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WELCOME TO Zanvar Group of industries (Established – 1982)

WELCOME TO Zanvar Group of industries (Established – 1982). GROUP COMPANIES (FOUNDRY DIVISION). SHRIRAM FOUNDRY LTD. – TS:16949 Present Production Capacity – 1000 Mts./month Proposed Capacity from Aug. 11 1500 Mts./Month Total manpower utilize – 510 nos

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WELCOME TO Zanvar Group of industries (Established – 1982)

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  1. WELCOME TOZanvar Group of industries(Established – 1982)

  2. GROUP COMPANIES(FOUNDRY DIVISION) SHRIRAM FOUNDRY LTD. – TS:16949 Present Production Capacity – 1000 Mts./month Proposed Capacity from Aug. 11 1500 Mts./Month Total manpower utilize – 510 nos ASHTA LINERS PVT. LTD.- TS : 1694 1200 Mts./month S.J.IRON & STEELS PVT. LTD. TS:16949 - 1200 Mts./month 3000 Mts./month KASTURI FOUNDRY PVT. LTD. TS:16949 SHRIRAM FOUNDRY LTD. UTTRAKHAND 1300 Mts./month Present Total melting Capacity-6200 Mts./Month. Proposed total melting capacity up to Dec11- 9500Mts/ months

  3. GROUP COMPANIES(MACHINING DIVISION) • ED STEELS PVT. LTD. • ALKA ENGINEERING WORKS. • ZANVAR ENGINEERING EXPORTS. • RSZ INDUSTRIES. • ACCURATE ENGG. WORKS. • NEETA ENGG. WORKS. • KOLHAPUR AXLE PVT. LTD. • SACHIN INDUSTRIES. • VISION ENGINEERING.

  4. OUR ESTEEMED CUSTOMERS(DOMESTIC) TATA MOTORS LTD. – PUNE. JOHN DEERE EQUIP. PVT. LTD.– PUNE. MAHINDRA & MAHINDRA LTD. – NAGPUR. CUMMINS INDIA LTD. – PUNE. ESCORTS LIMITED – FARIDABAD. CARRARO INDIA LTD.- PUNE. KIRLOSKAR OIL ENGINES LTD. – PUNE. CLAAS INDIA LTD. – FARIDABAD. TACO HENDRICKSON. – PUNE. WABCO – CHENNAI.

  5. OUR ESTEEMED CUSTOMERS(OVERSEAS) CONSOLIDATED METCO INC.–USA MEXICO. INTERNATIONAL TRUCK & ENG. – USA. CARRARO SPA.- ITALY, POLAND. CLASS. – GERMANY. JOHN DEERE – FRANCE,MEXICO. OERLIKON - FAIRFIELD – USA. KNORR-BREMSE. – FRANCE. . CUMMINS IPO, RMEP USA & DAVENTRY,UK.

  6. PRODUCTS Total No. of Components – 300 Nos. Weighing from 1 Kg. – 150 Kg. • BRAKE DRUMS • (10 VARIANTS) • BRAKE HUBS • (30 VARIANTS) • VENTILATED BRAKE DISCS/ROTORS (C.G. Iron) (7 VARIANTS)

  7. PRODUCTS • FLYWHEELS / FLY. HGS. • HYD.LIFT HOUSING

  8. PRODUCTS • TRUMPET HSG. • BRACKETS / SUPPORTS

  9. PRODUCTS • TRACTOR TRANSMISSIONS • COVERS

  10. PRODUCTS PULLEY (12 VARIANTS) SPINDLE HOUSINGS /

  11. PRODUCTS • CYLINDER BLOCK • POST BACKHOE SWING

  12. PRODUCTS • BED PLATE • CRANK CASE (10 VARIANTS)

  13. SHRIRAM FOUNDRY LTD. QUALITY CIRCLE ACIVITY. IMPROVEMENT IN PRODUCTION. PROJECT START DATE – 01 MAY 2011 MEETING ON EVERY SUNDAY 3.00 TO 5.00 PM

  14. GROUP FORMATION & SELECTION OF PROJECT. • GROUP NAME – SHRIRAM GROUP. • CO-ORDINATOR – Mr. B.K.JADHAV (PROD. MGR.) • FACILITATOR – Mr. V.M.GAVAD (PROD. I/C) • TEAM LEADER – Mr. A.A. SOLANKURE ( MELTING I/C) • TEAM MEMBERS – 1) Mr. A.L. MALVE ( DESINE & DEVP.) 2) Mr. S.S. KULKARNI (MENT. I/C) 3) Mr. S.V. VATHARKAR ( CORE SHOP I/C) 4)Mr. S.R.POSUGADE (MOULDING SHIFT I/C) 5)Mr. S.N. GARANDE (MOULDING SHIFT I/C) 6)Mr. S.N.YADAV (MELTING SHIFT I/C) MEETING DAY – WEEKLY (SUNDAY) SELECTION OF PROJECT PRODUCTION IMPROVEMENT

