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SHRIRAM FOUNDRY LTD.MACHINE SHOP

SHRIRAM FOUNDRY LTD.MACHINE SHOP. JAN . 2012. TEAM MEMBER:-. Mr. R.R.NERLEKAR.(I/C Pulley line) Mr.S.R.HIREMANI.(I/C Hub Line) Mr.S.M.Patil ( I/C F.A.Support line) Mr.G.M.SHAIKH (Tooling) Mr.Rafiq.Naikawadi ( Quality) Mr.P.P.Patil ( System). COMPARATIVE PRODUCTION STATUS.

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SHRIRAM FOUNDRY LTD.MACHINE SHOP

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  1. SHRIRAM FOUNDRY LTD.MACHINE SHOP JAN . 2012

  2. TEAM MEMBER:- • Mr. R.R.NERLEKAR.(I/C Pulley line) • Mr.S.R.HIREMANI.(I/C Hub Line) • Mr.S.M.Patil ( I/C F.A.Support line) • Mr.G.M.SHAIKH (Tooling) • Mr.Rafiq.Naikawadi ( Quality) • Mr.P.P.Patil ( System)

  3. COMPARATIVE PRODUCTION STATUS PART NAME & NUMBER:- Pulley 266.0 Component under production

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

  5. COMPARATIVE PRODUCTION STATUS PART NAME & NUMBER:- Pulley 476.0 Component under production

  6. COMPARATIVE PRODUCTION STATUS PART NAME & NUMBER:- Pulley 800.2(Double decker) Component under production

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

  8. COMPARATIVE PRODUCTION STATUS PART NAME & NUMBER:- Pulley 771(Double decker) Claas not need this component from next month because drawing has chenged.Whater stock will be dispatch in Feb 12.

  9. COMPARATIVE PRODUCTION STATUS PART NAME & NUMBER:- CONMET FRONT HUB - 10009730 Component under production

  10. COMPARATIVE PRODUCTION STATUS PART NAME & NUMBER:- CONMET ROTTER - 10009996 Machine utilized for nut plate..

  11. COMPARATIVE PRODUCTION STATUS PART NAME & NUMBER:- CONMET HUB – 10019828 (335 SERIES) Component under production

  12. COMPARATIVE PRODUCTION STATUS PART NAME & NUMBER:- CONMET HUB – 10019717 (Spline Hub)

  13. COMPARATIVE PRODUCTION STATUS PART NAME & NUMBER:- CONMET HUB – 10019817 (ADBHub)

  14. COMPARATIVE PRODUCTION STATUS PART NAME & NUMBER:- CUMMINS – Nut Plate(400/100) No schedule

  15. COMPARATIVE PRODUCTION STATUS PART NAME & NUMBER:- Front Axle support 1800 nos SRFM &1200 nos job 1st & 2nd set up done at kol axle& Alka engg,3000 nos all opn except HMC at SRF machine shop only.

  16. COMPARATIVE PRODUCTION STATUS PART NAME & NUMBER:- Nabe 1975457 108 nos ready for dispatch customer informed dispatch not required.

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

  18. COST DETAILS(ITEMWISE) PART NAME & NUMBER:- CONMET HUB 9730 Note:- To calculate labor cost take 35% overhead on Basic+DA

  19. COST DETAILS(ITEMWISE) PART NAME & NUMBER:- CONMET HUB 9717 WTJNL-2525 HOLDER RS. 1200/- Tool Cost Rs. 62.49 Note:- To calculate labor cost take 35% overhead on Basic+DA

  20. COST DETAILS(ITEMWISE) PART NAME & NUMBER:- CONMET HUB 9828 Note:- To calculate labor cost take 35% overhead on Basic+DA

  21. COST DETAILS(ITEMWISE) PART NAME & NUMBER:- CONMET HUB 9817 Carbide Drill Ø 14 Rs. 6500/- Tool Cost Rs. 50.11 Note:- To calculate labor cost take 35% overhead on Basic+DA

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

  23. COST DETAILS(ITEMWISE) PART NAME & NUMBER:- CUMMINS – NUTPLATE (100/400) No Sehedule 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:- CONMET HUB – NEB HUB 5457 Note:- To calculate labor cost take 35% overhead on Basic+DA

  26. COST DETAILS(ITEMWISE) PART NAME & NUMBER:- Pulley 189 /190 Note:- To calculate labor cost take 35% overhead on Basic+DA

  27. COST DETAILS(ITEMWISE) PART NAME & NUMBER:- Pulley 145 Note:- To calculate labor cost take 35% overhead on Basic+DA

  28. COST DETAILS(ITEMWISE) PART NAME & NUMBER:- Pulley 800.2 Hard Casting -TTER -2525 Holder 2nos. A4 SMR Holder 1 nos Extra Ins. A4G3mm 10 nos. Total Rs.20947/- Tool Cost Rs. 311.62 Rough grooving resharp insert stock complited,new insert under trial cost planned 230 RS per job. Note:- To calculate labor cost take 35% overhead on Basic+DA

  29. COST DETAILS(ITEMWISE) PART NAME & NUMBER:- Pulley 771 Hard Casting -TTER /L -2525 Holder 5 nos./ A4SMR -2525 Holder 2 nos./ TDT 4 INS. Extra. 14nos. Total Rs. 42327 Tool Cost 303.18 Rough grooving resharp insert stock complited,new insert under trial cost planned 230 RS per job. 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 266 Hard Casting- A4G & TDT INS.Extra 14 nos. Total Rs. 11637 Tool Cost Rs. 135.71 Note:- To calculate labor cost take 35% overhead on Basic+DA

