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SHRIRAM FOUNDRY LTD.MACHINE SHOP

SHRIRAM FOUNDRY LTD.MACHINE SHOP. MARCH. 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 MARCH. 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 190.0

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

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

  6. COMPARATIVE PRODUCTION STATUS PART NAME & NUMBER:- Pulley 642.0 Component under production.

  7. COMPARATIVE PRODUCTION STATUS PART NAME & NUMBER:- Pulley 266.0 Claas not need this component from next month because drawing has chenged.Whater stock will be dispatched. Component under production

  8. COMPARATIVE PRODUCTION STATUS PART NAME & NUMBER:- FAIRFILD HOUSING - 619

  9. COMPARATIVE PRODUCTION STATUS PART NAME & NUMBER:- CONMET FRONT HUB - 10014340

  10. COMPARATIVE PRODUCTION STATUS PART NAME & NUMBER:- CONMET HUB - 10004446

  11. COMPARATIVE PRODUCTION STATUS PART NAME & NUMBER:- CONMET HUB – 10019727 (Spline Hub) Component under production.

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

  13. COMPARATIVE PRODUCTION STATUS PART NAME & NUMBER:- CONMET HUB – 10019736 (335 SERIES)

  14. COMPARATIVE PRODUCTION STATUS PART NAME & NUMBER:- CONMET HUB – 10020463 (HIGH BHN)

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

  16. COMPARATIVE PRODUCTION STATUS PART NAME & NUMBER:- Front Axle support Prod – SRF – Reg 1332 nos,Mod – SRF – 434,Alka – 70 nos,Axcel – 513 nos.Total – 2453 nos.

  17. COST DETAILS(ITEMWISE) PART NAME & NUMBER:- CONMET HUB 4446 Note:- To calculate labor cost take 35% overhead on Basic+DA

  18. COST DETAILS(ITEMWISE) PART NAME & NUMBER:- CONMET HUB 4340 Note:- To calculate labor cost take 35% overhead on Basic+DA

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

  20. 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

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

  22. COST DETAILS(ITEMWISE) PART NAME & NUMBER:- CONMET HUB 9727 HFHL -2525 Holder 1qty. & HFPR 4020 INSERT RS-6161/ Tool Cost Rs.87.88 HFHL -2525 Holder 1qty. Rs. 4000/- Tool Cost Rs.60.08 Carbide Drill Ø 14 Rs. 6500/- Tool Cost Rs. 50.11 Note:- To calculate labor cost take 35% overhead on Basic+DA

  23. COST DETAILS(ITEMWISE) PART NAME & NUMBER:- CONMET HUB 20142 HFHL -2525 Holder 1qty. & Spot face cutter Rs. 8100/- Tool Cost Rs.80.11 Note:- To calculate labor cost take 35% overhead on Basic+DA

  24. COST DETAILS(ITEMWISE) PART NAME & NUMBER:- CONMET HUB 20463 BARNSHING TOOL Rs- 2950 /- Tool Cost Rs.87.02 Note:- To calculate labor cost take 35% overhead on Basic+DA

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

  26. 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

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

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

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

  30. 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 Hard Casting -Extra Ins. A4G3mm 7qnt.& TDT 4E 13 qnt. TTER -2525 -1 HOLDER Total Rs. 15237 Tool Cost Rs. 342.75 Note:- To calculate labor cost take 35% overhead on Basic+DA

  31. COST DETAILS(ITEMWISE) PART NAME & NUMBER:- Pulley 771 Note:- To calculate labor cost take 35% overhead on Basic+DA

  32. COST DETAILS(ITEMWISE) PART NAME & NUMBER:- Pulley 413 A 4SMR-2525 HOLDER Rs. 7447 Tool Cost Rs. Cost 218.02 Note:- To calculate labor cost take 35% overhead on Basic+DA

