SHRIRAM FOUNDRY LTD.MACHINE SHOP

1. SHRIRAM FOUNDRY LTD.MACHINE SHOP July. 2011

2. TEAM MEMBER:- • Mr.P.S.ACHARI • Mr.P.K.PATIL. • Mr.R.R.NERLEKAR. • 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. ( Rough to finish 44 nos per shift – 1set up s/f & 2 set up finish) 400 nos casting stock at our end & 144 ready for dispatch.Job in production.

4. COMPARATIVE PRODUCTION STATUS PART NAME & NUMBER:- CONMET ROTTER - 10009996 Rough to finish trial success, Casting stock – 406,Ready for dispatch – 104) 2 set up rough & 1set up finish per shift 45 no's

5. COMPARATIVE PRODUCTION STATUS PART NAME & NUMBER:- CONMET HUB 10019727 Spline After removing the setting 50 nos casting received. Casting stock – machined, Ready for dispatch – 27 nos.

6. COMPARATIVE PRODUCTION STATUS PART NAME & NUMBER:- CONMET HUB – 10019716 Spline Component in production

7. COMPARATIVE PRODUCTION STATUS PART NAME & NUMBER:- CONMET HUB – 10019736

8. COMPARATIVE PRODUCTION STATUS PART NAME & NUMBER:- CONMET HUB – 10019759 After removing the setting 74 nos casting received.

9. COMPARATIVE PRODUCTION STATUS PART NAME & NUMBER:- CONMET HUB – 10019815 After removing the setting 170 nos casting received.

10. COMPARATIVE PRODUCTION STATUS PART NAME & NUMBER:- CONMET FRONT HUB – 10020463 – High BHN Productivity increased per shift 22 to 28 nos.

11. COMPARATIVE PRODUCTION STATUS PART NAME & NUMBER:- Pulley 476.0 Casting late received. Job in production

12. COMPARATIVE PRODUCTION STATUS PART NAME & NUMBER:- CLASS PULLEY – 644 800.2 Casting to finish trial success – per shift 21 nos.

13. COMPARATIVE PRODUCTION STATUS PART NAME & NUMBER:- Pulley 642.0

14. COMPARATIVE PRODUCTION STATUS PART NAME & NUMBER:- Pulley 413.0 96 nos ready for dispatch

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

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

17. COMPARATIVE PRODUCTION STATUS PART NAME & NUMBER:- Pulley 771.0 48 nos Ready for dispatch. Casting to finish trial success – per shift 21 nos.

18. COMPARATIVE PRODUCTION STATUS PART NAME & NUMBER:- Pulley 189.0

19. COMPARATIVE PRODUCTION STATUS PART NAME & NUMBER:- Pulley 190.0

20. COMPARATIVE PRODUCTION STATUS PART NAME & NUMBER:- Nabe 1975457 Component in production.

21. COST DETAILS(ITEMWISE) PART NAME & NUMBER:- CONMET HUB 1946 For mnt variable bearing cost is 36020 RS,deduct this amount then cost – 23.16 RS. Note:- To calculate labor cost take 35% overhead on Basic+DA

22. COST DETAILS(ITEMWISE) PART NAME & NUMBER:- CONMET HUB 20463 SOMT 09T306 DT IC908 brokan Rs. 14954 Tool Cost RS. -68.39 Note:- To calculate labor cost take 35% overhead on Basic+DA

23. COST DETAILS(ITEMWISE) PART NAME & NUMBER:- CONMET HUB 9716 - Spline Note:- To calculate labor cost take 35% overhead on Basic+DA

24. COST DETAILS(ITEMWISE) PART NAME & NUMBER:- CONMET HUB 9727 - Spline Total Production 50 nos. Ø 17 Carbide Drill Tool Cost Rs. 54.84 Note:- To calculate labor cost take 35% overhead on Basic+DA

25. COST DETAILS(ITEMWISE) PART NAME & NUMBER:-CONMET ROTTER 9996` Casting to Finish For mnt variable bearing cost is 36020 RS,deduct this amount then cost – 23.16 RS. Note:- To calculate labor cost take 35% overhead on Basic+DA

26. COST DETAILS(ITEMWISE) PART NAME & NUMBER:- CONMET HUB – 9815 Note:- To calculate labor cost take 35% overhead on Basic+DA

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

28. COST DETAILS(ITEMWISE) PART NAME & NUMBER:- CONMET HUB – 9736 Note:- To calculate labor cost take 35% overhead on Basic+DA

29. COST DETAILS(ITEMWISE) PART NAME & NUMBER:- CONMET HUB – NEB HUB 5457 TCLNR -2525 HOLDER RS-1500 TOOL COST RS.15.55 Only Truning Note:- To calculate labor cost take 35% overhead on Basic+DA

