College Internship Report Kirloskar Oil Engines Limited

ENSURE AVAILABILITY MATERIAL HANDLING EQUIPMENTS

A SUMMER INTERNSHIP PROJECT

Submitted by

PARESH VENGULKAR

In partial fulfillment for the award of the degree of

MASTER OF BUSINESS ADMINISTRATION

Under the guidance of Mr. Chandrajit Bagal Group Leader SCM Department KIRLOSKAR OIL ENGINES LIMITED

SCHOOL OF MANAGEMENT STUDIES NATIONAL INSTITUTE OF TECHNOLOGY CALICUT NIT CAMPUS PO, CALICUT KERALA, INDIA 673601

(JUNE-JULY, 2013)

ENSURE AVAILABILITY MATERIAL HANDLING EQUIPMENTS

A SUMMER INTERNSHIP PROJECT

Submitted by

PARESH VENGULKAR

In partial fulfilment for the award of the degree of

MASTER OF BUSINESS ADMINISTRATION

Under the guidance of Mr. Chandrajit Bagal Group Leader SCM Department KIRLOSKAR OIL ENGINES LIMITED

SCHOOL OF MANAGEMENT STUDIES NATIONAL INSTITUTE OF TECHNOLOGY CALICUT NIT CAMPUS PO, CALICUT KERALA, INDIA 673601

(JUNE-JULY, 2013)

DECLARATION I hereby declare that this submission is my own work and that, to the best of my knowledge and belief, it contains no material previously published or written by another person nor material which has been accepted for the award of any other degree or diploma of the university or other institute of higher learning, except where due acknowledgment has been made in the text.

Place: Kolhapur

Signature

Date: 20-07-2013

Name: Paresh Vengulkar Reg. ID: M120008MS

CERTIFICATE This is to certify that the summer internship project report submitted by Paresh Vengulkar to School of Management Studies, NIT, Calicut and Kirloskar Oil Engines Limited, Kagal in partial fulfilment of the requirements for the award of the degree of Master in Administration is a bona fide record of the research work carried out by him under my (our) supervision and guidance. The content of the thesis, in full or parts have not been submitted to any other Institute or University for the award of any other degree or diploma.

Place Kolhapur Mr. Chandrajit Bagal Date 20-07-2013

(Group Leader SCM Departent)

ACKNOWLEDGEMENT It is matter of honor for me to express my gratitude towards all those who guided directly and indirectly in completing this project report. I would like to specially thank, Mr. Chandrajit Bagal (Group Leader SCM Department), for all his valuable guidance and resources provided; Mr. Digvijay Ingale for his support and information throughout this project and Mr. Rahul Pawar (Human Resource Department) for giving me an opportunity to do the Internship at Supply chain management Department, Kirloskar Oil Engines Limited, Kagal.

Date: 20-07-13 Place: Kolhapur

Paresh Vengulkar SOMS, NITC Reg. ID M120014MS

INDEX

ITEM

Executive Summary Company Overview Problem Statement Objective Literature Review Research Methodology Analysis of Data Conclusion Appendix

EXECUTIVE SUMMARY

KIRLOSKAR OIL ENGINE LIMITED KAGAL, Engine plant one is big size plant in which has fast moving items is consumed in daily production plan. There is more than 200 engines are made in daily production. And continuous supply of raw material makes it very complex process. Most of raw material is heavy in nature, so carry them to the different parts of the plant is very difficult task. So in order to speed up in-house supply chain, KOEL has been using advance material handling equipments. Productivity of the plant depends on supply of raw material and movement of finished goods, this project aims at studying the use of material handling equipments and ensures its availability.

COMPANY OVERVIEW

It has now been more than a century since the Kirloskar story started. They started with an aim of becoming the pioneers in fields in which our country needed innovation.

In the 100 years and more that they have been in existence as a family and as an organization, they've been seminal to Indian agricultural and industrial development.

