S.J.IRON & STEELS PVT.LTD. MACHINE SHOP

1. S.J.IRON & STEELS PVT.LTD. MACHINE SHOP JAN 2012

2. TEAM MEMBERS:- • Mr.P.V.PATIL • Mr.D.J.WAGARE • Mr.V.G.KHAMBE • Mr.M.M.DOIJAD • Mr.Y.N.CHOUGALE

3. COMPARATIVE PRODUCTION STATUS PART NAME & NUMBER:- 407 FRONT BRAKE DRUM(EURO) (2651 3340 3720) CT-05 (I st Opr.) & CT-06 ( II nd Opr.) Machines Utilized for 2 shifts CT-06 Machine Capacity = 2916 nos. ( 54 nos. per shift X 2 shifts X 27 days ) CT-05 (I st Opr.) & CT-06 ( II nd Opr.) Machines Utilized for 2 shifts CT-06 Machine Capacity = 2700 nos. ( 54 nos. per shift X 2 shifts X 25 days )

4. COMPARATIVE PRODUCTION STATUS PART NAME & NUMBER:- 407 REAR BRAKE DRUM(EURO) (2065 3560 3705) CNC-02( Ist Opr.) & CNC-03( II nd Opr) Machines Utilized for 2 shifts Machines Capacity = 2268 nos. (42 nos. per shift X 2 shifts X 27 days ) CNC-02( Ist Opr.) & CNC-03( II nd Opr) Machines Utilized for 2 shifts Machines Capacity = 2100 nos. (42 nos. per shift X 2 shifts X 25 days )

5. COMPARATIVE PRODUCTION STATUS PART NAME & NUMBER:- 1616 BRAKE DRUM (2631 4210 3701) CT-04 & VTL 03 Machines Utilized for 2 shifts Machines Capacity = 3240 nos. ( 60 nos. per shift X 2 shifts X 27 days ) CT-04 & VTL 03 Machines Utilized for 2 shifts Machines Capacity = 3000 nos. ( 60 nos. per shift X 2 shifts X 25 days ) Eicher Brake Drum IA-208622 =150 nos. & IA -208969=84 jobs are machined on same machine

6. COMPARATIVE PRODUCTION STATUS PART NAME & NUMBER:- 1109 BRAKE DRUM (2064 4210 3701) CT-01 & CT-02 Machines Utilized for 2 shifts Machine Capacity = 3240 nos. ( 60 nos. per shift X 2 shifts X 27 days ) CT-01 & CT-02 Machines Utilized for 2 shifts Machine Capacity = 3000 nos. ( 60 nos. per shift X 2 shifts X 25 days ) Eicher Brake IA-202649 machined on same line Eicher Brake IA-202649 machined on same line Casting Shortage

7. COMPARATIVE PRODUCTION STATUS PART NAME :- EICHER BRAKE DRUM IA-202649 MATERIAL NOT LIFTED BY EICHER MOTORS

8. COMPARATIVE PRODUCTION STATUS PART NAME :- 35 HP FLYWHEEL VTL-01( Ist Opr.) & VTL-02 (II nd Opr) Machines Utilized for 1 shift Machine Capacity = 2160 nos. ( 80 nos. per shift X 1 shift X 27 days ) VTL-01( Ist Opr.) & VTL-02 (II nd Opr) Machines Utilized for 1 shift Machine Capacity = 2000 nos. ( 80 nos. per shift X 1 shift X 25 days )

9. COMPARATIVE PRODUCTION STATUS PART NAME :- 55 HP FLYWHEEL VTL-01( Ist Opr.) & VTL-02 (II nd Opr) Machines Utilized for 1 shift Machine Capacity = 2160 nos. ( 80 nos. per shift X 1 shift X 27 days ) 35 HP MACHINED ON SAME LINE

10. COST DETAILS(ITEMWISE) PART NAME & NUMBER:- 407 FRONT & FRONT EURO BRAKE DRUM RS. 27.55 REGULAR TOOL COST ,HOLDER COST RS. 3.03, DRILL COST RS.6.68 & SPARE COST RS.6.99 RS. 25.27 REGULAR TOOL COST ,HOLDER COST RS. 2.59, DRILL COST RS.4.76 & SPARE COST RS.6.73 Note:- To calculate labor cost take 35% overhead on Basic+DA

11. COST DETAILS(ITEMWISE) PART NAME & NUMBER:- 407 REAR BRAKE DRUM EURO RS. 25.42 REGULAR TOOL COST . HOLDER COST = 1.52 RS. , DRILL COST RS. 1.74 & SPARE COST= RS.5.70 RS. 33.36 REGULAR TOOL COST . HOLDER COST = 2.03 RS. , DRILL COST RS. 3.04 & SPARE COST= RS.5.92 Note:- To calculate labor cost take 35% overhead on Basic+DA

