturin* operations and their seDuence. <0 A determination of lot si+es 90 ,etermination of scrap factors =0 An analysis of cost of the product

$0 L"a1i+g: )nce the route has $een esta$lished! the %or& reDuired is loaded a*ainst the selected machine or %or&station. The total time reDuired to perform the operation is computed $y multiplyin* the unit operation times *iven on the standard process sheet  $y the num$er of parts to $e processed. This total time is then added to the %or&  already planned for the %or&station. This is the function of loadin*! and it results in a ta$ulated list or chart sho%in* the planned utili+ation of the machines or %or&stations in the plant. The net step is the eecution of the schedule plan as per the route chal&ed out it includes the assi*nment of the %or& to the operators at their machines or %or&   places.

So oadin* determines %ho %ill do the %or& as 7outin* determines %here and Schedulin* determines %hen it shall $e done.

c0 S*e1)i+g: Schedulin* is the last of the plannin* functions. t determines %hen an operation is to $e performed! or %hen %or& is to $e completed the difference lies in the detail of the schedulin* procedure. n Astra de3centrali+ed schedulin* system is follo%ed %here all process plannin*! loadin*! and schedulin* for the units are done in main unit the details of the schedule may specify the startin* and finishin* time for an operation. And accordin*ly location PP- %ith the help of production supervisor  schedules on day to day $asis to meet completion time for the %or& in a *iven department. t means %or&in* out of time that should $e reDuired to perform each operation and also the time necessary to perform the entire series as routed! ma&in* allo%ances for all factors concerned. t mainly concerns %ith time element and priorities of a jo$.

The pattern of schedulin* differs from one jo$ to another %hich is eplained as $elo%F

69

I

Mase! S*e1)eF Schedulin* usually starts %ith preparation of master schedule %hich

is monthly! $ro&en do%n to %ee&ly production reDuirement for each product for a definite time period! $y havin* this as a runnin* record of total production reDuirements the PP- is in $etter position to shift the production from one product to another as per  the chan*ed production reDuirements. This forms a $ase for all su$seDuent schedulin* activities. A master schedule is follo%ed $y operator schedule %hich fies total time reDuired to do a piece of %or& %ith a *iven machine or %hich sho%s the time reDuired to do each detailed operation of a *iven jo$ %ith a *iven machine or process.

I

P!"1*i"+ s*e1)eF The main aim is to schedule that amount of %or& %hich can

easily $e handled $y one unit %ithout interference. To sta$ili+e or avoid freDuent chan*es in location of manufacturin* any product! at the initial period i.e at the time of   prototype itself feasi$ility study is carried out and as far as possi$le %here all the  processEs can $e done in totality that location is selected as manufacturin* unit for that *iven product. tEs not independent decision as it ta&es into account follo%in* factors. 10 Physical plant facilities of the type reDuired to process the material $ein* scheduled. i&e some jo$s may reDuire laser cuttin* %hich in availa$le only %ith one unit out of 6 Astra 5nits. 20 Personnel %ho possess the desired s&ills and eperience to operate the eDuipment and perform the type of %or& involved. 60 Necessary materials and purchased parts.

•

S*e1)i+g "0 J"< "!1e! ma+0a*!i+g F Schedulin* is of utmost importance as it

 $rin*s out efficiency in the operations and reduces cost price. Astra PP- $asically maintains different types of schedules to have a close scrutiny of all sta*es namely an enDuiry schedule! a production schedule! a shop schedule out of a$ove three! a shop schedule is the most important as it ena$les to see at a *lance. 1. The total load on any section. 2. The operational seDuence. 6. The sta*e! %hich any jo$ has reached.

•

C"m
much %or&( as loadin*! and '%hen as schedulin*! in actual operations these three functions are often com$ined and performed concurrently. )$viously! it is desira$le that 6=

a minimum of chan*es $e made after schedules are esta$lished. This o$jective can $e approached if the amount of %or& scheduled for the unit or department is eDual to or  sli*htly *reater than the manufacturin* cycle. ?or optimum control! it should never $e less than the manufacturin* cycle.

B. P!"1*i"+ *"+!"):

Production control is the process of plannin* production in advance of operations! esta$lishin* the etract route of each individual item part or assem$ly! settin*! startin* and finishin* for each important item! assem$ly or the finishin* production and releasin* the necessary orders as %ell as initiatin* the necessary follo%3up to have the smooth function. The production control is of complicated nature. The production  plannin* and control department can function at its $est only %hen the production mana*er! the purchase mana*er! the personnel mana*er and the financial controller  assist in plannin* production activities.

a Dis3a*i+g: Authori+in* the start of an operation on the shop floor is the function of 

dispatchin*. This ?unction may $e centrali+ed or decentrali+ed. n Astra said function is ,e3centrali+ed %herein production supervisors are authori+ed to start each of the machine operations $ased on the routin* and schedulin* of the %or& throu*h his department. ,ispatchin* involves issue of production orders for startin* the operations.  Necessary authority and conformation is *iven forF 1. Movement of materials to different %or&stations. 2. Movement of tools and fitures necessary for each operation. 6. Be*innin* of %or& on each operation. <. 7ecordin* of time and cost involved in each operation. 9. Movement of %or& from one operation to another in accordance %ith the route sheet. =. nspectin* or supervision of %or&  ,ispatchin* is an important step as it translates production plans into production.

< Re3"!i+g "! F"))"4  3 : n Astra this function is carried on daily $asis %hich starts

%ith production meetin* %ith necessary departments li&e Press Shop! ?a$ Shop! Po%der -oatin*! )ffloadin*! Purchase! Maintenance Juality and PP-. The manufacturin* activity of a plant is said to $e 'in control( %hen the actual performance 68

is %ithin the o$jectives of the planned performance. #hen jo$s are started and completed on schedule! there should $e very little! if any! concern a$out the meetin* of  commitments. :very production pro*ramme involves determination of the pro*ress of  %or&! removin* $ottlenec&s in the flo% of %or& and ensurin* that the productive operations are ta&in* place in accordance %ith the plans. i&e mornin* meetin* concern in3char*e in respective department monitors/revie%s dayEs production at the end of  shift. t spots delays or deviations from the production plans. t helps to reveal detects in routin* and schedulin*! misunderstandin* of orders and instruction! under loadin* or  overloadin* of %or& etc. All pro$lems or deviations are investi*ated and remedial measures are underta&en to ensure the completion of %or& $y the planned date! currently measures li&e providin* necessary ji*s G fitures! identifyin* unnecessary activities and eliminatin* them alon* %ith overtime %or&in* is emphasised.

* C"!!e*i8e A*i"+: This is the &eystone of any production plannin* and control

activity. f all processes are on schedule that means in all pro$a$ility production is not  $ein* scheduled to its optimum productive capacity. #ith an optimum schedule! manufacturin* delays are the rule! not the eception. As a -orrective action in Astra activities of adjustin* the route! reschedulin* of %or&! repairs and maintenance of  machinery or eDuipment! control over inventories is initiated. Alternate methods li&e overtime! increase in %or& force is ta&en to handle pea& loads. 1 I+s3e*i"+: This is mainly to ensure the Duality of *oods. t can $e reDuired as effective

a*ency of production control. To move to%ards %orld class manufacturin* unit Astra is in the process of im$i$in* this inspection process in the $lood of producer operator0. As such necessary on*oin* trainin* are provided operators.

e Re3)a++i+g: 7e3plannin* is not corrective action. 7e3plannin* revises routes! loads!

and schedules! a ne% plan is developed. Astra $ein* jo$ shopper and have vide variety  products and lar*e customer $ase this function is often reDuired. -han*es in customer  reDuirements! machine $rea&do%ns! a$senteeism! material shorta*es or any other  factors affectin* the day to day %or&in* often indicate that a re3plannin* is needed.

As in many manufacturin* industries today! Astra is under increasin* pressure to transform  $usinesses from ma&e3to3forecast $ased on the predictions *iven $y customers0 to small  $atch made3to3order MT)0 production. The emphasis is also stron* on just3in3time 6"

deliveries and minimal stoc&holdin* throu*hout the manufacturin* process. The customer  no%adays epects a fast delivery of Duality products that are ali*ned %ith current trends. ?lei$ility on the shop floor is $ecomin* essential and attitudes have had to chan*e from  pre3set machine runs for producin* and stoc&in* to a ne% ean approach of ma&in* only %hat can $e sold.

#ithin our or*ani+ation it %as %idely reco*ni+ed that the performance of production systems is not only determined $y the %ay the production system is controlled $ut also $y its or*ani+ational desi*n. And as a measure to try and improve performance de3centrali+ed  plannin* came into eistence %herein for all 6 units! plans are released $y central PP- and  $ased on central PP- plans! location PP- at each unit does function of controllin* the  production $y simultaneously implementin* plannin* and control systems and utili+in* or*ani+ational measures. Not%ithstandin* its importance! the field of production and operations mana*ement still lac&s. )ne of the reasons for this shortcomin* seems to $e a lac& of understandin* ho% plannin* and control systems interact %ithin or*ani+ational  plant.