30. COST DETAILS(ITEMWISE) PART NAME & NUMBER:- CONMET HUB – Housing 619 Note:- To calculate labor cost take 35% overhead on Basic+DA

31. COST DETAILS(ITEMWISE) PART NAME & NUMBER:- Pulley 771 TTER &A4 SMR Holder Rs. 11947 Tool Cost Rs. 144.74 Casting to Finish TTER -2525 A4SML 2525 HOLDERRs. 9000 Tool Cost Rs. 244.96 TTER &A4 SMR Holder Rs. 11947 Tool Cost Rs. 184.09 Note:- To calculate labor cost take 35% overhead on Basic+DA

32. COST DETAILS(ITEMWISE) PART NAME & NUMBER:- Pulley 642 For mnt variable bearing cost is 36020 RS,deduct this amount then cost – 23.16 RS. Note:- To calculate labor cost take 35% overhead on Basic+DA

33. COST DETAILS(ITEMWISE) PART NAME & NUMBER:- Pulley 266 A 4 SMR Holder 3 Nos. Rs. 26945/- Tool Cost Rs. – 104.63 Note:- To calculate labor cost take 35% overhead on Basic+DA

34. COST DETAILS(ITEMWISE) PART NAME & NUMBER:- Pulley 145.0 Tool Cost Rs. 106.31 For mnt variable bearing cost is 36020 RS,deduct this amount then cost – 23.16 RS. Note:- To calculate labor cost take 35% overhead on Basic+DA

35. COST DETAILS(ITEMWISE) PART NAME & NUMBER:- Pulley 413 Note:- To calculate labor cost take 35% overhead on Basic+DA

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

37. COST DETAILS(ITEMWISE) PART NAME & NUMBER:- Pulley 189-190 4ASMR -2525 3 HOLDER & Ø11.1 CARBIDE DRILL RS. 17286 TOOL COST RS. 34.89 For mnt variable bearing cost is 36020 RS,deduct this amount then cost – 23.16 RS. Note:- To calculate labor cost take 35% overhead on Basic+DA

38. COST DETAILS(ITEMWISE) PART NAME & NUMBER:- Pulley 800.2 WTJNL-2525, A4SMR 2525 HOLDER RS. 6200 TOOL COSTRS. 205.86 Note:- To calculate labor cost take 35% overhead on Basic+DA

39. MACHINE UTILISATION IN % (CNC)

40. MACHINE UTILISATION IN % (CNC)

41. MACHINE UTILISATION IN % (CNC)

42. MACHINE UTILISATION IN % (CNC)

43. Majour Losess Details (Whole shop)

44. REJECTION DETAILS(ITEMWISE IN %) Part Name:- CONMET HUB 1946 PRD-838 NOS, IN H MR 4.42%( 37) PRD-427 NOS, IN H MR-1.87%( 8) PRD-461 NOS, IN H MR-1.52%( 7) SF MR- 0.22% (1) ***ACTION ON MAJOR REJECTION CAUSES

45. REJECTION DETAILS(ITEMWISE IN %) Part Name:- CONMET ROTTER 9996 PRD- 700 NOS, SF MR 3.57% (25 ), IN H MR1.00% (7 ) PRD- 1285 NOS, SF MR 1.25% (16 ), IN H MR1.48% (19 ) PRD- 637 NOS, SF MR 1.73% (11 ), IN H MR 0.78% (5 ) ***ACTION ON MAJOR REJECTION CAUSES

46. REJECTION DETAILS(ITEMWISE IN %) Part Name:- CONMET 10020463 PRD- 634 NOS,, IN H MR 5.04%(32), SF MR 1.57 % ( 10) PRD-394 NOS,, IN H MR 3.05%(12), ***ACTION ON MAJOR REJECTION CAUSES

47. REJECTION DETAILS(ITEMWISE IN %) Part Name:- CONMET 10009727 PRD- 214 NOS,, IN H MR 7.47 %(16) PRD- 347 NOS,, IN H MR 1.15 %(4) ***ACTION ON MAJOR REJECTION CAUSES

48. REJECTION DETAILS(ITEMWISE IN %) Part Name:- CONMET 10019716 PRD- 88NOS,, IN H MR 1.14%(1), ***ACTION ON MAJOR REJECTION CAUSES

49. REJECTION DETAILS(ITEMWISE IN %) Part Name:- CONMET 10019815 PRD- 237NOS,, IN H MR 8.44%(20), PRD- 367NOS,, IN H MR 6.54%(24), ***ACTION ON MAJOR REJECTION CAUSES

50. REJECTION DETAILS(ITEMWISE IN %) Part Name:- CONMET 10019736 PRD- 118NOS,, IN H MR 5.08%(6), PRD- 383NOS,, IN H MR 1.57%(6), ***ACTION ON MAJOR REJECTION CAUSES