Production Planning and Control Study at Astra Metal Systems

STUDY OF PRODUCTION, PLANNING AND
CONTROL IN ASTRA METAL SYSTEMS PVT LTD.

Name : VASUDEV N BHANAJI
Regise! N". : #$$%#&'(&
NAME OF THE INSTITUTE: SYMBIOSIS CENTRE FOR DISTANCE
LEARNING, BATCH : #$$%
1
NO OBJECTION CERTIFICATE
This is to certify that Mr Vasudev N Bhanaji is an employee of M/s Astra Metal Systems
Pvt. td.! for the past " years.
#e have no o$jection for him to carry out a project %or& titled 'STUDY OF
PRODUCTION, PLANNING AND CONTROL IN ASTRA METAL SYSTEMS PVT
LTD( in our )r*ani+ation and for su$mittin* the same to the ,irector! S-, as a part of
fulfilment of the P,.BA /)perations0 Pro*ram.
#e %ish him all the success.
Si*nature of the competent
authority of the of the 1nstitute
/ )r*ani+ation
P)a*e: Verna! .oa! 1ndia
Dae: 223,ec32414
2
DECLARATION BY THE LEARNER
This is to declare that 1 have carried out this project %or& myself in part fulfilment of the
P.,BA Pro*ram of S-,.
The %or& is ori*inal! has not $een copied from any%here else and has not $een su$mitted
to any other 5niversity / 1nstitute for an a%ard of any ,e*ree / ,iploma.
Dae: 223,ec32414 Sig+a,!e:
P)a*e: Verna! .oa Name: Mr Vasudev N Bhanaji
6
CERTIFICATE OF SUPERVISOR -GUIDE.
-ertified that the %or& incorporated in this Project 7eport 'STUDY OF PRODUCTION,
PLANNING AND CONTROL IN ASTRA METAL SYSTEMS PVT LTD/ su$mitted
$y Mr Vasudev N Bhanaji is his ori*inal %or& and completed under my supervision.
Material o$tained from other sources has $een duly ac&no%led*ed in the Project 7eport.
Sig+a,!e "0 G,i1e:
Name: Mr Pradip A. P. da -osta.
A11!ess: Astra Metal Systems Pvt. td.
389! Verna 1ndl. :state! Verna ; .oa <46822
2,a)i0i*ai"+: ,ip. Production :n**.
Desig+ai"+: ,irector
S3e*ia) Fie)1 "0 4"!5: )perations
E63e!ie+*e: Product ,evelopment /< years0
Vendor ,evelopment /< years0
)perations /1= years0
Dae: 22
nd
,ecem$er 2414
P)a*e: Verna ; .oa ; 1ndia <46822
<
1. 1ntroduction>>>>>>>>>>>>>>>>>>> = 3 1<
2. )$jectives and Scope>>>>>>>>>>>>>>> 19
6. imitations >>>>>>>>>>>>>>>>>>>. 19
<. Theoretical Perspective>>>>>>>>>>>>>> 19 3 2"
9. Methodolo*y and Procedure of #or& >>>>>>>> 2" 384
=. Analysis of ,ata>>>>>>>>>>>>>>>>>. 81
8. ?indin*s! 1nferences and 7ecommendations>>>>>>> 82 3 8<
". -onclusion>>>>>>>>>>>>>>>>>>>> 89 38=
@. Summary of the Project 7eport >>>>>>>>>>> 88
ANN:A57:S
10 Proposal
110 7eferences >>>>>>>>>>>>>>>>>>>> 88
1110 ist of ?i*ures! -harts! ,ia*rams>>>>>>>>>>> 8"
1V0 ist of Ta$les >>>>>>>>>>>>>>>>>> 8"
INTRODUCTION
As!a Mea) S7sems P8. L1. -AMSPL.! are in field of Precision Sheet Metal
?a$rication 1ndustry! Manufacturin* and Supplyin* Sheet Metal ?a$ricated Products.
