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SHRIRAM FOUNDRY LTD.MACHINE SHOP

SHRIRAM FOUNDRY LTD.MACHINE SHOP. Oct. 2011. TEAM MEMBER:-. Mr. R.R.NERLEKAR.(I/C Pulley line) Mr.S.R.HIREMANI.(I/C Hub Line) Mr.G.M.SHAIKH (Tooling) Mr.S.B.PATIL ( Quality) Mr.P.P.Patil ( System). COMPARATIVE PRODUCTION STATUS. PART NAME & NUMBER:- CONMET FRONT HUB - 10001946.

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SHRIRAM FOUNDRY LTD.MACHINE SHOP

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  1. SHRIRAM FOUNDRY LTD.MACHINE SHOP Oct. 2011

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

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

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

  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 – 100143439Rear Hub) 1st set up 256 jobs machined found 121 nos CR & 7 nos MR. To fulfill the customer schedule again production start.

  7. COMPARATIVE PRODUCTION STATUS PART NAME & NUMBER:- CUMMINS – Nut Plate(400/100)

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

  9. COMPARATIVE PRODUCTION STATUS PART NAME & NUMBER:- CONMET FRONT HUB – 10020463(250 BHN) 108 no's CR & 11 no's CR.

  10. COMPARATIVE PRODUCTION STATUS PART NAME & NUMBER:- CONMET FRONT HUB – 10019817(ADB hub) 100 no's ready for dispatch & under production.

  11. COMPARATIVE PRODUCTION STATUS PART NAME & NUMBER:- Pulley 413.0(SG Iron) 32 no's CR.(one day production)

  12. COMPARATIVE PRODUCTION STATUS PART NAME & NUMBER:- Pulley 800.2(Double decker) CR 57 nos, MR 05 nos.(3day production) CR 43 nos, MR 05 nos.

  13. COMPARATIVE PRODUCTION STATUS PART NAME & NUMBER:- Pulley 642.0 59 no's CR.

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

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

  16. 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

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

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

  19. COST DETAILS(ITEMWISE) PART NAME & NUMBER:- CONMET HUB – 9759 Ø16.570 carbide drill Rs. 6500 /- 01 nos Tool Cost Rs. 45.20 Note:- To calculate labor cost take 35% overhead on Basic+DA

  20. COST DETAILS(ITEMWISE) PART NAME & NUMBER:- CUMMINS – NUTPLATE (100/400) Note:- To calculate labor cost take 35% overhead on Basic+DA

  21. COST DETAILS(ITEMWISE) PART NAME & NUMBER:- CONMET HUB – 4343 Ø12.57x215 shr/57 01 nos rs. 1271 & SHR/450 01 NOS Rs. 1875 Tool Cost Rs. -50.86 Note:- To calculate labor cost take 35% overhead on Basic+DA

  22. COST DETAILS(ITEMWISE) PART NAME & NUMBER:- CONMET HUB – Hub 9817 Note:- To calculate labor cost take 35% overhead on Basic+DA

  23. COST DETAILS(ITEMWISE) PART NAME & NUMBER:- CONMET HUB – 20463 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:- Pulley476 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 A4 SMR Holder Rs. 4500/ Casting Problem CNMA 120412 Insert Breakage Tool Cost Rs. 219.20 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 145 Note:- To calculate labor cost take 35% overhead on Basic+DA

  29. COST DETAILS(ITEMWISE) PART NAME & NUMBER:- Pulley 189 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

  30. 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 1 nos Tool Cost Rs. 328.05 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

  31. MACHINE UTILISATION IN % (VTL – Oct 11) Pulley Pulley

  32. MACHINE UTILISATION IN % (CNC – Oct 11) HUB Pulley

  33. MACHINE UTILISATION IN % (CNC - Oct 11) ROTTER/NUTPLATE Pulley

  34. MACHINE UTILISATION IN % (VTL – VMC –Oct 11) HUB HUB

  35. Majour Losess Details (Whole shop)

  36. REJECTION DETAILS(ITEMWISE IN %) Part Name:- CONMET HUB 1946 PRD- 310 NOS, IN H MR- 5.16%( 16) PRD-931 NOS, IN H MR-2.69%( 25) PRD-284 NOS, IN H MR 1.06%( 3) SF MR 0.35% ( 1) ***ACTION ON MAJOR REJECTION CAUSES