12. COST DETAILS(ITEMWISE) PART NAME & NUMBER:- 1616 BRAKE DRUM (2631 4210 3713) RS.19.08 REGULAR TOOL COST ,HOLDER COST RS. 1.82 & SPARE COST RS. 4.36 & DRILL COST RS.0.55 RS.19.99 REGULAR TOOL COST ,HOLDER COST RS. 2.09 & SPARE COST RS. 2.99 & DRILL COST RS. 10.83 LINE CABELING WORK / MACHINE WIRING Note:- To calculate labor cost take 35% overhead on Basic+DA

13. COST DETAILS(ITEMWISE) PART NAME & NUMBER:- 1109 BRAKE DRUM (2064 4210 3701) RS. 12.61 REGULAR TOOL COST , SPARE COST RS.0.38 & DRILL COST RS 9.41 RS. 16.56 REGULAR TOOL COST , HOLDER COST RS.0.81, SPARE COST RS. 2.12 & DRILL COST RS. 0.36 LINE CABELING WORK Note:- To calculate labor cost take 35% overhead on Basic+DA

14. COST DETAILS(ITEMWISE) PART NAME & NUMBER:- 35 HP FLYWHEEL RS. 30.48 REGULAR TOOL COST , HOLDER COST RS. 0.63 DRILL COST RS.3.50 & SPARE COST RS. 0. 48 RS. 24.55 REGULAR TOOL COST , HOLDER COST RS. 1.26 DRILL COST RS.12.27 & SPARE COST RS. 0.74 Note:- To calculate labor cost take 35% overhead on Basic+DA

15. COST DETAILS(ITEMWISE) PART NAME & NUMBER:- 55 HP FLYWHEEL RS. 37.08 REGULAR TOOL COST ,& SPARE COST RS. 0.68 RS. 33.58 REGULAR TOOL COST ,& SPARE COST RS. 2.99 & DRILL COST RS.1.32 LINE CABELING WORK Note:- To calculate labor cost take 35% overhead on Basic+DA

16. COST DETAILS(ITEMWISE) PART NAME & NUMBER:- EICHER BRAKE DRUM IA-202649 RS.20.51 REGULAR TOOL COST , SPARE COST RS. 0.92 HOLDER COST RS. 2.38 RS. 18.21 REGULAR TOOL COST , SPARE COST RS. 4.05 Note:- To calculate labor cost take 35% overhead on Basic+DA

17. MACHINE UTILISATION IN % (CNC TURNING) Machine Utilized for 2 shifts Machine Capacity = 2800 nos. ( 56 nos. per shift X 2 shifts X 25 days ) Machine Utilized for 2 shifts Machine Capacity = 2700 nos. ( 54 nos. per shift X 2 shifts X 25 days )

18. MACHINE UTILISATION IN % (CNC TURNING) Machine Utilized for 2 shifts Machine Capacity = 2100 nos. ( 42 nos. per shift X 2 shifts X 25 days ) Machine Utilized for 2 shifts Machine Capacity = 2100 nos. ( 42 nos. per shift X 2 shifts X 25 days )

19. MACHINE UTILISATION IN % (CNC TURNING) Machine Utilized for 2 shifts Machine Capacity = 4000 nos. ( 80 nos. per shift X 2 shifts X 25 days ) Machine Utilized for 2 shifts Machine Capacity = 4000 nos. ( 80 nos. per shift X 2shifts X 25 days )

20. MACHINE UTILISATION IN % (CNC TURNING) Machine Utilized for 2 shifts Machine Capacity = 3000 nos. ( 60 nos. per shift X 2 shifts X 25 days ) Machine Utilized for 2 shifts Machine Capacity = 3000 nos. ( 60 nos. per shift X 2shifts X 25 days )

21. MACHINE UTILISATION IN % (CNC TURNING) Machine Utilized for 2 shifts Machine Capacity = 3000 nos. ( 60 nos. per shift X 2shifts X 25 days ) Machine Utilized for 2 shifts Machine Capacity = 3000 nos. ( 60 nos. per shift X 2 shifts X 25 days ) Machine Utilized for 2 shifts Machine Capacity = 3000 nos. ( 60 nos. per shift X 2 shifts X 25 days )

22. MACHINE UTILISATION IN % (CNC TURNING)

23. REJECTION DETAILS(ITEMWISE IN %) Part Name:- 407 Front Euro Brake Drum Ø95 Bore Casting Rej. Ø72 Bore & Ø 95 Bore Rej. Ø72 Bore SF Rej. Ø72 Bore SF Rej. ***ACTION ON MAJOR REJECTION CAUSES