AMSP started its operation in 1@@". 1t is an 1S) @4413244" -ertified -ompany. 1t
initiated its eBpansion plan $y settin* up an unit in Sancoale 1ndustrial :state! %here it can
use lar*er space for the purpose of production and also addin* stora*e space. 1t aims at
caterin* to the Sheet ; Metal -omponent / Product needs of 5C! .ermany and 5SA $ased
9
customers. 1t also plans to increase its capacity throu*h eBpansion. 1t has $een outsourcin*
certain activities and for some activities also provides its o%n infrastructure. 1ts production
is $ased on customer specification. 1t has no desi*nin* of its o%n. Astra follo%s Statistical
Process -ontrol Systems for all $asic manufacturin* processes. The Principles of 9S for
house3&eepin* is an on3*oin* activity %hich Astra $elieve is of utmost importance to its
vision to $e a '#orld -lass Manufacturin* -ompany(.
Astra Metal Systems Pvt. td. is strate*ically located at Verna 1ndustrial :state in .oa ;
1ndia %hich is in close proBimity to the Airport! 7ail Terminus as %ell as the sea port all
%ithin ran*e of 19&m $oundary. 1t has plant area of 1244 sD.mts.
Astra Metal Systems Pvt. td. %as promoted $y < technocrats Mr. Satish A. Shinde! Mr.
-harlton -olaco! Mr Pravin .. Pai and Mr Pradip A. P. da -osta.
-ompanyEs clientele %ith their product ran*e %hich includesF
Siemens td. Medical :n*ineerin* ,iv! Verna! .oa /A3ray housin*s! machine parts and
Machine enclosures.0
,ie$old 1ndia Pvt. td. /ATM Sheet Metal -omponents0
Andre% Telecommunications 1ndia Pvt. td. /Base Antenna Parts G Accessories0
,3in& 1ndia td! Verna! .oa. /:nclosures G parts for net%or&in* products0
Tata -onsultancy Services 3 Tivim .oa. /Mail / -heDue sortin* machine parts.0
.il$arco Veeder 7oot 1ndia Pvt.td. /?uel ,ispensin* Cios&s0
Siemens A. /PT,3Berlin! .ermany0 Sheet Metal -omponents for Po%er Sector0.
Mc.eoch Technolo*ies Marines 3 Birmin*ham! 5C /Marine li*htin* ?ittin*s 0
Pentair #ater Pvt. td. /Sheet Metal -omponents G :nclosures for #ater3Treatment0
V:S Andover ; Hampshire !5C /Sheet Metal -omponents G :nclosures for Air
Handlin* systems G controls0
Miscellaneous customer
O!ga+i9ai"+a) S!,*,!e "0 As!a Mea) S7sems P8. L1.
=
Pa*e 1 of <
)r*ani+ational chart continued....
Pa*e 2 of <
8
Pa*e 6 of <
"
Pa*e < of <
@
B!ie0 1eai)s "0 1e3a!me+s i+ As!a a+1 :ei! !")es ;Res3"+si<i)iies
P!"1,*i"+ De3a!me+s:
&. P!ess S:"3
14
I Punchin*
I Bendin*
I 1nsertin*
#. Fa<!i*ai"+
I #eldin*
I ,rillin*
I Sanderin*
(. S,!0a*e 0i+is:i+g
I Po%der -oatin*
I Pre3treatment
Se!8i*e De3a!me+s:
&. Dis3a*:
I Prepares an 1nvoice -um -hallan
I Sees to it that the pac&a*in* is done as per customer needs and specifications
I Arran*es the material to $e dispatched.
#. S"!es
I -lassification of *oods
I B1N card system
I Maintain .1N
I )utsourcin* *oods
(. 2,a)i7
I -ompany documentation
I Monitor G measure productsF 1ncomin*! 1n3process G ?inal sta*e.
I -ontrol of ,ra%in*s
I -ontrol of non3conformin* products at all sta*es
I -ali$ration )f :Duipments
I Vendor authentication
I Special process validation
'. Mai+e+a+*e
I 7educe Machine ,o%ntime
I Preventive Maintenance
I Servicin* )f Machinery Accordin* To %ee&ly/monthly/Juarterly/Kearly Plan
I .ive ist )f Spares To Purchase
11
=. HR
I 7ecruitment F :mployee referrals and ne%spaper ads
I Selection F 1ntervie% Method
I )rientationF 1nformal intro.