)ur )r*anisation %as eamined durin* a continuous period of si months. After this intensive research period! all 6 units %ere follo%ed durin* a period of one year. ,urin* this  period developments re*ardin* the plannin* and control system and the or*anisational desi*n of the production and distri$ution system %ere o$served. The si+e of the firm is  ± 194 employees0. All distinctive functional areas li&e production! sales! procurement eisted G only mar&etin* did not eist.

,ata %as *athered $y studyin* internal reports! visitin* and o$servin* meetin*s! and $y means of semi0 structured intervie%s. n all cases plannin*! production! materials and lo*istics employees %ere intervie%ed for several times. #ithin each or*anisation the employees $ein* intervie%ed consisted of employees %or&in* at $oth the lo%er! middle and hi*her mana*ement levels. Both the semi30 structured intervie%s and the Duestionnaires %ere conducted. n all case studies some participative research elements %ere included. These included Duestions li&eF do %e need a lo*istical or materials mana*ement department! ho% can conflicts $et%een Production! Sales and o*istics $e reduced! are there any co3ordination  pro$lems $et%een Purchasin*! Production and Sales and if! ho% can they $e solved! and 6@

last $ut not leastF are interfaces %ithin the company $et%een functional areas mana*ed  properly. ?rom this evaluation in all units an improvement and reor*anisation process needs to $e conducted.

Questions

#nit 1 better ,ommunicati on) nee(s Re(esi*n or*anization structure

#nit 2

#nit 3

nee(s re(esi*n or*anizati on structure

Re(e-ne responsibilit ies an( aut$orities

/es

/es

R') Lean process

R'

R'

aterials

aterials

aterials

No

No

No

$o% can con&icts bet%een 'ro(uction) Sales an( Lo*istics be re(uce(+ are t$ere any co.or(ination problems bet%een 'urc$asin*) 'ro(uction an( Sales+ /es i) $o% can t$ey be sole(+ (o %e nee( a lo*istical or materials mana*ement (epartment+ Are interaces %it$in t$e company bet%een unctional areas mana*e( properly+ P!"1*i"+ De3a!me+s -P!"*ess:

P!ess S"3

I

Punchin*

I

Bendin*

I

nsertin*

Fa
I

#eldin*

I

,rillin*

I

Sanderin*

S!0a*e 0i+isi+g

I

Po%der -oatin*

I

Pre3treatment

P!ess S"3:

Astra $ein* $asically sheet metal manufacturin* unit! -A,3-AM systems are %idely used. Typically! sheetmetal parts are produced $y a num$er of different 2, and 6, operations. n this study! %e only consider the cuttin* and $endin* process. Startin* from a flat $lan&! a suita$le cuttin* process %ill $e chosen to produce the 2, part. Since material is an <4

important cost component! optimi+ation of this process %ill $e driven $y the need to decrease the scrap percenta*e. Nestin* al*orithms! implemented in computer systems! is used to *roup a num$er of parts %ith the same thic&ness on a sin*le sheet. f the reDuired end product is a 6, part! air $endin* %ill $e applied. The $endin* process is la$or intensive and reDuires an operator continuously. The production time of a 6, part is influenced $y the num$er of time3consumin* setups $et%een parts. A part reDuires a certain production layout! i.e. a seDuence of punch3die com$inations positioned on the press $ra&e. nterchan*in* production layouts is time consumin* and thus needs to $e avoided as much as possi$le. Plannin* of the air $endin* process is still hi*hly eperience3$ased.

Here focus is on an inte*rated approach for production plannin* of sheet metal parts for  turret punch press cuttin*0 and press $ra&e air $endin*0.

See mea) "3e!ai"+s: "3imi9ai"+ "0 e 1isi+* 3!"*esses

Sheet metal operationsF Sheet metal operations are used to transform a flat $lan& into 2, or 6, o$jects $y applyin* different processesF punchin*! cuttin*! $endin*! %eldin*! po%der  coatin*! platin*! etc. The thic&ness typically varies $et%een 4." and 9 mm. n the first step! a cut to si+e sheet or standard si+e sheet %ill $e punched on turret punch press TPP0 or cut %ith the laser! resultin* in a 2, intermediate or end product.

f 6, parts are reDuired! air $endin* is used. By applyin* a vertical force! the sheet is forced into a die. ,ependin* on the ma*nitude of this force! the $end an*le %ill vary. :ach  $end line reDuires a certain toolset. Such toolset comprises a punch and a die! positioned on the press $ra&e. ?or $endin* one part! often consistin* of multiple $end lines! different toolsets mi*ht $e needed.

Those sets %ill all $e positioned on the press $ra&e! resultin* in a production layout. -han*in* production layouts is time consumin* and should $e avoided as much as possi$le. The operatorEs eperience plays an important role in reducin* the num$er of tool chan*es at the press $ra&e.

?i*ure displays the different sheet metal operations.

<1

T!!e P+* P!ess -Ci+g: Nesi+g "0 e "!1e!s

-urrently! Astra manufacture ta&es production $atch si+e %ith smaller lot si+es than $efore. To decrease the costs for sheet metal punchin* or laser cuttin*! nestin* is applied. -urrently nestin* is $asically done to produce items %ith minimum $atch si+es that too under same  product $rand and same customer.

?uture nestin* plans %ill imply com$inin* multiple orders of the same material on a sheet! such that the amount of %aste material is reduced. This can $e of different product and different customers.

The pro$lem of com$inin* different parts on a sheet is &no%n as the cuttin* stoc& Pro$lem. n the first sta*e the parts are en*a*ed in minimum area rectan*ular modules either sin*ly or in com$ination %ith other parts. n the second sta*e! those modules are *rouped on a sheet! minimi+in* the %aste material. An important remar& is the fact that these simplifications can create additional %aste material. Parallelo*ram shaped parts can ideally  $e nested %ithout any %aste material.

An instruction to punchin* operator is *iven usin* o$ )rder for pro*ram to $e punched G shall chec& for the follo%in* parametersF 1. Pro*ram No <2

2. -A, ?ile Name 6. Sheet Si+e <. Sheet thic&ness 9. Material used =. NoEs of sheets to $e punched 8. o$ description G Si*nature ". Special nstructions

Punchin* operator than chec&s the Tools indicated in the Pro*ram to $e punched G note do%n the correct die clearances *iven G direction of Tool loadin*. Tool loadin* %ith  proper direction and proper clearance is initiated for that particular thic&ness.

P+* T"") Basi*s

Toolin* for a punch press consists of a punch! die and stripper. The punch is located in a *uide mechanism that fits in the turret on a turret punch press. Turrets hold a variety of  tools and inde to $rin* different punch tools into the %or& +one of the machine.

:ach punch tool has a correspondin* die that is located under the machine toolOs %or&ta$le. The si+e and shape of the hole created in the sheet metal is determined $y the *eometry of  the punch. -learance $et%een the punch and die is adjusted to reflect the material thic&ness.

#hen the punch press is actuated! a ram descends! causin* the punch to &noc& out the material creatin* a slu*. The die is desi*ned to allo% the slu* to fall throu*h. The stripper  holds the sheet metal in place until the punch is fully %ithdra%n from the sheet. Most sheet metal punch tools used in shops today are self3strippin*. nstead of usin* the ram to push the punch throu*h the material and pull it out! these tools are $uilt %ith an internal sprin* that automatically retracts the punch. The ram then only needs to %or& in one direction. This saves cycle time and %ear on the turret punch press. T"") Li0e

The punchin* process *enerates heat. There is friction $et%een the punch and the *uide assem$ly as the punch reciprocates %ithin its $ushin*s. Modern turret punch presses are capa$le of 1!444 stro&es per minute. Most punch presses are eDuipped %ith! or have availa$le! an automatic oil lu$rication system. t supplies an air3oil mist throu*h ports in the <6

*uide assem$ly to lu$ricate the movin* parts in the tool. This si*nificantly etends the life of %ear parts %ithin the punch tool.

Be+1i+g: Mi+imi9ai"+ "0 e +m
?or the $endin* operation! production time minimi+ation is reDuired. After careful studies of dra%in* proper tools are selected accordin* to the sheet thic&ness! $end shape and  $endin* len*th. 7elationship $et%een Sheet Thic&ness t0 and V3%idth See i*5+ess

$.=#.% mm

(.$? mm

@&$ mm

&# mm "! m"!e

V3%idth

=t

"t

14t

12t

V3)penin* selections normally should $e as per the standards i.e for material thic&ness less then 6mm it should $e =T! and for 6mm to
Selection of Punch and ,ieEs -om$ination is done such that components are $ent %ith minimum noEs of Tool Set upEs! also as far as possi$le ,ie removal is avoided %hile seDuencin* of $ends.