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

  34. COST DETAILS(ITEMWISE) PART NAME & NUMBER:- Pulley 642 Note:- To calculate labor cost take 35% overhead on Basic+DA

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

  36. COST DETAILS(ITEMWISE) PART NAME & NUMBER:- Pulley 266 Hard Casting- A4G & TDT INS. Extra 14 nos. Total Rs. 11637 Tool Cost Rs. 135.71 Hard Casting- OD Extra Material CNMG INS. 12 qnt.Extra Use Total Rs. 9729 Tool Cost Rs. 167.00 Note:- To calculate labor cost take 35% overhead on Basic+DA

  37. COST DETAILS(ITEMWISE) PART NAME & NUMBER:- Front Axle Support ( JD FAS ) Ø 32 Burnishing Tool/ And Milling CutterT otal Rs. 22725 Tool Cost Rs. -91.04 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

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

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

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

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

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

  43. Majour Losess Details (Whole shop)

  44. REJECTION DETAILS(ITEMWISE IN %) Part Name:- CONMET 10019828 PRD- 159 NOS, IN H MR- 3.14% (5) PRD- 219 NOS,, IN H MR 1.37% (3) ***ACTION ON MAJOR REJECTION CAUSES

  45. REJECTION DETAILS(ITEMWISE IN %) Part Name:- CONMET HUB 9727 PRD- 379 NOS, IN H MR 5.28% (20), IN THIS REJECTION 6JOB REJECTED IN DIA 208.99 3MM UNDERSIZE, 2 JOB REJECTED FOR LENGTH 26.605 TOOL MARK , 2 JOBS REJECTED FOR DIA 149.1 SEMIFINISHF TOOL MARK & 2 JOBS FOR DIA. 149.1 OVERSIZE , 3JOBS REJECTED IN Ddia 123S/F TOOL MARK. PRD- 763 NOS, IN H MR 2.23% (17), SF MR 0.52 % (4) ***ACTION ON MAJOR REJECTION CAUSES

  46. 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) PRD- 216 NOS, IN H MR 4.17% (9), ) (IN THIS REJECTION 4 NOS EJECTED FOR DIA 139.988 OVERSIZE) ***ACTION ON MAJOR REJECTION CAUSES

  47. REJECTION DETAILS(ITEMWISE IN %) Part Name:- CONMET HUB 20142 PRD- 291 NOS, IN H MR- 5.15% (15) –( IN THIS 4JOBS ARE REJECT IN DIA 123 SEMIFINISH TOO L MARK , 3 JOBS DAMAGE MR & 4 JOBS IN 24.86 TOOL MARK) SF MR - 0.69 %(2) ***ACTION ON MAJOR REJECTION CAUSES

  48. REJECTION DETAILS(ITEMWISE IN %) Part Name:- CONMET HUB 4446 PRD- 225 NOS, IN H MR- 2.22% (5) ***ACTION ON MAJOR REJECTION CAUSES

  49. REJECTION DETAILS(ITEMWISE IN %) Part Name:- CONMET ROTTER 9996 PRD- 432 NOS, IN H MR 2.31% (10 ) ( IN THIS REJECTION 6JOB REJECTED IN HOLE 13.47 WALL SHIFT) PRD- 955 NOS, IN H MR 0.31% (3 ) SUB CONTRACTOR MR- 01.36% (13 ) ( 12 JOBS REJECTED IN HOLE 13.47 WALLSHIFT) PRD- 1267 NOS, IN H MR 0.63% (8 ) SF MR 0.79% (10 ) ( 8 JOBS REJECTED IN HOLE 13.47 WALLSHIFT) ***ACTION ON MAJOR REJECTION CAUSES

  50. REJECTION DETAILS(ITEMWISE IN %) Part Name:- PULLEY 800.2 PRD- 315NOS,, PRD- 68NOS,, PRD-290 NOS,, IN H MR 1.03 % (3), ***ACTION ON MAJOR REJECTION CAUSES

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