They gave India its first iron plough, pump and engine; inventions that were derived from the need of the hour and went on to become signs of the time. Which is why their group history can in many ways can be considered a history of the economic and industrial revolution in India

Kirloskar Oil Engine Limited (KOEL) will set up a greenfield export-oriented unit at Kagal in Kolhapur district for an investment of Rs. 550 crores which will manufacture 100,000 engines.

The Memorandum of Understanding to this effect was signed by KOEL Chairman and Managing Director Mr. Atul Kirloskar and Industry Secretary Mr. V K Jairath. Industry minister Mr. Ashok Chavan, Chief Secretary Mr. D K Sankaran and other senior officials from the state government and KOEL were present.

VISION AND VALUES:

GUIDING PRINCIPLES: Innovation, speed and transparency are the organizational personality traits that we nurture and develop. Building on these values and guiding principles we aim to maintain our position as the world's leading player in the diesel engine segment and to offer the best in its class products and services to all our customers around the world.

PRODUCTS OF KIRLOSKAR OIL ENGINES ( KAGAL ) GENSETS:

KOEL specialises in the manufacture of both air air-cooled and liquid-cooled cooled diesel engines and generating sets across a wide range of power output from 5 kVA to 625 kVA and 1800 kVA to 6300 kVA. We also offer engines operating on alternative fuels such as bio-diesel, bio diesel, natural gas, biogas and straight vegetable oil (SVO). The “Kirloskar Green Genset” is the market leader and most preferred brand among customers in the power generation and telecom industry in India. Our customised power solutions suits a wide range of applications applications including both standby and prime power requirements. Our generating sets are available in both open and sound proof, environmentally friendly canopies. The major markets served are: Service industries such as telecom, IT/ITES, BPO, shopping malls, hotels, hotels, hospitals, and banks; educational and financial institutions. Infrastructure projects such as airports, roads, bridges, residential and commercial complexes, townships, high-rise rise buildings and many more Other significant industries include engineering, manufacturing, FMCG, automobile and auto ancillaries, textile, pharmaceuticals, dairy, and food processing. Defence agencies, such as the air force, army and navy, as well as the coast guard

OFF HIGHWAYS:

The Off Highway business group's activities are molded according to the motive power needs of customers who require products from 20 hp to 800 hp in the Off Highway space globally. We manufacture a variety of quality diesel engines powering more than 85 Off Highway applications across seven sectors. KOEL engines are the preferred choice when it comes to powering earth moving, construction, mining, fluid handling, material handling equipments and marine applications. AGRI ENGINES:

In the agriculture market, we fulfil the motive power needs of customers; essentially farmers, who require products in 3 hp to 130 hp in the global agri space. We manufacture a variety of quality diesel pumpsets and agri engines powering more than 25 applications across five sectors. Our pumpsets have been greening the soils of India, Egypt, Africa, and Latin and Central America. We are the most preferred brand amongst farmers because of our reliable performance and fuel efficiency.

DEPARTMENTS IN KOEL: 1. HUMAN RESOURCE DEPT. : This dept. consist of security , training , human resource management and safety. 2. ATPP: In ATPP dept. Assembly, testing, painting, packing is done. It consist of three dept. namely 1. Genset 2. Medium engine 3. Small engine. 3. QUALITY CONTROL: Here following factors control the quality. 1. RQI(Receipt quality insurance) 2. Process Quality. 3. Mr. Customer. 4. SCM(Supply Chain Management): In SCM following activities are done: 1. Development of component (New/ Existing/ Modified Component) 2. Supplier finalization. 3. Price negotiation. 4 .Supplier part sample (Approved from CRE) 5. Part Delivery. 6. Logistics.