RECOMENDED VOPENING DIES TO BE USED FOR BENDING. Re*"m. Mi+ Be+ F)a+ges A*ie8e1.-mm "+ Di00. P+*es. S.T5s.VOPEN #&$ -$.?! '&=-&.=! '=#&=-&.=!'$?-$.?! '>&=&-&.=! 4." = < 9 9 9 9 1 = < 9 9 9 9 1.2 " =.2 8.2 8.2 8.2 8.2 1.9 14 8 " " " " 1." 12 @ 14 14 14 14 2 12 @ 14 14 14 14 2.9 1= 11.9 12.9 12.9 12.9 12.9 6 1= 12 16 16 16 NA < 29 1".9 1".9 1".9 1".9 NA

Blan& are chec&ed and ensured there are no $urrs in the supportin* area $ac& *au*e0. Tool ori*in point is set $y *ivin* adeDuate pressure. ?ormula R ma pressure / "69  punch len*th. Ma pressure ; 8.1/"69 mm0 -N- pro*ramme is corrected to *ive enou*h feed speed ?SW! $ac& *au*e retract len*th and ,3ais movement.

<<

Actual $endin* is done and dimensions are chec&ed in each cycle! pro*ramme is corrected only in the case of dimension variation. This pro*ramme is saved for $atch production. ,imensions related to $endin*! are %ritten do%n in $endin* report re*ister. Parts are chec&ed after predefined $atch to avoid any sort of deviation from dra%in* specifications.

After completin* $endin* operation of $atch! the part are moved to net station $ased on route! herein process locations are defined to store the material from %here net station collects material for further processin*. Parts are identified %ith %hite ta*Es filled %ith data li&e part no! part description! Dty! date of production. ?or the production plannin* model some important data reDuirements need to $e fulfilled. ?irst! the partsE characteristics! sheetsE characteristics and the production layouts are needed. The partEs characteristics and the sheetEs dimensions can $e etracted from the Bill of Material. The production layout is determined $ased on the press $ra&e operatorEs eperience. All data is put in datasheets to $e lin&ed %ith the plannin* model.

Second! the Punchin* times and the $endin* times are needed. The Punchin* times are determined usin* Soft%are output! %hile the $endin* times are determined $y means of a time3motion study.

F+*i"+i+g "0 P!ess S"3:

Press3Shop n char*e plans production as per %ee&ly plan released $y PP-. This is $ro&en do%n to daily plan for Turret Punch! Press3Bra&e! nsertin* respectively0. Shift n3char*e chec&s for the manpo%er! material G machine availa$ility.

Pro*ram for punchin* is made ready as per daily production plan G same is do%nloaded on m/c $ased on o$ order slip %hich is issued to operator. )perator chec&s for tools that are reDuired to process the do%nloaded pro*ram G accordin*ly load the Turret.

Su$seDuent to punchin* and prior to $endin* the $lan&ed material is made $urr free to avoid any hindrances %hile $endin* )n Press3Bra&e! $ased on the process seDuence tool set up is carried out and accordin*ly jo$s are processed.

<9

?irst piece inspection is carried out G relevant data is recorded in in3process inspection re*ister JA Maps0. f any variation in product characteristics is noticed than it is corrected G jo$ are re3inspected G a*ain re3relevant data is recorded in in3process inspection re*ister.

After the first piece is accepted! production is carried out as per process seDuence. The inspection of the products is done at freDuency defined for monitorin* G measurement of   product. Material to $e moved to concerned department for further processin* is moved as  per $elo% movement note 1. To stores for further processin*0F3 material movement note start %ith PS3 follo%ed  $y increasin* serial no. if moved from Bendin* and TS if moved after punchin* 2. To stores ,ispatch0F3 material movement note start %ith P,3 follo%ed $y increasin* serial no. if moved from Bendin* and T, if moved after punchin* 6. To ?a$rication ShopF3 material movement note start %ith P?3 follo%ed $y increasin* serial no. if moved after $endin* and T? if moved after punchin* <. To Po%der -oatin* ShopF3 material movement note start %ith PP3 follo%ed $y increasin* serial no. if moved after $endin* and TP if moved after punchin*

n3process rejections that occur in the process are entered in inspection re*ister and controlled as per set procedures for controllin* N- Non conformin*0 items. An operator  does the inspection for parameters identified in dra%in*s! and in case of non3conformities necessary disposition and corrective actions are initiated.

Fa
?a$rications involvin* sheet metal! plate or pipes %hich are commonly %elded $y an arc  process. The most %idely used %eldin* processes rely on fusion of the components at the  joint line. n fusion %eldin*! a heat source melts the metal to form a $rid*e $et%een the components. T%o of the most important processes use a *as shield to protect the %eld metal from atmospheric contamination. M / MA / T %eldin* principles as shielded metal arc %eldin* is a semi3automatic  process %hich is suita$le for $oth manual and mechanised operation. t is &no%n $y a variety of namesF M 3 Metal nert as! MA 3 Metal Active as! -ar$on ,ioide / Ar*on

<=

A lo% volta*e 1".<4V0! hi*h current =4.944A0 arc $et%een the end of a %ire electrode and the %or& provides the heat needed for the %eldin* operation. The arc and the %eld are  protected from atmospheric contamination $y a *as shield.

Time study of fa$rication process is carried out to facilitate eecution of fa$rication activity.

Srl

Time in minutes

Part no

,escription

Jty

  *   n    i    d    l   e    #  

Product

  r   e    t   n   u   o   c    /   *   n    i    l    l    i   r    ,

  *   n    i   p   p   a    T

   /   *   n    i   r   e    d   n   a S   *   n    i   r   u    $   e    d

  *   n    i    l    l    i    ?    /   r   e    t    t   a   p    S

Total Time

  *   n    i    l    i   o

  *   n    i    t   e   v    i   r

  *   n    i    t   s   e    t

   l   a   v   o   m   e   r    d n   n   e mins    $

MM2.9

1

9<2411" 441

?ront -over

1

"

3333

3333

@

14

3333

3333

3333

3333

28

2

9<2414@ 441

Top Panel -omplete

1

3333

19

3333

3333

3333

6"

-ap -omplete

1

3333

3333

3333

3333

<1

9<12<11 441

1

<9

24

24

1"4

1

3333

3333

"

3333

3333 9

24

9

64 12

3333

9<24169 441

Tan& Housin* -omplete -olumn -ap

19 64

3333

<

3333 19

19 1=

3333

9<12<64 441

" 14

3333

6

3333

3333

64

=

9<24119 441

-assette Bo

1

9

3333

3333

19

19

3333

3333

3333

3333

69

8

9<21=9@ 441

#heel uard

1

19

3333

3333

1"

3333

3333

3333

3333

<9

"

9<12<21 441

Top Plate -omplete

1

14

3333

3333

12 "

=

3333

3333

3333

3333

2<

@

9<16=61 442

inverter $ase tray

1

6

33333

@

3333

92

-over -omplete

1

33333

33333

=

14 9

3333

9<12<2@ 441

29 "

9

14

33333 9

3333

3333

2<

9

3333

F+*i"+i+g "0 Fa< S"3:

Based on time study production is line up for net day. #herein daily Production line3up for man G machine -)2 #eldin*! Spot %eldin*! ,rillin*! Sanderin*! etc.0 is monitored and measured.

<8

?a$3Shop n char*e plans production as per %ee&ly plan released $y PP-. This is $ro&en do%n to daily plan for #eldin*! ,rillin*! Sanderin*! ,e$urrin*! fillin*! $uffin*0. Shift n3 char*e chec&s for the manpo%er! material G machine availa$ility.

Visual inspection for Duality of fa$rication is carried out $y operators themselves $efore movin* said item to net station. n case of detection of any visual defects! the shift supervisor initiates necessary disposition and corrective action.

?irst piece is verified for conformity as per the procedure for monitorin* G measurement of   product! and then the production is $e carried out as per process seDuence route0. Here a*ain similar to Press Shop material movement method is follo%ed for identifyin* movement from fa$rication to other department! %here in T is placed %ith ? for ?a$0

n3process rejections that occur in the process are entered in inspection re*ister and controlled as per set procedures for controllin* N- Non conformin*0 items. An operator  does the inspection for parameters identified in dra%in*s! and in case of non3conformities necessary disposition and corrective actions are initiated.

