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


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


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

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

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 application

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

banks; educational and financial institutions.

Infrastructure projects such as airports, roads, bridges, residential and commercial

complexes, townships, high-rise buildings and many more

Other significant industries include engineering,

ancillaries, textile, pharmaceuticals, dairy, and food processing.

Defence agencies, such as the air force, army and navy, as well as the coast guard

PRODUCTS OF KIRLOSKAR OIL ENGINES ( KAGAL )

in the manufacture of both air-cooled and liquid-cooled diesel engines and


to 6300 kVA. We also offer engines operating on alternative fuels such as bio-diesel, natural



Our customised power solutions suits a wide range of applications including both standby


proof, environmentally friendly canopies.

Service industries such as telecom, IT/ITES, BPO, shopping malls, hotels, hospitals, and

banks; educational and financial institutions.


rise buildings and many more

Other significant industries include engineering, manufacturing, FMCG, automobile and auto

ancillaries, textile, pharmaceuticals, dairy, and food processing.


cooled diesel engines and


diesel, natural



s including both standby


, hospitals, and


manufacturing, FMCG, automobile and auto


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:

Fig: Store department flowchart

The department also maintains a buffer stock for each line. The various factors influencing

this process are

1. Lead time

2. Lack time

3. Total replenishment time

4. Production volume per line

RECEIPT UNLOADING INSPECTION

STORAGE OR LINE

SET BACK TO SUPPLIER

REJECTION

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 :

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.

Date: Shift:

Supplier:

GRR No/ Sticker No.:

Bin No.

Quantity:

Position:

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 Enables quick change over for multi shift operation.

• Load backrest

o 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:

Asset number : 138165

Capacity : 1500 kg

Machine No. : 763

Location : R1040 store

Driver : Vijay Khad

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)

Cuts off lifts at 80% discharge level.


STACKER 2:

Asset number : 133721

Capacity : 1500 kg

Machine No. :

Location : R1040 store

Driver : Prashant Dhotre

Maximum Height: 6000 mm


are also used to place material on racks of store(As specified in rack system)

STACKER IN EP1


Driver : Prashant Dhotre


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

Asset Number: 133696

Department: R1040 assembly line

Capacity: 500N-2000N

Machine No.: 7

Voltage : 48V

Driver: Swapnil Rajput

TOW TRUCK 2


Department: HA assembly line

Capacity: 500N-2000N

Machine No.: 531

Voltage : 48V

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 No. of components in

a trolley

Trips(For 90 setting)

Cylinder head 2 cylinder 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

Crankcase 2 cylinder 3 30

3 cylinder 2 45

4 cylinder 2 45

Crankshaft Same for all 5 18

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.

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) 800

Load centers (mm) 500

Work and its route:

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 posit

LOAD CENTRE

(HA and R1040 assembly store)

respect to load centers:

700 570

600 800


Material from store itself and place it on specified position.


SE STORE (Small engine store)


Machine Number: 540

Location: SE store

Capacity: 800kg


Voltage: 48V

Driver: Abhijeet Kamble


Capacity (Kg) 1300 1140 930

Load centers (mm) 500 600 800

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


Voltage: Amar Satpute


Capacity (Kg) 800 700 570

Load centers (mm) 500 600 800

Work and its route:


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):


Model Number: 62-8FD30

Driver: Vijay Patil


Capacity with respect to load center:

Capacity (Kg) 3000 2700 2000

Load Center (mm) 700 800 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


Driver: Amar Bhosale



Capacity (Kg) 2500 2260 1640


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:



Driver: Umesh Bamane



Capacity (Kg) 2500 2260 1640


Work and its route:

It is being used for placing packed Varsha and Small engines to specified area.

5C STORE:



Driver: Bhaskar Patil



Capacity (Kg) 2500 2260 1640


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



Capacity (Kg) 2800 2550 1890


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



Capacity (Kg) 2500 2260 1640


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:


Machine Number: 525

Model Number: 8FD25

Driver: Girish Chaugule



Capacity (Kg) 2500 2260 1640


Work and its route:

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

DISPATCH:

Asset Number:

Model Number: 8FD25

Driver: Sadashiv Kapade



Capacity (Kg) 2500 2260 1640


Work and its route:

It carries material from machine shop lines to the dispatch area.

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 Item Item

description

Quantity color Pick up

location

Placing

location

TR

1 2H.006.01.0.00

Turbo

charger

1 regular R45 212

2 2H.036.11.0.00

Gear cover 1 4R.FR.02 302

-

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.

Positions on kit trolley

Application

code

1to99 100to199 200to299 300to399 400to499 Total

parts

2R 7 17 12 4 13 54

4H:2188

4H-3312

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

tag.

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

assembly line.

KOEL

Single Engine trolley

Application code:

Status: Authorized Sign & date

A) Ready for assembly filling store

B) Ready for assembly use Sub Assembly

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 Type Quantity in 1 trolley

Crankcase(HA and R1040) 2R 3

3R 2

4R 2

Cylinder head (R1040) 2R 6

3R 4

4R 4

Crankshaft New Trolley 8

Old trolley 5

Camshaft 2R 30

3R 20

4R 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 Type Quantity in 1 Bin

Connecting rod R1040 and HA 5

DV 3

Cylinder head HA 2

SMALL HYDRA (MOVABLE CRANE):

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.

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