5. STORE: 1. In this dept. storage and planning of material is done. 2. Main work of this dept. is to keep the part in proper location in proper manner. 3. There are various equipments are used for transportation of material. 6. PPC: 1. PPC dept. done co-ordination with all top and bottom management. 2. Main work of PPC dept. is Planning, Production and control. 3. Material availability is checked according to BOM. 7. MACHINE SHOP: In this dept. machining of critical components is done. 5C components are critical components.5C components are as follows 1. Connecting Rod. 2. Crank shaft. 3. Cam shaft. 4. Cylinder head. 5. Crankcase. 8. UTILITY 9. MAINTAINANCE AND TOOL ROOM 10. SAFETY

SUPPLY CHAIN MANAGEMENT DEPARTMENT: On my first day of internship Mr. Digvijay Ingale explained me about supply chain department of Kirloskar. Department, structure, Buffer penetration report and overall working Kirloskar Supply chain management works in following way: Supply chain Management: Company’s SCM activities are operated from two places and it is consist of two main parts 1. Sourcing and Vendor development 2. Procurement 1. SOURCING:








The first step in sourcing is to check the design for manufacturing. This department takes designs from manufacturer and checks it for feasibility and costs. The next step is supplier or vendor selection. According to the requirement of the design of products the material required are determined and the supplies for these materials are selected. This is decided by the Supplier Quality Inspection (SQI) department. It studies the design and decides the supplier on the basis of costs, quality and accuracy required for the particular design of product. The third step is to pilot the design for regular production. The design is forwarded to PPC department for planning the assembly of product according to the demand and estimated time required for production.

After sourcing and vendor development the next job of this department is procurement of the product. 2. PROCUREMENT:







The first step in procurement is receiving the assembly plan from PPC (Planning production and control) department. PPC department plans the assembly of the product according to the design requirement and the cost reduction and forward production plan to purchase department. The second step is to run the MRP (Material Resource Planning). According the assembly plan received from PPC, the requirement of raw material is decided. Also some specific parts that cannot be manufactured in the plant are






identified and suppliers are shortlisted according to quality requirement of the product. The R&D (Research and development) department of the company is not much stressed. But the critical tests for specific parts are carried out by this department. The third step is to obtain and analyze the output of MRP. According to the output of MRP, the requirement of material and the schedules of the production are generated by this department. This is done by considering many factors such as product takt-time, time for completion of assembly for one sample, demand in market, availability of materials etc.

This department is also responsible for the communication of quality problem to the suppliers. If there is any problem with the material casted or the precision of finished product bought, this department communicates the problems to the suppliers the necessary measures are taken by suppliers to improve the quality.

STORES: It is one of the important links in supply chain management. The basic function of this department is handling the material from the time is received up to it is sold. The working of this department is broadly classified into five major functions: 1. RECEIPT: In this function a symmetric and standard approach is used to check and record all the instructions. This includes making of GRR (Good receiving receipt), checking invoice at the gate and also producing documents like OFB (Original for buyer), DFT (Duplicate for transfer). Sometimes acknowledgement copy and extra copy is required for different purpose like cashing and excise duty etc. 2. UNLOADING: During invoice verification, every vehicle is given a tracker which tracks the position of the vehicle throughout the plant. This helps in determining the time taken for unloading. There are three gates where material is unloaded. 3. STORAGE: After material is unloaded it is taken to different places through trolleys, Forklifts, caskets, bins etc. Different storage methods are used to store different materials. For e.g. low value and low volumes items are stored according to ‘Two Bin System’. Each bin contains the material for 3 days. When a bin pets emptied it is taken for replenishment. Meanwhile the other bin is used for production. 4. ACCOUNTABILITY: After the storage, the materials are issued for different lines according to the plan issued by PPC. Accountability section verifies the product physically and also checks for daily consumption of the materials.

5. DISPATCH: The main aim of this process is to inspect or check the final product. Scrap disposal is also managed by this process. Overall flowchart of this department is:

STORAGE OR LINE

RECEIPT

UNLOADING

INSPECTION

SET BACK TO SUPPLIER

REJECTION

Fig: Store department flowchart

The department also maintains a buffer stock for each line. The various factors influencing this process are 1. 2. 3. 4.