P"41e! C"ai+g:

Po%der coatin* is $y far the youn*est of the surface finishin* techniDues in common use today. t %as first used in Australia a$out 1@=8. Po%der coatin* is the techniDue of  applyin* dry paint to a part. The final cured coatin* is the same as a 23pac& %et paint. n normal %et paintin* such as house paints! the solids are in suspension in a liDuid carrier! %hich must evaporate $efore the solid paint coatin* is produced. n po%der coatin*! the po%dered paint may $e applied $y either of t%o techniDues. I

The item is lo%ered into a fluidised $ed of the po%der! %hich may or may not $e electrostatically char*ed! Astra does not have this set up0 )7

I

The po%dered paint is electro3statically char*ed and sprayed onto the part. Astra uses this method.

The part is then placed in an oven and the po%der particles melt and coalesce to form a continuous film. There are t%o main types of po%der availa$le to the surface finisherF I

Thermoplastic po%ders that %ill re3melt %hen heated! and

<"

I

Thermosettin* po%ders that %ill not re3melt upon reheatin*. ,urin* the curin*  process in the oven0 a chemical cross3lin&in* reaction is tri**ered at the curin* temperature and it is this chemical reaction %hich *ives the po%der coatin* many of  its desira$le properties.

P!e3a!ai"+ 0"! P"41e! *"ai+g:

The $asis of any *ood coatin* is preparation. The vast majority of po%der coatin* failures can $e traced to a lac& of a suita$le preparation. The preparation treatment is different for  different materials. n *eneral! for all applications the preparation treatment for aluminium is as follo%sF -lean

)r 

-lean

7inse

7inse

:tch

:tch

7inse

7inse

-hromate

Phosphate

7inse

7inse

,emin 7inse

,emin 7inse

)ils and *reases are removed in %ea& al&ali or neutral deter*ent solutions and the surface is etched to remove heavy oides. After rinsin*! the aluminium is dipped into a chromate or   phosphate solution to form a conversion coatin* on the aluminium. This film is chemically attached to the aluminium. After rinsin* the aluminium is finally rinsed in demineralised %ater. The conversion coatin* has t%o functionsF I

t presents a surface to the po%der %hich favours adhesion more than the oides that form very readily on aluminium surfaces! and

I

t reduces the incidence of under film corrosion.

The use of demineralised %ater reduces the presence of chemical salts on the aluminium surface. ?or steel the preparation Astra has set up hot treatment plant %hich $asically follo% as per   $elo% flo%.

Srl 1 2 6

Description ,e*reasin* #ater 7inse ,erustin*

Vol

Time

Temp.

Points

Ph.

93=  3

19 min.

=43894-

@4 3114

3

3 19 324

=38 3

19324

1 min 14 min

4

7T 7T4-

<@

 3

1 min

7T4-

3

=38

4.4"

1 min.

7T4-

3

A$ove @

2@ 361

3

7T4-

3

=38

=43894-

3

<3=

<

#ater 7inse

9

Activation

=

Phosphatin*

9

8

#ater 7inse

3

1 min

"

Passivation

4.429

1 min.

938 min <"3994-

The *rain refiner is used after acid cleanin* of steel surfaces and $efore +inc phosphatin*! other%ise the +inc phosphate coatin*s produced %ill $e very coarse %ith lo% adhesion. The  po%der coatin* applied to a coarse phosphate %ill produce rou*h coatin*s a little li&e sandpaper0 and possess lo% adhesion. H"4 is i 1"+e  e)e*!"sai* s3!a7

The po%der is applied %ith an electrostatic spray *un to a part that is at earth or *round0  potential. Before the po%der is sent to the *un it is fluidisedF I

to separate the individual *rains of po%der and so improve the electrostatic char*e that can $e applied to the po%der and

I

so that the po%der flo%s more easily to the *un.

Because the po%der particles are electrostatically char*ed! the po%der %raps around to the  $ac& of the part as it passes $y to%ards the air off ta&e system. The po%der %ill remain attached to the part as lon* as some of the electrostatic char*e remains on the po%der. To o$tain the final solid! tou*h! a$rasion resistant coatin* the po%der coated items are placed in an oven and heated to temperatures that ran*e from 1=4 to 214 de*rees - dependin* on the po%der0. 5nder the influence of heat a thermosettin* po%der *oes throu*h < sta*es to full cure. M:T! ?)#! :! -57:. The final coatin* is continuous and %ill vary from hi*h *loss to flat matt dependin* on the desi*n of the po%der $y the supplier. P"41e! *"ai+g g+s

There are at least three types of electrostatic *uns in useF I

-orona char*in* *uns %here electric po%er is used to *enerate the electrostatic char*e. -orona *uns are either internal or eternal char*in*.

94

I

Tri$o char*in* *uns %here the electrostatic char*e is *enerated $y friction $et%een the po%der and the *un $arrel.

I

Bell char*in* *uns %here the po%der is char*ed $y $ein* flun* from the  perimeter of the $ell

 Not all po%der is applied usin* *uns. )ne system ma&es use of electrostatic tunnels.

F+*i"+i+g "0 S!0a*e C"ai+g S"3:

i&e functionin* of Press Shop and ?a$3Shop! functionin* of surface coatin* is also initiated $ased on production plans released $y PP- as per %ee&ly plan. This is $ro&en do%n to daily plan for treatment and po%der coatin*0. Shift n3char*e chec&s for the manpo%er! material G machine availa$ility. Time study of po%der coatin* process is done to facilitate eecution of po%der coatin* activity.

T"a) Time

Time i+ mi+es

S!)

Pa! +"

Des*!i3i"+

27

  g   +    i    5   s   a    M

  3   ,    :   *   ,   "    T

9

33333

33333

33333

1

33333

<

1 1

33333

9<12<11 441

Tan& Housin* -omplete

1

2

9<12<21 441

Top Plate -omplete

1

6

9<12<2@ 441

-over -omplete

< 9

9<12<64 441 9<2414@ 441

= 8 " @

9<24119 441 9<2411" 441 9<24169 441 9<21=9@ 441

-ap -omplete Top Panel -omplete -assette Bo ?ront -over -olumn -ap #heel uard

  g   +    i   3   3   a    T

9 33333

1

1 1 1 1

14

  g   +    i       a   "    C

2 33333 2 33333 33333

  g   +    i   +   a   e    )    C

  s   e       ,   +    i   m   +    I

94

84

33333

14

14

1

9

33333

14

6 9

33333

6 8

33333

= 18

9 9 9 <

33333

33333 2 33333 33333

9 " < =

6 33333 6 33333 33333

14 24 @ 14

P!e T!eame+ P!"*ess C"+!")

Before loadin* material in treatment $ath! Pre3treatment parameters li&e Pointa*e / Temperature / pH are chec&ed as per %or& and said data is recorded in -hemical Test 7eport 7e*ister.

91

Pre3treatment is carried out $y loadin* jo$s inside $as&et! loadin* of jo$s is done &eepin* in mind %ater/chemicals should not accumulate on jo$. Than the jo$s are inspected for oil mar&s G rust! if needed jo$s are retreated.

 o$s %ith overlappin* surface are heated in oven for temperature $et%een 194 to 244X $efore coatin*. After heatin* the jo$s in oven! they are inspected for -hemical :ntrapment G oil! only -hemical/)il free material is ta&en for coatin*. o$s %ith -hemical :ntrapment G oil are treated a*ain. o$s %ithout any overlappin* surface need not $e heated in oven  $efore coatin*! instead they are &ept for air dryin* G are coated &eepin* in one of the criteria of coatin* treated jo$s %ithin 2< hours to avoid any undue effect on coated jo$s. P"41e! C"ai+g P!"*ess C"+!"): Before start of coatin*! Po%der -oatin* uns are

chec&ed for char*ea$ility G flo% of po%der. o$s %hich reDuire earthin* or $earin* surface for rollers are mas&ed %ith ru$$er sleeves or mas&in* tapes. -oated jo$s are inspected for  any visual defects G ,?T! and same is recorded in inspection re*ister. ?urther activities li&e touch/re3tappin*/cleanin* are carried out $efore movin* the jo$s to concerned department.

Surface coatin* process is validated $y pre3treatin* and phosphatin* 9 nos of -7-A test specimen of si+e 84.4  1<4.4  1.4 m.m. Test specimen is coated in the po%der coatin*  $ooth %ith 2 ; 6 passes to achieve the reDuired 144 Y ,?T. Than the panels are $a&ed at 1"4 ; 1@4 X- for a period of 24 ; 64 minutes. Test Panels are allo%ed to cool to the room temperature and send for third party analysis %herever reDuired. -urrently Astra conducts  $elo% mentioned tests.

