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SHRIRAM FOUNDRY LTD.MACHINE SHOP

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

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SHRIRAM FOUNDRY LTD.MACHINE SHOP

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  1. SHRIRAM FOUNDRY LTD.MACHINE SHOP Sept. 2011

  2. TEAM MEMBER:- • Mr.P.K.PATIL • Mr. R.R.NERLEKAR. • Mr.S.R.HIREMANI. • Mr.G.M.SHAIKH • Mr.S.B.PATIL

  3. COMPARATIVE PRODUCTION STATUS PART NAME & NUMBER:- CONMET FRONT HUB - 10001946 ( Rough to finish Component in production. 400 nos casting stock at our end & 144 ready for dispatch.Job in production.

  4. COMPARATIVE PRODUCTION STATUS PART NAME & NUMBER:- CONMET ROTTER - 10009996

  5. COMPARATIVE PRODUCTION STATUS PART NAME & NUMBER:- CONMET HUB – 10019717 Spline Total 62 nos CR rejected at 5/8 tapped hole.After remove the setting casting received.

  6. COMPARATIVE PRODUCTION STATUS PART NAME & NUMBER:- CONMET HUB – 10013811

  7. COMPARATIVE PRODUCTION STATUS PART NAME & NUMBER:- CONMET HUB – 10019759 96 nos ready for dispatch.

  8. COMPARATIVE PRODUCTION STATUS PART NAME & NUMBER:- CONMET FRONT HUB – 10003845

  9. COMPARATIVE PRODUCTION STATUS PART NAME & NUMBER:- Pulley 476.0 Casting received delay component in production. Dispatch plan on 7th Oct

  10. COMPARATIVE PRODUCTION STATUS PART NAME & NUMBER:- Pulley 413.0

  11. COMPARATIVE PRODUCTION STATUS PART NAME & NUMBER:- Pulley 266.0

  12. COMPARATIVE PRODUCTION STATUS PART NAME & NUMBER:- Pulley 800.2 CR 43 nos, MR 05 nos.

  13. COMPARATIVE PRODUCTION STATUS PART NAME & NUMBER:- Pulley 190.0 Casting received delay component in production. Dispatch plan –on 4th Oct

  14. COMPARATIVE PRODUCTION STATUS PART NAME & NUMBER:- Pulley 145.0

  15. COMPARATIVE PRODUCTION STATUS PART NAME & NUMBER:- Nabe 2222845

  16. COMPARATIVE PRODUCTION STATUS PART NAME & NUMBER:- Nabe 1975457 Turning completed & pending for drilling..

  17. COST DETAILS(ITEMWISE) PART NAME & NUMBER:- CONMET HUB 1946 6.5x200 TS DRILL 04 NOS. RS 2600/- TOOL COST RS. 41.24 Note:- To calculate labor cost take 35% overhead on Basic+DA

  18. COST DETAILS(ITEMWISE) PART NAME & NUMBER:-CONMET ROTTER 9996` Casting to Finish Note:- To calculate labor cost take 35% overhead on Basic+DA

  19. COST DETAILS(ITEMWISE) PART NAME & NUMBER:- CONMET HUB – 9717 Note:- To calculate labor cost take 35% overhead on Basic+DA

  20. COST DETAILS(ITEMWISE) PART NAME & NUMBER:- CONMET HUB – 9759 Ø16.570 carbide drill Rs. 6500 /- 01 nos Tool Cost Rs. 45.20 Ø24 U Drill 1 nos. & SHR/450 4 nos Total Rs. 24925 Tool Cost Rs.-58.90 Note:- To calculate labor cost take 35% overhead on Basic+DA

  21. COST DETAILS(ITEMWISE) PART NAME & NUMBER:- CONMET HUB – 3845 SRDCL -2525 HOLDR RS. 1500 & Ø 10.90 CARBIDE DRILL RS. 2500/ TORAL RS. 4000/- TOOL COST RS. 40.76 Note:- To calculate labor cost take 35% overhead on Basic+DA

  22. COST DETAILS(ITEMWISE) PART NAME & NUMBER:- CONMET HUB – 3811 Note:- To calculate labor cost take 35% overhead on Basic+DA