Lead time Lack time Total replenishment time Production volume per line

PROBLEM STATEMENT: To study and ensure the availability of material handling equipments in engine plant one.

OBJECTIVES: Keep record of material handling system in engine plant one that will help in setting up new material handling system in engine plant two. To reduce the number of handlings as well as the overall cost of material handling equipment and reducing the distances through which the materials are handled. Improved working conditions and greater safety in movement of materials Contribute to better quality by avoiding damage to products by inefficient handling.

LITERATURE REVIEW:

Efficient material handling is important to manufacturing operations. Materials sent by vendors must be unloaded, moved through inspections and production operations to stores and finally to the shipping department Material handling principles: Eliminate handling If not, make handling distance as short as possible Keep moving If not, reduce the time spent at terminal points of a route as short as possible Use simple patterns of material flow The simplest path is a straight line, if not, avoid back tracking, crossovers Carry pay loads both ways If not, minimize time spent on transport empty by changing speed in return route Carry full loads If not, decrease carrying capacity by lowering the speed Use gravity If not use, use a cheaper power source. Equipment selection principle:  Why? What? Where? When? How? Who?  If we answer these questions about each move, the solution will become evident. The maintenance principle:  Plan for preventive maintenance and scheduled repairs of all handling equipment.  Pallets and storage facilities need repair too. The dead weight principle  Try to reduce the ratio of equipment weight to product weight. Don’t buy equipment that is bigger than necessary.

 Reduce tare weight and save money. The capacity principle  Use handling equipment to help achieve desired production capacity that is material handling equipment can help to maximize production equipment utilization.

These movements do not add value to the product but they do add value to the cost •

Material handling analysis is a subset of plant layout. Method study, plant layout and material handling are all part of the design of a production facility

•

Material handling system and plant layout enhance effectiveness of each other.

•

Efficient operation of appropriate material handling methods reduces costs and enables maximum capabilities to be derived from a given production facility.

RESEARCH METHODOLOGY: For data collection I had to visit all the areas of the plant where material handling system is being used. My Project guide gave me list of parameters to be recorded about various material handling equipments. To understand the material handling system I had visited following places in the plant: Store Machine shop line HA and R1040 assembly line Small engine store Varsha engine store Loading and Unloading area For every material handling equipment, I have gathered following information: Asset Number: Department: Capacity: Operator: Work and its route: For collecting this information I have visited all above mentioned areas in the plant, collected all the necessary data by interviewing operator, store manager and every employee who is related to material handling system.

MATERIAL HANDLING EQUIPMENTS IN ENGINE PLANT 1: Offline material handling equipment Online material handling equipment

OFFLINE MATERIAL HANDLING EQUIPMENTS: These equipments are used for unloading and dispatch purpose, for keeping material at its right position in stores and for providing raw casting to the machine shop line and assembly line. List of offline material handling equipments: Pallet trucks (Mainy) Stacker (Mainy) Reach truck (Toyota) Forklift (Toyota) Tow Truck (Toyota)

ONLINE MATERIAL HANDLING EQUIPMENTS: These equipments are used to provide raw material to the assembly line. For HA assembly line and R1040 assembly line they provide raw material other that 5C component. And for Varsha and E-series assembly line they provide every component including 5C component. In following departments they use kit trolleys: HA assembly line R1040 assembly line Varsha assembly line E-series assembly line

OFFLINE MATERIAL HANDLING EQUIPMENTS: PALLET TRUCKS (Company : Mainy)

CAPACITY: 2500kg For use in damp and corrosive environments. Ideal for chemical, paper, leather, food processing industries and cold storage. Engineering Excellence •

Enhanced productivity: Manual high lift offers efficiency and versatility

•

Higher Safety: Automatic activation of self adjusting stabilizers at loads higher than 400mm, for greater stability