S!) 1 2 6 < 9

Ca!a*e!s mpact Stren*th -onical Mandrel Bend Salt Spray 7esistance -ross -ut Adhesion

Sa+1a!1 Va)e 144C*;mZ<4/<4[ " m.m. 1/< 1444 Hrs t R 4/144

Re0 Sa+1a!1 ASTM ,28@< /@9 Ball\9/" ASTM , 9223B / ,N 96192 ,N 9619= ASTM B 118 ASTM , 669@ / ,N 96191

Va)i1i7 Pe!i"1 = Months = Months = Months = Months ,aily

The inspection of the products is done as per set procedures for monitorin* G measurement of product. ?inal rejections that occur in the process are entered in inspection re*ister. ?inished Material is moved to either dispatch department or for further assem$ly! as such for Astra ?a$ricated Material includin* in3house G material received from 92

vendors0 material movement note starts %ith ?P-3 follo%ed $y increasin* serial no! and for  o$ %or& items i.e customer supplied items0 material movement note starts %ith P-3 follo%ed $y increasin* serial no! for ?urther ProcessEs li&e assem$ly carried out in3house or off3loadin*0 material movement note start %ith P-3 follo%ed $y increasin* serial no.

n3process rejections that occur in the process are entered in inspection re*ister and controlled as per set procedures for controllin* N- Non conformin*0 items. An operator  does the inspection for parameters identified in dra%in*s! and in case of non3conformities necessary disposition and corrective actions are initiated. PRODUCTION PLANNING AND CONTROL

A Bird view of Production System Ma!5ei+g  De3a!me+

Cs"me!

Ne4 P!"1* De8e)"3me+

Mae!ia)s Ma+ageme+ Di8isi"+

Ve+1"!; S33)ie!s

Ra4 Mae!ia)s S"!es

Fi+a+*e De3a!me+

Hma+ Res"!*e De3a!me+

P!"1*i"+ De3a!me+ -S"3 0)""! Sa)es De3a!me+ 2a)i7 Ass!a+*e De3a!me+

Presently Astra Metal Systems Pvt. td. as&s for production lead time of < to = %ee&s as such starts production of < %ee&s $efore the planned completion date.

The $asic control pro$lem is that the capacity need in different phases of production chan*es a$ruptly as demand fluctuates. The Supervisors try to solve the pro$lem $y maimi+in* capacity in all production phases $y shufflin* the Dueue in order to minimi+e setups. ot si+e is &ept rather lar*e for the same reason. Shufflin* causeEs variation in Dueuin* times to *ro% and therefore throu*hput times *ro%. Prioriti+in* is used amply for  late jo$s. The effect is that lots pro*ress throu*h production Duite randomly and lead times are lon*. There is a lar*e amount of %or& in process and the need for capacity fluctuates a lot.

96

deally! the plannin* and control method should level the need for capacity in a %ay that allo%s for Duic& and predicta$le completion of each %or& phase and simultaneously results in adeDuate capacity utili+ation. The company has developed $ufferin*! orderin*! and forecastin* methods to*ether %ith its customers in order to level demand. Ho%ever! the demand for products produced $y Astra is hi*hly varia$le and difficult to forecast and therefore also $ufferin* is ris&y not only $ecause of increase in inventory level $ut more over may result in o$solescence.

The production schedulin* policy used in Astra Metal Systems Pvt. td.! is $ased on a system %here monthly demands are divided into short periods in %hich a predetermined amount of each product is produced. Althou*h this policy is appropriate for the flei$ility of the schedulin*! it may cause production of a$undant num$ers of setup %aste. The reason of this is that as period of schedulin* plan $ecomes smaller! the num$er of machine adjustments $ecomes hi*her! %hich in turn increases the num$er of setup %aste.

Therefore! the schedulin* periods and num$er of setup %aste are inversely proportional. f  lon*er schedulin* periods are chosen! then the production of setup %astes %ill $e decreased  $ut the flei$ility of the schedulin* %ill $e lost and ne% costs such as inventory holdin* costs %ill appear. )n the other hand! if the schedulin* period is shortened! then the schedulin* %ill $e more flei$le and the num$er of setup %aste %ill increase. ?or this reason! there is a need to find out an optimum schedulin* plan ta&in* into account the %aste production. Production plannin* and control can $e vie%ed vertically in a top3do%n! hierarchical fashion. Ho%ever! reDuires stron* cooperation hori+ontally across the functional disciplines.

Re)ai"+si3
n any manufacturin* enterprise production is the drivin* force to %hich most other  functions react. This is particularly true %ith inventories they eist $ecause of the needs of   production. The ultimate o$jective of PP-! li&e that of all other manufacturin* controls! is to contri$ute to the profits of the enterprise. As %ith inventory mana*ement and control! this is accomplished $y &eepin* the customers satisfied throu*h the meetin* of delivery schedules. Specific o$jectives of PP- are to esta$lish routes and schedules for %or& that

9<

%ill ensure the optimum utili+ation of materials! %or&ers! and machines and to provide the means for ensurin* the operation of the plant in accordance %ith these plans.

T73es "0 I+8e+"!ies:

i&e any other industry Astra Metal Systems Pvt. td. also has different &ind of inventory throu*hout its manufacturin* process. Astra maintains inventory in terms of stoc& of some &ind of physical commodity li&e ra% materials! component parts! supplies G consuma$le stores! %or&3in3pro*ress G finished *oods. The analysis of the cost structure of many of the  product reveals that inventories cost ran*e from 89 to "9 of the product cost. Thus inventories indicate a major of application of financial resources G efficient inventory control can contri$ute su$stantially to the profita$ility of the $usiness. The Principal Types of nventories are F NP5T Production nventory P7)-:SS n3process nventory )5TP5T ?inished nventory

1. Production Inventories:

tems %hich *o into the final products! ra% materials and

 $ou*ht out components. Astra $ein* $asically sheet metal fa$rication unit stoc& of -7-A! SS or P sheets is a must to start first operation of cuttin*. )n an avera*e Astra maintains ] 94 tons of ra% material in sheet form at any *iven time. 2.

Maintenance! 7epair and )peratin* nventoriesF tems %hich do not form a part of final

Product $ut are consumed in a prod. Processes spare parts! -onsuma$le items etc. 3. In Process Inventories:

#or&3in3pro*ress items %hich are partly manufactured and

A%ait the net sta*e in process. 4.

?inished oods nventories completed products ready for dispatch.

5. Miscellaneous Inventories:

#hich arise out of the a$ove four types of inventory scrap!

Surplus and o$solete items %hich are not to $e disposed off.

As a step to%ards %orld class manufacturin* unit Astra is $een practisin* 9S for Duite a fe% years.

99

 Here’s what 5-S means: Sort

Separate %hat is needed and %hat is not needed! and &eep only those thin*s that are needed in the %or&place. ,iscard unnecessary items. Set-In-Order 

 Neatly place and identify needed %or& items. ,esi*nate a place for  everythin* so that anyone can find it. Al%ays put thin*s $ac& in their  desi*nated spots. Shine

-lean up. Al%ays maintain a clean and shiny %or& place. dentify %hy thin*s are *ettin* dirty. Standardize

Become a role model for adherin* to the standards of the first three SEs and encoura*e others to follo% them. Ma&e rules and procedures to  promote a *ood %or& environment until the first three SEs $ecome every$odyEs second nature. Sustain

Maintain and practice the first four SEs. Be thorou*h in strai*htenin* up!  puttin* thin*s in order and cleanin*. Operate to the standard 

ean manufacturin* is certainly an effective strate*y $ut some principles such as one piece flo%! ta&t time! level schedulin* and Can$an all $rea& do%n for intermittent production hi*h mi and lo% volume supplies. The need of a pull system to &eep shop floor under  control. n a pull environment! in contrast to push systems! orders are released to factory only %hen the total %or&load does not eceed a predetermined level. Besides the manufacturin* efficiency! the company must ma&e availa$le a suita$le production plannin* and control system in order to meet their customerEs needs. The constant meetin* due dates %ill *ive to the relia$le supplier a very important competitive advanta*e.

Lea+ Ma+0a*!i+g 9=

ean manufacturin* is a multidimensional approach that encompasses a %ide variety of  mana*ement practices! includin* T! Duality systems! %or& team! cellular manufacturin*! Can$an! Juality -ircles! etc. in an inte*rated system. The core thrust of M is that these  practices can %or& syner*istically to create a streamline! hi*h Duality system and produce at the pace of customer demand %ith no %aste.

ean Manufacturin* $rin* a$out a chan*e in the approach to dynamic environment!  populari+in* the idea of incorporatin* flei$ility in manufacturin* system %ithout sacrificin* the efficiency. The strate*ic approach of use $uffers in human and other  resources to deal %ith uncertainties is less attractive choice for companies operatin* on M  $asis! thus necessitatin* findin* %ays to achieve manufacturin* flei$ility.