24. REJECTION DETAILS(ITEMWISE IN %) Part Name:- 407 Rear Euro Brake Drum Ø90 & Ø100 Bore Rej. Due to offset variation problem (M/c problem) Ø90 & Ø100 Bore Casting Rej. Ø14 mm & Ø160.8 shift MR & Ø18 H8.Oblong MR = 14 nos. Ø90 & Ø100 Bore Rej. (M/c Vib. problem) ***ACTION ON MAJOR REJECTION CAUSES

25. REJECTION DETAILS(ITEMWISE IN %) Part Name:- 1616 Brake Drum Brake Bore Out Casing Rej. Brake Bore Casing Rej. Out Casing machined ***ACTION ON MAJOR REJECTION CAUSES

26. REJECTION DETAILS(ITEMWISE IN %) Part Name:- 1109 Brake Drum Brake Bore Out Casing Rej. Brake Bore & Hub Bore Casting Rej. Out Casing machined ***ACTION ON MAJOR REJECTION CAUSES

27. REJECTION DETAILS(ITEMWISE IN %) Part Name:- Eicher Brake Drum IA-202649 Brake Bore Out Casing Rej. ***ACTION ON MAJOR REJECTION CAUSES

28. REJECTION DETAILS(ITEMWISE IN %) Part Name:- 35 HP FLYWHEEL Ø340 OD ,Ø152 Bore & Ø360 OD heavy Casting Rejection

29. REJECTION DETAILS(ITEMWISE IN %) Part Name:- 55 HP FLYWHEEL Ø 360 ,Ø340 OD & Ø118.046 Bore Casting Rejection Ø39.98 ,118.046 Rejection

30. OVERALL REJECTION (All Parts) 35 & 55 HP FLYWHEEL 407 FRONT EURO CASTING REJECTION 1109 ,1616 & EICHER DRUM 202649 CASTING REJECTION ***ACTION ON MAJOR REJECTION CAUSES

31. LABOUR EFFICIENCY

32. TOTAL EFFICIENCY

33. VAPCO

34. VAPCO VAPCO = (TOTAL SALES) - (VARIABLE COST ) TOTAL EMPLOYEE COST VAPCO = (2042660.00) – (1345547.79 ) / 539309.4 VAPCO = 1.29

35. S. J. IRON & STEELS PVT. LTD., ( Machine Shop ) DEPT: QA & Prod. CONTINUAL IMPROVEMENT SHEET DATE :20.01.2012 BEFORE :-Conveyors appeared dull AFTER : Coloring gave good appear- ence to the conve- yors. Team :-Mr. Bajirao Ghatge & Mr. Hajare

36. S. J. IRON & STEELS PVT. LTD., ( Machine Shop ) DEPT: QA & Prod. CONTINUAL IMPROVEMENT SHEET DATE : 27.01.2012 BEFORE :-Machine Appearance observed dull AFTER : Coloring gave good appear- ence to the machines Team :- Mr. Y.N.Chougale, Mr. Bajirao Magar , Mr. Nimbalkar

37. S. J. IRON & STEELS PVT. LTD., ( Machine Shop ) DEPT: QA & Prod. CONTINUAL IMPROVEMENT SHEET DATE : 05.01.2012 BEFORE :-Control Plan, Tooling & Gauging near work station not kept properly AFTER : A unique Table to accommodate Control Plans, WI, Tooling & Gauging made Team :- Mr. D.J.Wagare & Mr. M.M.Doijad

38. S. J. IRON & STEELS PVT. LTD., ( Machine Shop ) DEPT: QA & Prod. CONTINUAL IMPROVEMENT SHEET DATE : 24.01.2012 BEFORE :- AFTER : Team :- Mr. V.G.Khambe, Mr. S.M.Kale

39. Continual Improvements Jan./ Feb.-2012 • For Millipore Value controlling of Flywheels , Washing Machine - will be started from 09.02.2012. • For 407 Rear Euro Brake Line , crane will be added to minimise man power (helper).- Crane added • 1616 & 1109 Brake Drum / Flywheel line Separate cabeling work with energy meter completed. • 407 Front & Rear line separate cabling & energy meter work will be completed in Feb. 2012. • Aurum Drilling M/c for Front & Rear line panel & machine wiring work will be completed in Feb. 2012 to avoid frequent breakdown. • Boring Trolleys will be provided at required places. - provided • All machines will be coloured (inhouse) for aesthetic appearance of machine shop. – 407 Front & Rear line completed.

40. T H A N K Y O U