  23. COST DETAILS(ITEMWISE) PART NAME & NUMBER:- CONMET HUB – NEB HUB 5457 Note:- To calculate labor cost take 35% overhead on Basic+DA

  24. COST DETAILS(ITEMWISE) PART NAME & NUMBER:- CONMET HUB – NEB HUB 2222845 Note:- To calculate labor cost take 35% overhead on Basic+DA

  25. COST DETAILS(ITEMWISE) PART NAME & NUMBER:- Pulley 642 Ø13 carbide Drill Rs. 5240 Tool Cost Rs. 40.61 Note:- To calculate labor cost take 35% overhead on Basic+DA

  26. COST DETAILS(ITEMWISE) PART NAME & NUMBER:- Pulley 266 Total Production 10 nos. So Insert Life next month SVVNN-2525 Holder 1 Nos. Rs. 4500/- Tool Cost Rs. – 101.35 Note:- To calculate labor cost take 35% overhead on Basic+DA

  27. COST DETAILS(ITEMWISE) PART NAME & NUMBER:- Pulley 413 Rough grooving resharp insert stock complited,new insert under trial cost planned 175 RS per job. A4 SMR Holder Rs. 4500/ Casting Problem CNMA 120412 Insert Breakage Tool Cost Rs. 208.00 Casting Problem CNMA 120412 TT 7310 Insert Breakage Tool Cost Rs. – 150.35 Note:- To calculate labor cost take 35% overhead on Basic+DA

  28. COST DETAILS(ITEMWISE) PART NAME & NUMBER:- Pulley 189-190 4ASMR -2525, 1 HOLDER & Ø11.1 CARBIDE DRILL RS. 8000 TOOL COST RS. 34.89 Note:- To calculate labor cost take 35% overhead on Basic+DA

  29. COST DETAILS(ITEMWISE) PART NAME & NUMBER:- Pulley 145 Rough grooving resharp insert stock complited,new insert under trial cost planned RS 145 per job. 4ASMR -2525, HOLDER 3 nos Rs. 13500 TOOL COST RS. 185.72 Note:- To calculate labor cost take 35% overhead on Basic+DA

  30. COST DETAILS(ITEMWISE) PART NAME & NUMBER:- Pulley 476 Note:- To calculate labor cost take 35% overhead on Basic+DA

  31. COST DETAILS(ITEMWISE) PART NAME & NUMBER:- Pulley 800.2 Rough grooving resharp insert stock complited,new insert under trial cost planned 230 RS per job. TDT 4 E .04 K-10 Insert New Insert & TTER Holder 3 nos / A4SMR Holder 1 nos Tool Cost Rs. 422.88 Note:- To calculate labor cost take 35% overhead on Basic+DA

  32. MACHINE UTILISATION IN % (CNC)

  33. MACHINE UTILISATION IN % (CNC)

  34. MACHINE UTILISATION IN % (CNC)

  35. MACHINE UTILISATION IN % (CNC)

  36. Majour Losess Details (Whole shop)

  37. REJECTION DETAILS(ITEMWISE IN %) Part Name:- CONMET HUB 1946 PRD-931 NOS, IN H MR-2.69%( 25) PRD-461 NOS, IN H MR-1.52%( 7) SF MR- 0.22% (1) PRD-284 NOS, IN H MR 1.06%( 3) SF MR 0.35% ( 1) ***ACTION ON MAJOR REJECTION CAUSES

  38. REJECTION DETAILS(ITEMWISE IN %) Part Name:- CONMET ROTTER 9996 PRD- 813 NOS, IN H MR 5.29% (43 ) Due to improper fettling – 10 nos,Due opt neg at spot face,Wall shift 5 nos. PRD- 1222 NOS, IN H MR 2.86% (35 ) PRD- 1285 NOS, SF MR 1.25% (16 ), IN H MR1.48% (19 ) ***ACTION ON MAJOR REJECTION CAUSES