•

Easy loading: Loads can be easily placed at required ergonomic work height

•

Responsive Hydraulic System The hydraulic pump easy to operate and has an in-built automatic neutral position

HA AND R1040 ASSEMBLY STORE: Capacity: 1500 kg Work and its route: To place material from under inspection area to its respective position. Position of material is assigned by the store. And tag attached to the material under inspection area guides operator to place that particular material. TAG : Date:

Shift:

Supplier: GRR No/ Sticker No.: Bin No. Quantity: Position:

5C STORE: Capacity: 1500 kg Work and its route: Place 5C material in its position. (fixed Crane in 5C store helps to place 5C material) Take gears to the washing area. 5C CONSUMABLE STORE: Work and its route: It provides oil and paints to the following departments: -

R1040 assembly line Varsha line E-series Cylinder head line

They get this oil and paint from oil store area.

REJECTION AREA: Work and its route: Brings rejected material from following areas -

Machine shop line Kit trolly store SE and varsha assembly line Packing

Take rejected material to the loading area

PACKING AREA (Qty: 2) Work and its route: Packing purpose, carries material from racks to the packing area. Provides material on line (HA and R1040 assembly line)

SE STORE: Work and its route: Place material to its right position. Bring material from unloading area to SE store.

ENGINE PACKING: Work and its route: Help in engine packing and dispatch.

PALLET TRUCKS IN EP1

STACKER (COMPANY: MAINY)

Capacity 1500KG Lift height: 6000mm •

Versatile stacker, useful in almost all industrial work environment

•

Ergonomically designed for enhanced productivity and safety

•

Ideal for operation in narrow aisles and busy gangways due to compact design and small turning radius.

•

Ability to undergo highly intensive stacking and transportation in minimum time.

•

Wheel configuration ensures positive traction for firm grip & enhanced stability

OPTIONS •

Battery change trolley o

•

Load backrest o

•

Enables quick change over for multi shift operation.

Ensures stability of loads during movement.

Battery discharge indicator with pump lockout and hour meter o

Indicates state of charge

o

Cuts off lifts at 80% discharge level.

There are two stacker in engine plant 1 and both the stackers work in store department (HA and R1040 assembly line) STACKER 1:

STACKER 2:

Asset number

: 138165

Asset number

: 133721

Capacity

: 1500 kg

Capacity

: 1500 kg

Machine No.

: 763

Machine No.

:

Location

: R1040 store

Location

: R1040 store

Driver

: Vijay Khad

Driver

: Prashant Dhotre

Maximum Height: 6000 mm

Maximum Height: 6000 mm

Work and its route: Both stackers are helpful in placing material from store to its right position. These stackers are also used to place material on racks of store(As specified in rack system)

STACKER IN EP1

TOWING TRUCKS (COMPANY: TOYOTA) Towing trucks are an integral part of many production line and logistics operations because they offer highly efficient horizontal transport solutions. These are specialized trucks for moving roll cages and trolleys to heavy-duty electric and engine-powered models. All models are designed for optimum safety, productivity and operator comfort. These towing trucks provides only 5C components to the HA and R1040 assembly lines from machine shop lines. 5C components with specially designed trolleys are carried by these trucks. Engine plant 1 has two towing trucks.

TOW TRUCK 1

TOW TRUCK 2

Asset Number: 133696

Asset Number: 133457

Department: R1040 assembly line

Department: HA assembly line

Capacity: 500N-2000N

Capacity: 500N-2000N

Machine No.: 7

Machine No.: 531

Voltage : 48V

Voltage : 48V

Driver: Swapnil Rajput

Driver: Saddam Tahsildar

TOW TRUCK 1 Work and its route: This truck provides Cylinder head, Connecting rod and cam shaft to R1040 department. Driver collects these material from finished goods area of machine shop line.