I Trainin* F)n3the3jo$
I SafetyF Shoes! *loves! mas&s! *o**les! ear *ear
I 1nsuranceF :S1! Mediclaim Policy
I Health G Hy*ieneF .ood li*htin* G ventilation! %ater purifier! Shift system
I 1ncentives F Monetary form! $onus at festivals
I :mployee #elfareF Travel G food allo%ance
I eave of a$senceF -ard system! 14 days in advance! 62 days
%. Fi+a+*e
I Purchase payments
I ,is$ursement of salary
I Annual financial statement
I 7eserves
I ?ollo% up for receiva$les
>. Mae!ia)s
I 1nterrelated to PP-
I Schedulin*
I 7eorder level
I ?indin* out potential suppliers
I AB- analysis
?. Ma!5ei+g
I Mana*ed $y the M,
I Meets potential customers
I Advertisin* throu*h the 1nternet
@. De8e)"3me+
I Study the feasi$ility of ne% 1nDuiry
I ,evelopment of Blan&s for Production
I ,efine Process ?lo% for Production
&$. PPC
I Transfers information of ra% material to the purchase mana*er.
I -alculate the timin* for the jo$.
12
I Ma&e monthly plan for the various departments.
I Transfer of 1nformation relatin* to Production.
I Production control.
I 7elease Production orders planned from sales orders as standard or project.
I Production Bill of Materials
I Versions of manufacturin* $ills of materials and routin*s created.
I Multi3location plannin* throu*h efficient information and material flo%.
I 1nteractive action messa*in*Lfor the immediate $alancin* of supply and demand
I Multiple %or&sheets for revie%in* various production options
I Su$contractin* $y %or& center or operation
SAOT ANALYSIS -As!a Mea) S7sems P8. L1.
S!e+g:s O33"!,+iies
I :Bperienced staff I :Bpansion
I #ell defined process I ?orei*n mar&ets
I Technolo*y / Sophisticated machinery I ?or%ard 1nte*ration of product
I Technical eBpertise I )%n Product
I ar*e customer $ase I Serve additional customer *roups
Aea5+ess T:!eas
I Small scale operations I ?luctuation of -ustomer )rders
I ac& of Vision I Ne% :ntrants
I 5nplanned Approach I -ustomers *ro%in* $ar*ain po%er
I ,ependency on &ey human resource
I )perators/%or&ers non3involvement
Astra Metal Systems Pvt. td.! has identified the process needed and have determined the
process and its interactions as per $elo%F
16
O<Be*i8es:
T:e 3!ima!7 "<Be*i8e "0 3!"1,*i"+ 3)a++i+g a+1 *"+!") i+ As!a Mea) S7sems
P8. L1. is " e+s,!e :a :e 1esi!e1 3!"1,*s a!e ma+,0a*,!e1.
1<
I At the ri*ht time!
I 1n the ri*ht Duantities!
I Meetin* Duality specifications! and
I At minimum cost.
S*"3e: The Project study is limited to production and plannin* department.
Limiai"+s: Some of the inter related processes are not analysed in depth in vie%
of avoidin* any violation of company rules and re*ulations.

T:e"!ei*a) Pe!s3e*i8e:
Production Plannin* and -ontrol philosophy isF 'Fi!s 3)a+ 7",! 4"!5, a+1 :e+ 4"!5
7",! 3)a+(. Before startin* any %or&! plannin* is necessary for the effective utili+ation of
availa$le resources.
Production Plannin* is concerned %ith the determination! acDuisition and arran*ement of
all facilities necessary for the future operations! %hereas production control is concerned
%ith the implementation of a predetermined Production plan or policy and the control of all
aspects of Production accordin* to such a plan or policy.
PP- can $e defined as the process of plannin* the production in advance! settin* the eBact
route of each item! fiBin* the startin* and finishin* date for each item! *ivin* production
orders to shop and lastly follo%in* up the pro*ress of products accordin* to orders. 1t is
also called the Mnerve centerE of the factory.
MAIN FUNCTIONS OF PPC
The follo%in* are the &ey functions of Production Plannin* and -ontrolF
a0 7elease orders to the system in accordance %ith the priority plan. Priority means
control over the status of jo$s and %or& activities $y specifyin* the order in %hich
materials or jo$s are assi*ned to %or& centers.
$0 Assi*n jo$s to specific %or& centers.
c0 Provide seDuencin* priorities to specify the order in %hich jo$s are to $e processed.
d0 -ontrol the manufacturin* lead time $y trac&in* and eBpeditin* jo$s if reDuired.