Manufacturin* flei$ility means havin* the a$ility to rapidly increase or decrease  production level! or to shift production capacity Duic&ly from one product to another. Such flei$ility is achieved throu*h flei$le plants! processes! and %or&ers! as %ell as throu*h strate*ies that use the capacity of other or*ani+ations. The main features of the lean manufacturin* %hich help meet this o$jective include set3up reduction! multi3s&illed %or&ers! preventive maintenance! and cellular layout.

ean manufacturin* represents a more fundamental frame%or& for enhancin* efficiency throu*h elimination of %astes. Seven %astes identified under lean manufacturin* that needs to $e eliminated are Motion! #aitin*! )verproduction! Processin*! ,efects! nventory and Transportation. Production is lean if it is accomplished %ith minimal cost. The less o$vious source of cost is varia$ility. This can ta&e many forms! includin* varia$ility in process time! delivery time! yield rates! demand rates! etc.

S"me E6am3)es "0 ase a As!a

I

#aitin* for parts

I

-ountin* parts

I

Multiple inspections

I

)ver3runs in production

I

Movin* parts over lon* distances

I

Storin* and retrievin* inventory

I

oo&in* for tools 98

I

Machine $rea&do%n

I

7e%or&  

Lea+ ma+0a*!i+g im3)eme+ai"+

As an implementation strate*y manufacturin* process redesi*nin* on the $asis of lean manufacturin* principles is started. M System implementation process %as started %herein ?irst step adopted %as chan*es in company culture and *ets people commitment for sustainin* the chan*e to%ard lean. After that! process flo%! %or& method and  production times are under the process of revision. The main issue that Astra is facin* is simplifyin* the shop floor! developin* multis&illed %or&ers and set3up reduction. ?illin* lines $ecame more flei$le %hich could %or& %ith a lar*e variety of product in small Duantities. As a step to%ards improvin* throu*hput time thin&in* process is initiated at all levels li&e chan*es are made in the set3up procedure to reduce si*nificantly the set3up time. Trainin* of %or&ers is initiated to handle multiples machines $rin*in* more flei$ility for the shop floor. Thou*ht process of productive maintenance is &ic& started aimin* to *uarantee hi*her   process relia$ility. The achievements that are tar*eted to achieve after implementin* lean tools includes plant efficiency improvement! setup time and delivery lead time reduction. ean -oncept implementation in process... a Is Va)e

I

Value is %hat the customer is $uyin*

I

Al%ays thin& first a$out the end3customer   ;

#ho is the customer^

9"

 ; I

#hat are they $uyin*^

,escri$e value usin* the customersO %ords

a Is Va)e S!eam A+a)7sis

I

Plannin* tool to optimi+e results of eliminatin* %aste

To $e*in %ith! $ein* ean manufacturin* needs a cultural chan*e in thou*ht processes! thin&in* approach! etc. :mployees of Astra needed trainin* on said matter as such consultants %ere approached and selected one of the prominent leadin* consultant in sad field. Than the process of trainin*s $e*ins! after $rief trainin*s on manufacturin* #astes G VSM teams %ere formed at all 6 locations %ith *roup of 14312 mem$ers and each team selected an item from final product list as a case study.

This case study is of a product %hich is reDuired $y one of the most valua$le customer of  Astra %ho is %ith Astra from incorporation period rather Astra %as started to support said customer. The main o$jective is to analy+e ho% lean manufacturin* can $e effectively implemented on MT) strate*y! includin* the PP- system reDuirements.

e 4i)) 1is*ss *ase s17 "0 VSM 0"! Si+g)e Ta+5 H"si+g..

#e carried out value stream mappin* ri*ht from receipt of purchase order to dispatch of   product to customer. Team of 14 mem$ers %as formed %hich included at3least one  personnel from PP-! Production! Purchase! :cise! H7! Stores! Maintenance! Juality. Team selected a leader to *uide the team %ith valua$le support of lean consultant. #e selected MM2.9 sin*le tan& Housin* for Value Stream analysis. ?irst noted do%n all the processes that are involved ri*ht from receipt of purchase order  from customer to delivery of product. Here process flo% alon* %ith information flo% is mapped on A2 si+e. 5sin* lean manufacturin* flo% sym$ols. -alculated Total Product -ycle timeF ,etail off3line activities that are Non3Value added activities>

Than statement statin* the scope of the project is defined. Than all VA ratio calculations %ere done to find out %hich process to $e prioriti+ed for eliminatin* non3value added

9@

activities! alon* %ith present order to delivery time and its correspondin* VA time is %or&out.

?rom $elo% value stream mappin* it %as identified that %aitin* time amounts to 94<=4 mins eDuals to ] 69 days %here as actual cycle time is 1@9" mins eDuals to ] 1 and half  day for a $atch of 14 nos. Similarly results of all the team indentified %aitin* time a most dan*erous manufacturin* %aste. To conclude %ith it %as realised and understood $y all team mem$ers that %aitin* time is the most dan*erous manufacturin* %aste so all team needs to %or& to%ards eliminatin* this %aitin* %aste. As such a first step to%ards elimination of %aste in the form of %aitin*!  production lot %ere $ro&en do%n to smaller $atch si+e! *ivin* scope for line $alancin* at every sta*e. Herein concept of releasin* production plans for month is chan*ed to releasin* %ee&ly production plans %ith priority %ise ??).

Va)e S!eam Ma33i+g "0 MM #.= Si+g)e Ta+5 H"si+g -i+ a<)a! 0"!m Batch Si+eF 14 Nos

-ycle Time

 No )f  Men Transportation

,istance

#aitin* Time

Tool Set 5p

Mins

Nos

in Mts

Mins

Mins

Mins

Supplier To Astra 7a% Material

124

24444

241=4

Punchin*

16

2

1.9

9

144"4

12

,e$urin*

<9

1

2

=

2""4

2

Bendin*

69

1

2

<

1<<4

19

Ta* #eldin*

19

1

2

12

2""4

94

nternal -orner #eldin*

94

1

4

4

4

4

?ull #eldin*

94

1

4

4

4

4

124

1

9

<4

4

<

?rame #eldin*

24

1

9

29

144"4

<2.9

?ame Sanderin* Ta* #eldin* ?rame And Tan& Housin*

94

1

2

<

4

1

19

1

9

<4

<24

99

,rillin*

"4

1

14

24

1<<4

94

Tappin*

144

1

4

4

24

?ull #eld #ith Template

244

1

24

1<<4

94

M/- tem #eld

1<4

1

4

4

=9

Spatter 7emoval

94

1

14

2

124

Sanderin*

69

1

14

2

2<4

9

ea&a*e Test

94

1

9

9

1<<4

144

Bend 7emoval

94

1

14

1

4

Sanderin*

14

=4

nspection 7eport And o$  Num$erin*

94

1

Pretreatment

94

6

Pre3Heatin*

19

4

1<<4

14

94

2""4

4

2

14

<9

144

1

2

14

=4

Po%der -oatin*

94

6

29

9

=4

)ven -urin*

<9

4

2

9

=4

,e3mas&in* And -leanin*

644

1

14

14

=4

ead Pastin*

144

1

6

4

1<<4

Varnishin*

94

1

4

1<<4

7e3Tappin*

94

1

9

2

6=4

nspection

64

1

9

2

=4

1

9

9

144"4

1

9 9 &=?.= $.&

14 1944 &>@= &.#

19

Mas&in*

?inished ood Stora*e ?inished oods oadin* And ,ispatch Astra To -ustomer ,oor T"a) Time -i+ 1a7s

&@=? &.'

('

=$'%$ (=.$

=4

64

144

9

%%%.= $.=

After completion of VSM chart and calculation of VA and NVA time net step %as flo% dia*rams %ere dra%n related to only production process. #hile dra%in* flo% dia*ram of   process its related process time and NVA processes are also identified.

n ?lo% dia*rams elements related to %aitin* time %ere eliminated and only value added VA0 and non value added NVA0 activities %ere dra%n %ith respective process time.

=1

?rom a$ove findin* processes li&e Pre3treatment!Pre3heatin* and )ven currin* since more than one jo$ is processed in one cycle0 %hich %ere carried out in $atch %ere eleminated for  time $ein*. Than processes %hich %ere in t%o di*its fi*ures i.e 14 mins or more than 14 mins %ere identifed for further study for eleminatin* NVAEs %ithin the processes. )ut of  29 activities " activities %hich reDuired processin* time in dou$le di*it %ere considered for  further action.

=2

Srl

Activity

Time

1 ,emas&in* And cleanin*

64

2 ?ull %eldin*

24

6 Varnishin*

1"

< M/c item %eldin*

1<

9 Sanderin*

12

= ead pastin*

14

8 Mas&in*

14

" Tappin* @ ,rillin*

14 "

Ta&in* activity %hich needs hi*hest cycle time for further study to atleast $rin* do%n said cycle time to net hi*ht cycle time i.e nearer to cycle time for full %eldin* 24mins0

:very process has VA and NVA activities identifyin* and cuttin* do%n NVA is the net step for %hich commonly 5sed Tools for Pro$lem Solvin* and -ontinuous mprovement are made into use.

?irst tool used to identify VA and NVA %as ?ish Bone dia*ram or cause3and3effect dia*ram is dra%n identifyin* all possi$le causes to eliminate Non Value Added NVA0 activities %ithin micro level0 process.