TOW TRUCK 2 Work and its route: This truck provides crankcase and crankshaft to R1040 assembly line and all 5C component to HA assembly line. For one engine 1 crankcase, 1 cylinder head, 1 camshaft, 1 crankshaft and 2 to 4 connecting rods(depend on number of cylinders) are needed. In one shift around 90 engines are assembled, so for 90 setting following is the description of trips of two trucks. Component

Type

Cylinder head

2 cylinder

No. of components in Trips(For 90 setting) a trolley 6 15

3 cylinder

4

23

4 cylinder

4

23

Connecting rods

Same for all

250

1 or 2

Camshaft

2 cylinder

30

3

3 cylinder

20

5

4 cylinder

20

5

2 cylinder

3

30

3 cylinder

2

45

4 cylinder

2

45

Same for all

5

18

Crankcase

Crankshaft

TOWING TRUCK IN EP1

REACH TRUCK (COMPANY: TOYOTA)

Engine plant 1 has three reach trucks. They take care of placing material on the racks. Material on the racks keep in the boxes with pallets, reach trucks with forks lift boxes and keep it in specified position as mentioned in the rack system. Areas where reach trucks are present: 1. Store (HA and R1040 assembly line) 2. Packing 3. SE store (Small engine) Capacity of reach trucks differs with load centers. Following image will explain how load centers can be identified.

LOAD CENTRE STORE (HA and R1040 assembly store) Asset Number: 13722 Machine Number: 759 Location: R1040 store Capacity: 800kg Maximum Height: 6000mm Voltage: 48V Driver: Prashant Dhotre Capacity with respect to load centers: Capacity (Kg) Load centers (mm) Work and its route:

800 500

700 600

570 800

It places material on the racks. There are total 10 racks in store area. Reach truck collects Material from store itself and place it on specified position. posit

SE STORE (Small engine store) Asset Number: 137074 Machine Number: 540 Location: SE store Capacity: 800kg Maximum Height: 5000mm Voltage: 48V Driver: Abhijeet Kamble

Capacity with respect to load centers: Capacity (Kg) Load centers (mm)

1300 500

1140 600

930 800

Work and its route: It places material on the racks. There are total 5 racks in SE store area. Reach truck collects Material from store itself and place it on specified position.

PACKING AREA: Asset Number: 13724 Machine Number: 760 Location: R1040 store Capacity: 800kg Maximum Height: 6000mm Voltage: Amar Satpute Capacity with respect to load centers: Capacity (Kg) Load centers (mm)

800 500

700 600

570 800

Work and its route: It places material on the racks. There are total 5 racks in store area. Reach truck collects Material from material under inspection (Packing) and place it on specified position.

REACH TRUCK IN EP1

FORKLIFT (Company: Toyota)

Counterbalanced forklifts have been a source of various storage and handling system, where they perform loading, stacking, distribution and horizontal transport functions. Toyota Material Handling India brings you its engine powered machine which is according to the Industry standards for safety, productivity, reliability, comfort and environmental performance. Toyota engine-powered forklifts feature dedicated Toyota diesel and LPG engines setting new standards for the professional use of forklift truck. With this model we provide you a product series with load capacities ranging from 1.5 - 8.0 tons, you can be sure there is a Toyota model to meet your needs. Toyota forklifts are also equipped with the unique Toyota System of Active Stability (SAS), an exclusive technology designed to actively support safe forklift operation it is and electronic control technology that combines high performance with ease of operation with an excellent standard of safety. Engine plant 1 has eight forklifts. For driving these forklifts driver should have heavy vehicle license. Detailed description of each forklift is given below.

PACKING(HA AND R1040): Asset Number: 137074 Model Number: 62-8FD30 Driver: Vijay Patil

Maximum Height: 3000mm Capacity with respect to load center: Capacity (Kg) Load Center (mm)

3000 700

2700 800

2000 1000

Work and its route: This forklift is responsible for moving packed engines (R1040 and HA) to the dispatch area.