19
e0 Monitor the priority status of jo$s via summary! scrap! re%or&! and other reports.
f0 Monitor the capacity status of facilities via input/output reports of %or&load/capacity.
*0 ,isplayin* and settin* plannin* file entries manually
h0 Maintainin* master data
i0 :Becutin* total plannin* run for master schedule items
j0 displayin* availa$ility overvie% for material
&0 Processin* $ac&lo*s
l0 -onvertin* planned orders into purchase reDuisitions! production orders or process
orders
m0 :Becutin* mass chan*es of planned orders
n0 :Becutin* collective availa$ility chec& for components in the planned order to plan
materials that almost plan themselves in the operative flo%
o0 to *ain an overvie% of the future reDuirements and stoc& situation and to compare the
,emand plannin* %ith the availa$le capacities.
The production plannin* and control in a company is achieved $y inte*ratin* activities asF
I determinin* product demand!
I translatin* product demand into feasi$le manufacturin* plans!
I esta$lishin* detailed plannin* of material flo%s!
I capacity to support the overall manufacturin* plans!
T:e maB"! e)eme+s "0 a PPC a!e:
A. ,emand mana*ement
B. A**re*ate production plannin*
-. Master production schedulin*
,. 7ou*h3cut capacity plannin*
:. Material reDuirement plannin*
?. -apacity plannin*
.. )rder release
H. Shop floor schedulin* and control
1=
A. DEMAND MANAGEMENT:
Since Astra Metal Systems Pvt. td. is $asically No$ shopper! does not have its o%n
product and its production is $ased on customer specification hence plannin* %ith respect
to demand mana*ement does not ta&e place instead at Astra Metal Systems Pvt. td. PP-
interacts %ith customer for their tentative reDuirement for a Duarter or for su$seDuent 6
month %herein 1st month actual and neBt t%o months tentative demand. Based on %hich
further plannin* processes are initiated.
Dema+1 0"!e*asi+g:
I ,emand for products is the drivin* force for any production activity.
I ,emand forecastin* is an important input to production plannin*.
I ?orecastin* is concerned %ith estimatin* future demand /or reDuirement0 for
products.
B. AGGREGATE PRODUCTION PLANNING:
Astra Metal Systems Pvt. td. are -ontract 3 Manufacturers and have %ide variety of
customers! produces hi*h3variety! distinct products! as such there is vide fluctuation in
demand for product. )n the other end! the resources of the company /num$er of machines!
num$er of %or&ers! etc.0 remain constant. The $est approach to o$tain feasi$le solution is
to a**re*ate the information $ein* processed.
18
?or a**re*ation purposes the product demand is eBpressed in a common measurement unit
such as production hours. Production plannin* is concerned primarily %ith determinin*
optimal production! inventory! and %or& force levels to meet demand fluctuation.
Basi* s!aegies 0"))"4e1 " a<s"!< :e 1ema+1 0),*,ai"+s a!e:
I -urrently Astra Metal Systems Pvt. td. maintain %or& force $ut chan*es the
production rate $y permittin* planned overtime! idle time and su$3contractin*.
I 1f needed Astra Metal Systems Pvt. td. chan*es the production rate $y chan*in*
the si+e of the %or& force throu*h planned hirin*.
I :Bplore the possi$ility of planned $ac&lo*s if customers are %illin* to accept delays
in delivery of products.
I A suita$le com$ination of these strate*ies should $e eBplored to develop an optimal
a**re*ate production plan.
C. MASTER PRODUCTION SCHEDULE:
The primary use of an a**re*ate production plan is to level the production schedule so that
the production costs are minimi+ed. Ho%ever! the output of an a**re*ate plan does not
indicate individual product. This means that the a**re*ated plan must $e disa**re*ated into
individual product. The result of such a disa**re*ation is %hat is &no%n as master
production schedule.
Master production schedule does not present an eBecuta$le manufacturin* plan! $ecause
the capacities and the inventories have not $een considered in this sta*e. Therefore! further
analysis for the material and capacity reDuirements are reDuired to develop an eBecuta$le
manufacturin* plan.
The MPS translates the Sales G )perations Plan /S)P0 into a plan for producin* specific
products in the future. -urrently said activity is done usin* 'n( of eBcel files of different
customers. The MPS is the translation of the S)P into produci$le products that ma&e up
the output of a production plan.