  15. DATA COLLECTION • PRODUCTION DATA OF PREVIOUS THREE MONTHS VERIFIED BY ALL QUALITY CIRCLE MEMBERS AFTER VERIFICATION AROUND 1 TO 3 M.TON / DAY LESS PRODUCTION OBSERVED. Production losses in m.ton month of MARCH 2011

  16. Production losses in M.ton month of APRIL 2011

  17. Production losses in M.TON month of MAY 2011

  18. Production data Analysis of 3 month. • Values are in M.ton.

  19. DATA VERIFICATION & ACTION After 3 months data verification following major causes observed to production losses. Electrical problem Avg.36.29 M.Ton loss/ Month Transformer changed Mechanical problem Avg.18.0 M.Ton loss/ Month Action is in process. Core shortage problem Avg. 9.33M.Ton loss/ Month ( Shell core 3.31 M.ton / Month) ( Cold box 6.02 M.ton / Month) Other problem Avg. 4.05 M.Ton loss/ Month Pattern problem Avg. 2.83 M.Ton loss/ Month Raw material problem Avg. 1.0 M.Ton loss/ Month Action- Electrical and mechanical reasons we are taking actions like sand plant reconstruction & Auto line. It is huge investment & long time. For Core Shortage we will take immediately action.

  20. ACTION ON ROOT CAUSE FOR CORE SHORTAGE • Core to be prepared by sub contractor due to less man power in house. TARGET – FROM JULY FIRST WEEK. • Core storage away for molding work station space to be prepared near by work station. Extra man power utilize for core transporting TARGET - AUGAST FIRST WEEK. • Heavy Core box lifting arrangement to be provide. Extra manpower & time engaged for lifting core box. TARGET – JUNE FIRST WEEK. • Set wise core for particular item to be paint and drying accordingly. TARGET – IMMEDIATE. Core productivity to be increase by reduction in cycle time.

  21. CrankcaseCore production data analysis We have analysis core making cycle time for Wabco Crankcase 911 906 0176 and Knorr bremse crankcase 2969. Crankcase 0176 present cycle time is 9.08minutes / shoot (2core) and 76 no’s core / shift. Crankcase 2969 present cycle time is 6.30 minutes/ shoot (3 core) and 130 no’score / shift. Action:- By providing additional coils cycle time will reduce by 30%. Cost will invest For 0176 Crankcase Present curing time 300 sec = 4 coil. (2kw) . 75 sec Per coil. With adding 2 additional coils curing time will reduced (75x2)= 150sec. For 2969 Crankcase Present curing time 240 sec = 4 coil. (2kw) . 60 sec Per coil. With adding 1 additional coil curing time will reduced By 60 sec.

  22. ACTION TAKEN Lifting arrangement for heavy core box Additional hitter coil added

  23. Tangible benefits Based on above action and result core production increased by 30%. Next target cycle time will reduce by 50% by providing special coil of 2.5kw/3kw. Lead time is one month. Next target shell core process to be convert to cold box process with this cost will reduce and cycle time will reduce by 50%. Lead time is one month work is in process.

  24. Intangible benefits With lifting arrangement less man power &less time utilize. Worker satisfaction. With safety lifting arrangement no chance for accident. End customer will satisfied with fulfill order quantity.

  25. Drawing stand razing for coil slot

  26. Based on above data verification, action and its results we have got confidences to take action on similar shell cores items.Accordingly we are taking action s which affect on production losses. Similar part action

  27. Production loss due to shell Core shortage before & after action

  28. Production losses in M.TON After Action in month of JUNE2011 For Crankcase production regularly we can produced max 400 nos to 500nos. Casting in one time. With increasing core production We have produced on time 978nos casting on dt:2/7/2011.

  29. We thankful to our management who give us an opportunity to present presentation in front of you & also we thankful to Mr. Baphat sir and association team & special thankful to Mr. chilka sir and Mr. Bodus sir who gave support & guidelines every time. With everybody contribution in Zanvargroup we confidence to achieve goal & dreams of our chairman's who built up this organization. Thank you.

  30. ? Any question.

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