SE STORE (SMALL ENGINE): Asset Number: Machine Number: 627 Model Number: 62-8FD25 Driver: Amar Bhosale Maximum Height: 3000mm Capacity with respect to load center: Capacity (Kg) Load Center (mm)

2500 500

2260 600

1640 1000

Work and its route: This forklift carries packing material of Varsha engines to its packing area from unloading point. This forklift also carries unloaded material to the SE store (Sometimes up to washing area)

VARSHA AND SE PACKING: Asset Number: 133456 Model Number: 62-8FD25 Driver: Umesh Bamane

Maximum Height: 3000mm Capacity with respect to load center: Capacity (Kg) Load Center (mm)

2500 500

2260 600

1640 1000

Work and its route: It is being used for placing packed Varsha and Small engines to specified area.

5C STORE: Asset Number: 133456 Model Number: 62-8FD25 Driver: Bhaskar Patil Maximum Height: 3000mm Capacity with respect to load center: Capacity (Kg) Load Center (mm)

2500 500

2260 600

1640 1000

Work and its route: It carries unloaded material to the 5C store and HA and R1040 store. It also carries raw castings from 5C store to the machine shop line whenever needed. UNLOADING 1: Asset Number: Model Number: FD2N30 Driver: Krishna Patil Maximum Height: 3000mm Capacity with respect to load center: Capacity (Kg) Load Center (mm)

2800 500

2550 600

1890 1000

Work and its route: This forklift unloads material from vehicles and moves it to the unloading area. It also moves unloaded material to the HA and R1040 store.

UNLOADING 2: Asset Number:133454 Model Number: 8FD25 Driver: Amol Tahsildar Maximum Height: 3000mm Capacity with respect to load center: Capacity (Kg) Load Center (mm)

2500 500

2260 600

1640 1000

Work and its route: This forklift unloads material from vehicles and moves it to the unloading area. It also moves unloaded material to the HA and R1040 store.

ENGINE LOADING: Asset Number: 133452 Machine Number: 525 Model Number: 8FD25 Driver: Girish Chaugule Maximum Height: 3000mm Capacity with respect to load center: Capacity (Kg) Load Center (mm)

Work and its route:

2500 500

2260 600

1640 1000

It carries packed engines from packing area to the loading area.

DISPATCH: Asset Number: Model Number: 8FD25 Driver: Sadashiv Kapade Maximum Height: 3000mm Capacity with respect to load center: Capacity (Kg) Load Center (mm)

2500 500

2260 600

Work and its route: It carries material from machine shop lines to the dispatch area.

1640 1000

ONLINE MATERIAL HANDLING: HA AND R1040 ASSEMBLY LINE: For HA and R1040 assembly line ram material other than 5C components is being provided by kit trolleys. Each assembly line has 40 kit trolleys for carrying raw material. R1040 ASSEMBLY LINE: Each day PPC department (Production planning and control) decides quantity to be assembled. Store people update targets for that day on board. According to the target operator of kit trolley put raw material on separate trolley for each engine. There are total 32 types of engines that are assembled in R1040 line. For each type of engine separate data sheets are prepared, operator puts material on the kit trolleys according to the data sheets.

Application Code: 4H:2739 Sr. No 1 2

Item

Item Quantity description 1 2H.006.01.0.00 Turbo charger 2H.036.11.0.00 Gear cover 1

color regular

Pick up location R45

Placing location 212

4R.FR.02

302

TR

42 Kit trolleys filling card After collecting these parts, for heavy material and other critical parts operator takes other data sheet. This datasheet shows number of critical parts to be placed on kit trolleys. After this same operator from store area checks whether all parts are properly placed. For this purpose, one datasheet is there that shows application code and number of parts in different position on kit trolleys.

Application code 2R 4H:2188 4H-3312

1to99

100to199

Positions on kit trolley 200to299 300to399

7

17

12

4

400to499 13

Total parts 54

When operator confirms that all parts are placed properly on kit trolleys he fills following tag.