  32. COST DETAILS(ITEMWISE) PART NAME & NUMBER:- Front Axle Support ( JD FAS ) Only Labour Cost = 50.24per job, Including staff – 79.00,including admistrative(store,CMM op + helper,mnt,genaral staff) cost -113.11. Ø 32 Burnishing Tool/QCDA4 Adapter/Milling Cutter/TDC 17.1 /Ø12.2 Carbide Drill Total Rs. 22725 Tool Cost Rs. -85.61 Note:- To calculate labor cost take 35% overhead on Basic+DA

  33. MACHINE UTILISATION IN % (VTL – Jan 2012) Pulley Pulley

  34. MACHINE UTILISATION IN % (CNC – Jan 12) HUB Pulley

  35. MACHINE UTILISATION IN % (CNC – Jan 12) ROTTER/NUTPLATE Pulley

  36. MACHINE UTILISATION IN % (VTL – VMC – Jan 12) HUB HUB

  37. MACHINE UTILISATION IN % (VTL – VMC –DEC 11) JD Line

  38. Majour Losess Details (Whole shop)

  39. REJECTION DETAILS(ITEMWISE IN %) Part Name:- CONMET 10019730 PRD- 191 NOS,, PRD- 184 NOS,, IN H MR 1.09% (2) ***ACTION ON MAJOR REJECTION CAUSES

  40. REJECTION DETAILS(ITEMWISE IN %) Part Name:- CONMET HUB 9717 PRD- 179 NOS, IN H MR 2.23% (4), ) (IN THIS REJECTION 3 NOS EJECTED FOR HOLE 24.86 TOOL MARK) SF MR 1.68 % (3) ***ACTION ON MAJOR REJECTION CAUSES

  41. REJECTION DETAILS(ITEMWISE IN %) Part Name:- CONMET HUB 9817 PRD- 987 NOS, IN H MR- 3.04% (30) –( IN THIS 10JOBS ARE REJECT IN DIA 160.248 O/S , 4 JOBS IN 5/16 TAPPING WALLSHIFT foundry problem & 3 JOBS IN 24.86 OUT CUT) SF MR - 1.32 %(13) –( IN THIS 6JOBS ARE REJECT IN DIA 139. TOOL MARK , 4 JOBS IN DIA 152. TOOL MARK) PRD- 327 NOS, IN H MR-4.89% (16) –( IN THIS 5JOBS ARE REJECT IN HOLE 24.86 TOOL MARK & 3JOBS IN 5/8 WALLSHIFT) SF MR – 1.53%( 5) ***ACTION ON MAJOR REJECTION CAUSES

  42. REJECTION DETAILS(ITEMWISE IN %) Part Name:- CONMET HUB 9828 PRD- 159 NOS, IN H MR- 3.14% (5) ***ACTION ON MAJOR REJECTION CAUSES

  43. REJECTION DETAILS(ITEMWISE IN %) Part Name:- CONMET ROTTER 9996 PRD- 1267 NOS, IN H MR 0.63% (8 ) SF MR 0.79% (10 ) ( 8 JOBS REJECTED IN HOLE 13.47 WALLSHIFT) PRD- 610 NOS, IN H MR 1.64% (10) (IN THIS REJECTION 5 JOBS REJECTED IN HOLE 13.47 WALLSHIFT) SF MR 0.33% (2) PRD- 432 NOS, IN H MR 2.31% (10 ) ( IN THIS REJECTION 6JOB REJECTED IN HOLE 13.47 WALL SHIFT) ***ACTION ON MAJOR REJECTION CAUSES

  44. REJECTION DETAILS(ITEMWISE IN %) Part Name:- PULLEY 800.2 PRD- 68NOS,, PRD-290 NOS,, IN H MR 1.03 % (3), ***ACTION ON MAJOR REJECTION CAUSES

  45. REJECTION DETAILS(ITEMWISE IN %) Part Name:- PULLEY 476 PRD-419 NOS,, IN H MR 0.24 % (1), PRD- 379NOS, ***ACTION ON MAJOR REJECTION CAUSES

  46. REJECTION DETAILS(ITEMWISE IN %) Part Name:- Pulley 190.0 PRD- 382NOS, ***ACTION ON MAJOR REJECTION CAUSES

  47. REJECTION DETAILS(ITEMWISE IN %) Part Name:- ECC HUB 790/791/858.1/859.1 PRD- 684NOS,, IN H MR 5.40 %(37) SF MR 0.29 % (2) (36 NOS OF HUB 790.1 rejected in broaching angle fire.) PRD- 884 NOS,, SF MR 3.73% ( 33) REJECTED BY Padmavati Engg. PRD- 972NOS,, IN H MR 0.20 %(2) SF MR 0.10 % (1) ***ACTION ON MAJOR REJECTION CAUSES

  48. REJECTION DETAILS(ITEMWISE IN %) Part Name:- Pulley 266 PRD- 231 NOS, IH MR – 0.43 %(1). PRD- 78 NOS, IH MR – 1.28 %(1). ***ACTION ON MAJOR REJECTION CAUSES

  49. REJECTION DETAILS(ITEMWISE IN %) Part Name:- Pulley 771 PRD- 340 NOS, PRD- 334 NOS, IH MR – 0.30 %(1). ***ACTION ON MAJOR REJECTION CAUSES

  50. REJECTION DETAILS(ITEMWISE IN %) Part Name:- Pulley 145.3 PRD- 372 NOS, PRD- 408 NOS, IH MR – 0.49 %(2). ***ACTION ON MAJOR REJECTION CAUSES

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