  39. REJECTION DETAILS(ITEMWISE IN %) Part Name:- CONMET HUB 3845 PRD-626 NOS, IN H MR 3.67% ( 23) SF MR 0.16% (1) PRD- 680 NOS, IN H MR 2.21% ( 15),due to wall shift 3 nos,damage 2 nos. ***ACTION ON MAJOR REJECTION CAUSES

  40. REJECTION DETAILS(ITEMWISE IN %) Part Name:- CONMET 10003811 PRD- 198 NOS,, IN H MR 3.03%(6), ***ACTION ON MAJOR REJECTION CAUSES

  41. REJECTION DETAILS(ITEMWISE IN %) Part Name:- CONMET 10009717 PRD- 256 NOS,, IN H MR 2.73 %(7) ***ACTION ON MAJOR REJECTION CAUSES

  42. REJECTION DETAILS(ITEMWISE IN %) Part Name:- CONMET 10009759 PRD-499NOS,, IN H MR 9.02%(45), PRD- 672NOS,, IN H MR 0.89%(6), SF MR 0.60%( 4) PRD- 416 NOS,, IN H MR 1.44%(6), ***ACTION ON MAJOR REJECTION CAUSES

  43. REJECTION DETAILS(ITEMWISE IN %) Part Name:- PULLEY 800.2 PRD- 213 NOS,, IN H MR 8.92 %(19), SF MR 0.47%(1) PRD- 312NOS,, IN H MR 0.96%(3), ***ACTION ON MAJOR REJECTION CAUSES

  44. REJECTION DETAILS(ITEMWISE IN %) Part Name:- Pulley 413 PRD- 185 NOS IN H MR 3.24 %(6) . PRD- 118 NOS IN H MR 0.85 %(1) . PRD- 123 NOS IN H MR 0.81 %(1) . ***ACTION ON MAJOR REJECTION CAUSES

  45. REJECTION DETAILS(ITEMWISE IN %) Part Name:- PULLEY 266.1 14.63 %(12),Due PRD- 82NOS,, IN H MR to improper clamping 3 nos,size variation problem 6 nos. PRD- 114 NOS,, IN H MR 4.39 %(5), PRD- 88NOS,, IN H MR 14.77 %(13), SF MR 1.14%(1) ***ACTION ON MAJOR REJECTION CAUSES

  46. REJECTION DETAILS(ITEMWISE IN %) Part Name:- Pulley 476 PRD- 480NOS, I H MR 1.04% (5) SF MR 0.21% (1) PRD- 297 NOS, I H MR 0.34% (1) ***ACTION ON MAJOR REJECTION CAUSES

  47. REJECTION DETAILS(ITEMWISE IN %) Part Name:- Pulley 190 PRD-169NOS, PRD- 371NOS,, IN H MR 0.27 %(1) ***ACTION ON MAJOR REJECTION CAUSES

  48. REJECTION DETAILS(ITEMWISE IN %) Part Name:- ECC HUB 790/791/858.1/859.1 PRD- 422 NOS,, IN H MR 1.66 %(7) SF MR 2.61% ( 11) PRD- 941NOS,, IN H MR 3.93 %(37) SF MR 1.28 % (12) (34 NOS OF HUB 858.1 & 3 Nos of Hub 791.1 rejected due to machine trial in sletting PRD- 1129NOS, IN H MR 0.62 %(7) SF MR 1.06% (12) ***ACTION ON MAJOR REJECTION CAUSES

  49. REJECTION DETAILS(ITEMWISE IN %) Part Name:- Nabe Hub 2222845 /Nabe hub 5457 PRD- 289NOS, IN H MR 3.11 %(4) SF MR 1.38 % (10) PRD-208NOS, IN H MR 1.44 %(3) SF MR 0.96%(2) PRD-266NOS,, IN H MR 2.63 %(7) ***ACTION ON MAJOR REJECTION CAUSES

  50. OVERALL REJECTION (All Parts) Conmet – 1 nos Porosity at flange face,800.2 pulley circlief groove problem. PRD- 6198 IH MR- 3.22% SF MR 0.58% PRD- 6602 IH MR- 2.36% SF MR- 0.44% PRD- 6472 IH MR- 2.16% SF MR 0.22% 2 JOBS FOUND OVERSIZED FOR PILOT DIA. 219.760

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