  37. REJECTION DETAILS(ITEMWISE IN %) Part Name:- CONMET ROTTER 9996 PRD- 538 NOS, SF MR 3.53% (19 ) BORE OVERSIZE S.J IRON FOR IST OPERATION, IN H MR 2.79% (15 ) 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 ) ***ACTION ON MAJOR REJECTION CAUSES

  38. REJECTION DETAILS(ITEMWISE IN %) Part Name:- CONMET HUB 4343 PRD- 323 NOS, IN H MR 2.17% ( 7), SF MR 0.93 % (3) ***ACTION ON MAJOR REJECTION CAUSES

  39. REJECTION DETAILS(ITEMWISE IN %) Part Name:- CONMET 10020463 PRD- 457 NOS,, IN H MR 2.41 % (11) SF MR 0.22 %( 1) ***ACTION ON MAJOR REJECTION CAUSES

  40. REJECTION DETAILS(ITEMWISE IN %) Part Name:- CONMET 10019817 PRD- 200 NOS,, IN H MR 1.5 % (3) SF MR 1.5 %( 3) PRD- 374 NOS,, IN H MR 2.41 % (9) SF MR 0.27 %( 1) ***ACTION ON MAJOR REJECTION CAUSES

  41. REJECTION DETAILS(ITEMWISE IN %) Part Name:- CONMET 10009717 PRD- 236 NOS,, IN H MR 7.63 %(18) 3 JOB REJECTED IN BORE VIBRATION & 4 JOBS IN TAP BROKEN SF MR 0.42 %( 1) PRD- 256 NOS,, IN H MR 2.73 %(7) ***ACTION ON MAJOR REJECTION CAUSES

  42. REJECTION DETAILS(ITEMWISE IN %) Part Name:- CONMET 10009759 PRD- 305NOS,, IN H MR 3.28%(10), SF MR 3.28% (10) 10 JOBS REJECTED IN HOLE 24.86 OUT CUT ON SPM-03 M/C. 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- 312NOS,, IN H MR 0.96%(3), PRD- 389 NOS,, IN H MR 1.29 %(5), ***ACTION ON MAJOR REJECTION CAUSES

  44. REJECTION DETAILS(ITEMWISE IN %) Part Name:- Pulley 413 PRD- 185 NOS IN H MR 3.24 %(6) . PRD- 123 NOS IN H MR 0.81 %(1) . PRD- 322 NOS IN H MR 0.62 %(2) . ***ACTION ON MAJOR REJECTION CAUSES

  45. REJECTION DETAILS(ITEMWISE IN %) Part Name:- PULLEY 266.1 16.85 %(15),Due PRD- 89NOS,, IN H MR to improper clamping 3 nos,size variation problem 6 nos. PRD- 114 NOS,, IN H MR 4.39 %(5), ***ACTION ON MAJOR REJECTION CAUSES

  46. REJECTION DETAILS(ITEMWISE IN %) Part Name:- Pulley 476 PRD- 271NOS, I H MR 3.69% (10) SF MR 0.37% (1) PRD- 297 NOS, I H MR 0.34% (1) ***ACTION ON MAJOR REJECTION CAUSES

  47. REJECTION DETAILS(ITEMWISE IN %) Part Name:- Pulley 642 PRD- 547NOS, SF MR 0.73% (4) PRD- 683 NOS, I H MR 1.02% (7) ***ACTION ON MAJOR REJECTION CAUSES

  48. REJECTION DETAILS(ITEMWISE IN %) Part Name:- Pulley 189.0 PRD- 535NOS,, IN H MR 0.56 %(3) SF MR 0.37% ( 2) PRD- 321 NOS, IH MR 0.31 % (1) ***ACTION ON MAJOR REJECTION CAUSES

  49. REJECTION DETAILS(ITEMWISE IN %) Part Name:- Pulley 145.3 PRD- 436 NOS,, IN H MR 1.61%(7) ***ACTION ON MAJOR REJECTION CAUSES

  50. REJECTION DETAILS(ITEMWISE IN %) Part Name:- ECC HUB 790/791/858.1/859.1 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- 963 NOS,, IN H MR 0.42 %(4) SF MR 3.95% ( 38) REJECTED BY Padmavati Engg. PRD- 1129NOS, IN H MR 0.62 %(7) SF MR 1.06% (12) ***ACTION ON MAJOR REJECTION CAUSES

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