KOEL Single Engine trolley Application code: Status: A) Ready for assembly filling B) Ready for assembly use

Authorized Sign & date store Sub Assembly

This tag confirms that kit trolley is ready for assembly line. Same procedure is there for HA assembly line.

MATERIAL HANDLING ON MACHINE SHOP LINES: FORKLIFT: Forklift provides raw castings to the machine shop lines. One forklift is entirely dedicated to provide raw castings and 5C store. This forklift also provides help for placing rejected material, finished goods to its position. KIT TROLLEYS: Kit trolleys are specially designed to fit 5C component. Forsome 5C component kit trolleys are designed with different capacities. Component Crankcase(HA and R1040)

Cylinder head (R1040)

Crankshaft Camshaft

Type 2R 3R 4R 2R 3R 4R New Trolley Old trolley 2R 3R 4R

Quantity in 1 trolley 3 2 2 6 4 4 8 5 30 20 20

BINS: HA cylinder head, Connecting rod, DV con rods use bins for finished goods. As these components are small in size small plastic bins are suitable for them. And for carrying them to the assembly lines separate kit trolley is used. Component Connecting rod

Type R1040 and HA DV Cylinder head HA SMALL HYDRA (MOVABLE CRANE):

Quantity in 1 Bin 5 3 2

Sr No.: 7105-10 Capacity: 500 Kg Machine Number: 408 Location: R1040 and HA machine shop line Work: This movable crane is used for bringing rejected material down from the machine shop line. This crane is useful for only HA and R1040 machine shop lines.

PROBLEMS AND SUGESTIONS:

Maintenance and quality problems of stackers (Mainy) Stacker of Mainy company are being used for placing material on to the racks, These stackers has forks which carries material boxes. But these forks are not good in terms of safety and quality as compared to Toyota reach truck. Both Toyota reach truck and Mainy stackers are helpful for placing material boxes on racks. Safety issues: Forks of Toyota reach trucks nicely adjust to the boxes and prevent boxes from falling by forming slope. But forks of stacker cannot be adjusted and remains straight. So while handling material with Reach truck operator feels safer as compared to stacker. Maintenance Problems: Stackers have more maintenance problems as compared to reach trucks. Forks of Stackers were damaged in the past and they are not as good as reach trucks. Due to these problems maintenance time required for stackers is more and its availability reduces so reach truck is good option. And as maintenance of reach truck is easy and convenient so reach truck of Toyota provide solution to this problem.

Missing Asset Numbers? Company has given asset number to every useful instrument. Asset number is the unique identifier for an asset. But these asset numbers are missing from pallet trucks and also from some forklifts. It is also found that two forklift has same asset number. This problem might because those asset number plates were fell down. Providing asset number will not increase availability of these instruments but it will matter the company which believes in 5S and kaizen.

Problem of R1040 crankcase machine shop line

Raw castings of R1040 crankcase are very long from input conveyor, and it requires unnecessary trips of forklifts. So if raw castings of R1040 are placed near input conveyor then these unnecessary trips of forklifts could be avoided. Raw castings can be placed in front of input conveyor, if they get some place from SE store then raw castings could be stored at that place and it will be convenient for operators of R1040 line to put raw castings on input conveyor.

CONCLUSION The material handling is important activity in any manufacturing plant. The speed of the material flow across the supply chain depends on the type of the material handling equipment and the sophistication in the system. In daily operation the material handling system is designed in and around the plant. Commonly, the following material handling operations are performed in the EP1, unloading the incoming material from transport equipment, moving the unloaded material to the assigned storage place, lift the material from its storage place during order picking, move the material for inspection and packing, and load the packages on to the transport vehicle. These operations are performed using manual or mechanized controlled material handling equipment. The mechanized system shifts the fatigue to machine and brings effectiveness to human efforts. The selection of the appropriate system depends on the factors such as volumes to be handled, speed in handling. So as a conclusion I can say that material handling does not add value to the product

but they do add value to the cost.