=6

Brain stormin* tool is used to identify possi$le causes %hile dra%in* fish $one dia*ram. Herein each team mem$er starts *ivin* root cause %hich are than *rouped accordin*ly under Man! Machine! Method or material discipline of only one at a time0 %ith at3least 6 rounds for each mem$er %here in minimum 6 causes are identified $y each mem$er! same is continued till mem$ers do not have any more points. #hile doin* this activity team does not ar*ue on %hether points that one mem$er has *iven is ri*ht or %ron*.

)nce these possi$le causes are identified than collectively net round of $rain stormin* is done %here in mem$erEs de$ate on each points and accordin*ly decide on valid and non3 valid causes! non3valid causes are stri&eout.

All other causes %hich are a*reed up on net step is to chal& out action plan! herein there may $e more than one action plan for one possi$le cause %hich than are assi*ned usin* 6# G 1H concept #ho! #hen! #hat and Ho%0.

Than team identifies '%ho %ill $e doin* that tas& he/she may $e %ithin the VSM team or  outside one team %hich depends on need of activity. Belo% is Action Plan initiated for  ,emas&in* G -leanin* %hich need 64 mins. ,emas&in* And -leanin* ta&es 64 mins Hi*h NVA0 Sr  l

Man

1 2

-auses

-hitchattin* %hile demas&in* 5ntrained Person

:cess use of mas&in* tape and 6  paper  < )perator does demas&in* slo%ly 9 ,istractin* %or&place surroundin* Machine

Material

1

mproper i*htin*

1 2 6 < 9

lue remains after removin* the mas&in* tape Poor Duality of mas&in* tape Mas&in* tape is used Mas&in* tape cuts %hile removin* Smooth cloth is used

-orrective Action :ducate %or&ers %herein they can have their discussions durin* tea! lunch $rea&s.

#ho

#hen

Manju

 613 ,ec

-han*e the process of   mas&in* itself. 5se sheet metal plates G scre%s ti*htened usin* $attery operated scre% drivers! instead of paper G mas&in* tape! than define ne% revised %or& instructions for carin* out mas&in* G demas&in* 7ohit

243,ec

chan*e of process addressOs this point

7ohit

243,ec

chan*e of process addressEs chan*e of process addressEs

7ohit 7ohit

243,ec 243,ec

=<

Method

1 2 6 < 9 = 8 " @ 14 11

12

Manual removal of mas&in* tape &erosene Applin* More contact area of jo$ surface and mas&in* Paper is used Holdin* of jo$ is reDd %ith one hand %hile demas&in* No time standard mproper tools used for demas&in* Proper seDuence fro removin* the tape is not used ,emas&in* is done after coolin* #ron* shape of paper is used #or& place or*ani+ation lue stic&s to the hand of operator  and *ets transferred on the jo$ %hich a*ain needs to $e cleaned

chan*e of process addressEs chan*e of process addressOs this point

7ohit

243,ec

7ohit

243,ec

chan*e of process addressEs

7ohit

243,ec

chan*e of process addressEs chan*e of process addressEs

7ohit 7ohit

243,ec 243,ec

chan*e of process addressOs this point

7ohit

243,ec

Similarly $rain stormin* is follo%ed $y action plan for ?ull %eldin*! Varnishin*! M/c item %eldin*! Sanderin*! ead pastin*! Mas&in* and Tappin*. ,ay to day follo% up is done for  the action plans so as to ma&e sure that tar*et dates for implementation are not defaulted.

#hile doin* $rain stormin* and action plans VA and NVAEs are monitored and measured. All data related to fact findin*s are collected filed for future reference alon* %ith any other  relevant information! photo*raphs etc. #ith each improvement action plan implementation VA calculations are done to trac& %hether team is movin* in ri*ht direction or not.

7esults of VSM study %as its on*oin* continual improvement process! most of the actions that are su**ested and implemented a*ainst said product are also applica$le *lo$ally for the  product ran*e that Astra manufactures for different customers. i&e for e.*. one of the cause for more cycle time for full %eldin* %as unor*anised %or&place as such team %or&ed out on ne% layout %hich is not only applica$le for product %hich %as ta&en for case study! said action %as also applica$le for entire ran*e of product that Astra manufactures in3 house.

Fa*"!s A00e*i+g P!"1*i"+ P)a++i+g a+1 C"+!") F"!e*as gi8e+ <7 *s"me!s: ts value to production plannin* and control is that it %ill

indicate future trends in demand for product that needs to $e supplied. #or& shift policies!  plans for an increase or decrease in manufacturin* activity! or possi$le plant epansions

=9

may often $e $ased upon the customer forecasts and in turn affect the plannin* of the  production plannin* and control *roup.

Sa)es O!1e!: This is the second of the five classes of orders. t is a re%rite of the customer 

order specifyin* %hat they %ant in terms of product and Duantity and authori+in* shipment of the *oods to the customer.

S"*5 O!1e! -B00e! s"*5i+g: This third class of order is not al%ays used. t is

 particularly ta&en in conjunction %ith customer.

S"3 O!1e!: This fourth class of order deals %ith the manufacture of component parts.

?orecasts *iven $y customers! sales orders! and stoc& orders $uffer stoc&s0 are for the finished product.

Sa+1a!1 P!"*ess see:  This form is prepared $y process en*ineerin* and it is the source

of $asic data as to the type of machine to $e used! the time reDuired for processin* and the seDuence of operations in the manufacture of the product. 7outin* and schedulin* of shop orders! as %ell as loadin* of %or&stations in advance of schedulin*! depend on up3to3date standard process sheets $ein* availa$le to the production plannin* and control *roup.

E+gi+ee!i+g S3e*i0i*ai"+s:  Blueprints and $ills of materials are used $y production

 plannin* and control %hen they $ecome a component part of the pac&a*ed instructions issued to the shop throu*h the control office. )ne *ood plannin* procedure is to accumulate all necessary data for a shop order in a sin*le pac&a*e the standard process sheet! the $lueprint! the $ill of material if an assem$ly operation is involved0! the route sheet! and possi$ly the schedule for the production of the order.

R"e See:  This is the form on %hich the route of a shop order is indicated. n practice!

this form is *enerally com$ined %ith one of the other forms in the system. ?or eample! the shop order! the standard process sheet! and the route sheet are often one piece of paper3 usually called the shop order or he manufacturin* order.

J"< Ti*5es: This is the fifth and last type of order in a manufacturin* situation. o$ tic&ets

authori+e the performance of individual operations in the manufacturin* process. ==

Ce+!a)i9e1 P!"1*i"+ P)a++i+g a+1 C"+!")F -entrali+ation or decentrali+ation of 

duties of the production control staff depends upon the desi*n of the production plannin* and control system. n a completely centrali+ed setup! determination of shippin* promises analysis of sales! stoc&! and shop orders preparation of routes! load charts! and schedule charts and dispatchin* of %or& to the shop complete %ith jo$ tic&ets and all other  necessary paper %ould $e accomplished $y a central production plannin* and control unit. n addition! as %or& is completed! a careful analysis of the actual performance %ould $e made! and if corrective action %ere reDuired! it %ould $e initiated $y this *roup.

De*e+!a)i9e1 P!"1*i"+ P)a++i+g a+1 C"+!"):  No matter ho% *eneral the plannin*

may $e under central PP-! the plan must eventually $e developed into a detailed plan on the shop floor. As such Astra is endeavourin* to ma&e each foreman a mana*er of his o%n departmental operation.

Meas!eme+ "0 E00e*i8e+ess: n determinin* the effectiveness of a production plannin*

and control system! Astra has Duite a fe% pro$lems. The &ey criterion mi*ht %ell $e %hether or not shippin* promises are $ein* &ept ; the percenta*e of the order shipped on time. This! ho%ever! %ould not $e a true criterion if ecessive overtime of epeditin* costs %ere involved in *ettin* any of these orders shipped.

=8

Res)s a+1 a+a)7sis "0 e *ase s1ies: To a certain de*ree! production activities are repetitive and often lar*ely predicta$le. No a**re*ated production plan... No eplicit overall control concept... A$sence of priorities in allocatin* production capacities... insta$ility in the production plannin*... a lar*e no of rush orders... uncertainties in the production... fra*mented allocation of authorities and responsi$ilities %ith respect to production and distri$ution.... Personal conflicts and domain discussions $et%een PP- and other ,epts. Hi*h de*ree of de3concentration %ith respect to  plannin* activities.... n practice! ho%ever! 6units solved conflictin* issues $et%een Production and Purchase or PP- $y applyin* a functional hierarchy and not $y some inte*ratin* mechanism $et%een the parties involved. t is noticed that the de*ree of  inte*ration $et%een functional areas in Astra is much lo%er than one %ould epect.

t is interestin* to note that there is necessity for improvin* the overall performance in terms of decreasin* costs! shortenin* delivery times! improvin* delivery relia$ility! Duality and customer service. ?rom this! chan*in* the plannin* and control as %ell as the or*anisational desi*n of the production system should $e re*arded as a potential opportunity to contri$ute to this improvement.