D. ROUGHCCUT CAPACITY PLAN:
The o$jective of rou*h3cut capacity plannin* is to ensure that the master production
schedule is feasi$le. ?or each product family the avera*e amount of %or& needed and &ey
1"
%or& centers unit can $e calculated from each 1temEs Bill of Materials and from production
routin*s /process plannin* sheets0.
The availa$le resources are compared %ith the resource reDuirements profile o$tained for
all the %or& centers considerin* all the product families.
1f the availa$le resources are less than reDuired! then decisions related to overtime!
su$contractin*! hirin* %or&ers are ta&en.
-onsider t%o families of Sin*le Tan& Housin*s /t%o of the items reDuired $y customer for
t%o different final products0 developed in standard hours of resources per 12 units as
follo%sF
#or& -enter Sin*le Tan& MM2.9 Sin*le Tan&s MM14 Total resources
reDuired for all
families
/Standard time /in Mins0
per 12 5nits0
/Standard time /in Mins0
per 12 5nits0
Punchin* 1= 21 68
,e$urrin* 9< == 124
Bendin* <2 <2 "<
#eldin* "4< 1424 1"2<
Sanderin* 1"= 644 <"=
,rillin*! tappin* 21= 21= <62
Pre3treatment 8" 8" 19=
Mas&in* 124 124 2<4
Po%der -oatin* 11< 124 26<
,e3mas&in*/ead
Pastin*
6=4 6=4 824
Varnishin* 612 6=4 =82
T"a) Time -i+
Mi+s.
#($# #>$( =$$=
Res",!*e 0"!
Ta+5s i+ :",!s
(? '= ?(
Res",!*e 0"!
Ta+5s i+ s:i0s
= % &&
E. MATERIAL RE2UIREMENTS PLANNING:
I The material reDuirements plannin* system is essentially an information system
consistin* of lo*ical procedure for mana*in* inventories of component assem$lies!
su$assem$lies! parts! and ra% materials in a manufacturin* environment.
I The primary o$jective of an M7P system is to determine ho% many of each item in the
$ill of materials must $e manufactured or purchased and %hen.
1@
The &ey concept used in determinin* material reDuirements areF
a0 Product structure and $ill of materials
$0 1ndependent versus dependent demand
c0 Parts eBplosion
d0 .ross reDuirement
e0 -ommon3use items
f0 Scheduled receipts/)n3hand inventories/Net reDuirements
*0 Plant order releases
h0 ead time
a0 Product structure and Bill of MaterialsF
Product is the sin*le most important identity in an or*ani+ation. A product may $e made
from one or more assem$lies! su$assem$lies and components.
A <i)) "0 mae!ia) /B)M0 is an en*ineerin* document that specifies that the components
and su$assem$lies reDuired to ma&e each end item /product0.
Here %e have com$ined most of the data needed for production in sin*le B)M! data in
addition to Matl. Specifications li&eF Th&! #idth in mts! en*th in mts! #ei*ht in &*s! and
type of Matl. Belo% data is also maintained in one file for $est useF
-ontrol of product li&eF ,ra%in* No! 7ev No! 7ev ,ate.
7outin* F ProcessOs and Process SeDuence
ocation of processOs /out of 6 units %hich location %ill do %hich process0F i.e location
of Punchin* / aser! Bendin*! ?a$! Surface ?inish /Po%der coatin* / Platin*0
Time estimate of processOs li&eF No. of Setup for $endin*! No of Bends! No of ,rills /
-.S.C! No of Taps! No )f Spots! Area for surface finish etc..
?or e.* Specimen of Bill of Material for one of the Cios& since data cannot fit its $ro&en in
6 part.
S!.