7esults of VSM study %as its on*oin* continual improvement process! most of the actions that are su**ested and implemented a*ainst said product are also applica$le *lo$ally for the ="

 product ran*e that Astra manufactures for different customers. i&e for e.*. one of the cause for more cycle time for full %eldin* %as unor*anised %or&place as such team %or&ed out on ne% layout %hich is not only applica$le for product %hich %as ta&en for case study! said action %as also applica$le for entire ran*e of product that Astra manufactures in3 house.

Fi+1i+gs, I+0e!e+*es a+1 Re*"mme+1ai"+s: Some of the chan*es need to $e initiated for $etter co3ordination! communication! inte*ration! follo%3up action. Meetin* %ith respect to certain predefined points needs to $e eecuted at the start and end of shift on daily $asis %ith shift operators and shift in3char*e! than on daily $asis %ith departmental heads to analyse and resolve day to day issues! and finally %ith functional heads on future *oal/ o$jectives on %ee&ly $asis.

1. Shift Be*innin* G Shift :nd / -han*e Meetin* a. Participants F i. Shift )perators G Shift n char*e  $. Time G ,uration F i. 9314mins c. A*enda F i. Production in last Shift ii. ap in actual Production G plan iii. Pro$lems encountered in the previous shift iv. Production Plan for the net shift v. Availa$le Manpo%er  vi. -han*e )ver reDuirements vii. Preventive Maintenance Plans viii. House Ceepin* i. Any )ther Planned Stoppa*e =@

2. ,aily #or& Mana*ement Meetin* $y ,epartment head a. Participants F i. Shift n char*e ii. PPiii. Maintenance iv. ,ispatch v. Purchase/Stores vi. Juality  $. Time G ,uration F i. 24364mins c. A*enda F i. Productivity evel G rejection status of day $efore ii. ,ayEs Plan considerin*! *aps in plan v/s actual of day $efore iii. ?reDuency G duration of m/c maintenance G their countermeasures iv. ,ispatch plan v. Juality pro$lems/ customer complaints G their counter measures vi. ap Analysis for Production /maintenance/ dispatch /chan*e over time

6. #ee&ly meetin* of ,epartmental Heads a. Participants F i. Shift n char*e ii. PPiii. Maintenance iv. Purchase/Stores v. Juality  $. Time G ,uration F i. =4389mins c. A*enda F i. Productivity in terms of stro&es/minute! stro&es/person! spots per person G efficiency ii. Juality coverin* in process rejection in PPM of the Press shop! ?a$rication shop G Po%der coatin*. Qero ,efects. iii. -ustomer -omplaints 84

iv. ,elivery Performance %.r.t -ustomer schedule v. ,o%ntime due to m/c Brea&do%n vi. A$senteeism vii. )vertime #or&in* viii. Vendor Performance %.r.t Juality G delivery i. -apacity 5tili+ation . #or&place mprovements! 9S Audit results i. Safety3Accidents ii. :mployee developments! :mployee rievances! Trainin* imparted G employee Participation in su**estions iii. mprovements in the Duality system iv. nventories v. -ustomer satisfaction internal/:ternal vi. -ontinual mprovements

n order to reach the *oals set! production should $e made more predicta$le. The proposed remedies areF After the initial Dueue arran*ement in the $e*innin* of production! the Dueue order should only $e reor*ani+ed in one %ell thou*ht control point. n other places prioriti+in* or  shufflin* orders should $e avoided.

Stoc& should $e used in order to level capacity need and provide fast service. nstead of the current practice of havin* lots of %or& in process every%here in production! stoc& should  $e &ept as final stoc& or as $uffer stoc&. Smaller $atches should $e used in order to level capacity need. Small $atches also allo% concurrent processin* and therefore shorten throu*hput time.

The simulation model should $e used for ans%erin* Duestions li&eF #hich one of the alternative points should $e chosen as the Dueue reor*ani+in* point^ Ho% %ell do the alternative schedulin* and Dueuin* lo*ics %or& in this case^ #hat is the effect of the proposed stoc& policies on production^ #hat is the effect of smaller $atch si+es and ho% small can the $atches $e^

81

C"+*)si"+s: The efficiency of Production Plannin* and -ontrol department depends upon the information it *ets from other departments and the accuracy of such information. To  prepare load and schedule chat! it must &no% the preventive maintenance schedule. To *ive realistic delivery date! it must &no% the %or& content of each jo$. PP- %hich are *enerally reDuires the $elo% information. Astra need to have formal departments li&e sales/mar&etin* and su$ department of PP-. 1. Production 1. Juantity to $e manufactured.  pro*ramme. 2. ,elivery date. I+0"!mai"+ Deai)s C"+*e!+i+g

Sales order or )rder Acceptance S"!*e

Sales De3a!me+ "!igi+ai+g i+1i*ae1 I+0"!mai"+

Cind and Duality of material.,ra%in*s/Bill of Material Juantity of material Stoc& -ards reDuired 6. Stoc& on hand and reservations Tool -ard <. ead time reDuired for  procurement. 1. Standard and special toolin*

2. Production 1. materials 2.

,ra%in* -ontrol ,es&  Stores Purchase

6. Toolin*

PP- / Prod

<. Juality Standards

9. )peration Methods.

1. 2. 6. <. 1.

=. Path of Materials.

,imensional reDuirements. ,ra%in*s -ustomerEs feed$ac&  ?inish reDuirements Tolerance reDuirements Hardness desired. Process sheets -apacity charts )perations and their

seDuence. 2. Machine tool for each indicated operation 6. i*s and fitures needed <. Speeds G ?eeds.

1 ist of )perations and their 8. )peration time. SeDuence 2. Alternatives possi$le

,ra%in* -ontrol des& Mar&etin* ,ept

PPPP-

:perience

7oute sheets Plan layout

PP-

#or& Measurement data

,evelopment dept.

". Schedulin* 1. Setup time and standard time for Machine oad G ScheduledP.P.charts each operation ,aily production reports @. Pro*ress of Production /Time tic&et/Perforated slips #or&. 82 1. Startin* and finishin* dates. 1. #or& -ompleted as on date.

Astra need to have $etter control over plannin* %hich is done manually. Because of  comple nature of process transactions AstraEs needs to have inte*rated :7P system to avoid conflicts and hierarchical interferences. Astra *oin* ahead %ith implementation of  :7P module for plannin*! follo%in* performance criteria $y %hich production plannin* and control systems mi*ht $e jud*ed! since all plannin* activity is done usin* %ith data throu*h ecel Astra currently measures only $road $ase delivery commitments for the month. 1. nventory turnover  2. ,elivery lead time 6. Percent of time meetin* delivery promises <. Percent of orders reDuirin* 'splits( $ecause of unavaila$le material. 9. Num$er of epeditors =. Avera*e unit cost.

86

Smma!7: The rapid *ro%th in the num$er of options provided $y manufacturers/suppliers to their  customers has forced Astra to $e flei$le enou*h under hi*h varia$le demand. n addition! the orders should $e shipped %ith hi*her Duality and shorter due3date times.

Astra $ein* $asically jo$ shopper and has lar*e variety of products under um$rella for  different customers! %hich are $ased on customer specifications. There is hi*h variation in demand and %ith lo% volume orderEs! as such Astra needs to operate accordin* to the Ma&e3to3)rder MT)0 strate*y. Astra have to cope %ith unsta$le production schedules and materials mana*ement due to freDuent chan*es in planned production orders! and a lot of   production process inefficiencies as %ell.

As a conseDuence! the Production Plannin* and -ontrol PP-0 $ecomes rather comple and often $ased on inaccurate data the $i* challen*e for Astra to operate on MT) strate*y is to meet customer demand on time. To achieve this o$jective! companies have adopted continuous improvement pro*rams to enhance their manufacturin* process. Ne% manufacturin* principles such lean manufacturin* M0 %hich is under %ay of  implementation same have helped Astra to *reat etend to reali+e %astes in manufacturin* and or*anisation is confident to manufacture on MT) $asis $ecause of the reduced lead time that is achieved even %hen lean implementation is not even half %ay throu*h.

Re0e!e+*es: )hno! Taiichi. Toyota Prodcution systeF $eyond lar*e3scale production. Bertrand! .#.M.! .-. #ortmann and . #ijn*aard! 1@@40 Production -ontrol. A Structural and ,esi*n )riented Approach. :ilon! Samuel. :lements of Production Plannin* and -ontrol! Bom$ay 7o$otics and computer inte*rated manufacturin*

8<