N". Le8e)s
Re8
N" Dae D!a4i+g N" Pa! N". Des*!i3i"+
$ $ PB@$@@? HPCL SLEED MONO DIOSD
1 : 4<.4".14 .B@1<<9 .B@1<<9 C1)SC ASS:MBK B)T:,
& & G &&.&#.$@ GB@&''> GB@&''> BASE ASLYCSLIM MONO
2 : 19.4@.4" .B81<@@ .B81<@@ BAS: A3 M:MB:7S1M M)N)
6 B)4944@9 #:, N5T M"
2 N 64.11.4@ .B81961 .B81961 BAS: K3M:MB:73M)N) S::C
6 B)4944@9 #:, N5T M"
6 B)4944@= #:, N5T M14
2 A 19.4@.4" .B81966 .B81966 M)T)7 MT.. M:MB:73S::C M)N)
24
6 B)4944@9 #:, N5T M"
2 4 64.4=.4= .=49<6 B)414128 ocatin* Pin /#elded0
2 4 19.4@.4" PB844@9 PB844@9 BAS: S1,: S5PP)7T AN.:F SP71NT
2 4 19.12.48 .B8196< .B8196< 7:S11:NT S5PP)7T B7A-C:T
6 B)4944@= #:, N5T M14
& B)4941=1 -arria*e Bolt 6"mm 7) H,! 9/"PBS#
& B)4941<8 SJ5A7: N5T 9/"O BS# QKP
& B)49416=
PA1N #ASH:7 1, 24.86 A ), 6".6 A 2.= MM
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# & A $%.&&.$@ PB>$&>& PB>$&>& De73a1 C)am3
( & PM$($$#& EP FOAM AITH GUM -&=$ E &#$ E =MM THD.
P!"*. SeF. T"a) 27 UOM S,!0a*e TYPE Ma).
>> & NOS FG
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11!1= 2 Nos P57: P)K:ST:7 BA-C /.)SSK0 SH::T M:TA -7-A .7A,: ,
< Nos B/)
2 Nos QKP B)/A3H
2 Nos QKP B)/A3H
2 Nos QKP B)/A3H
&&,&% ' N"s PURE POLYESTER BLACD -GLOSSY. SHEET METAL CRCA GRADE D
'' N"s BO;ACH
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6 4.21@ 4.949 4.<<2 1 < " 4 4 4 As!a As!a As!a

6 4.129 4.68@ 4.1@ 1 1 # 4 4 4 As!a As!a As!a

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21

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$0 1ndependent versus ,ependent ,emandF
The demand for the end item ori*inates from customer order and customer forecasts.
Such a demand for end items and spare parts is called i+1e3e+1e+ 1ema+1. The demand
$y a parent item for its components is called 1e3e+1e+ 1ema+1.
:.* A R independent demand /num$er of end item0
K R num$er of components for each end item
AK Rdependent demand /num$er of su$assem$ly demanded0
c0 Parts :BplosionF
The process of determinin* *ross reDuirements for component items i.e reDuirements for
su$assem$lies! components! and ra% materials for a *iven num$er of end3item units is
&no%n as parts eBplosion. Part eBplosion represents the eBplosion of parents into their
components.
d0 .ross 7eDuirements of -omponent 1temsF
.ross reDuirement of component items is the total num$er of component items reDuired to
manufacture the end products. .ross reDuirement of component items is computed $y
usin* the information from the product information and the $ill of materials.
e.* 1f the demand for end3item :1 is 94! than *ross reDuirements for the item components.
,emand of S1 R 1 B demand of :1 R 94 units
,emand of S2 R 2 B demand of :1 R 144 units
,emand of -1 R 1 B demand of S1 R 94 units
,emand of -< R 6 B demand of S2 R 644 units
22
e0 -ommon35se 1temsF
They are the component items %hich are used in different su$assem$lies of different end3
products. These items must $e added to have more economic purchasin*.
f0 )n3Hand 1nventory! Scheduled 7eceipts! and Net 7eDuirementsF
O+C:a+1 i+8e+"!7 is the availa$le items in stoc& from the previous period. S*:e1,)e1
!e*ei3 is the items already $een ordered $ut not $een received from the vendors yet. Ne
!eF,i!eme+ is found $y su$tractin* the "+-:a+1 i+8e+"!7 and s*:e1,)e1 !e*ei3s from
the g!"ss !eF,i!eme+s.
*0 Planned )rder 7eleaseF
P)a++e1 "!1e! !e)eases refer to the process of releasin* a lot of every component item for
production or purchase. ,etermination of lot si+e is an economic issue. The trade off is
$et%een :e i+8e+"!7 :")1i+g *"ss and the se ,3 *"ss.
ot si+es in M7P system are determined for component items for each sta*e seDuentially
startin* %ith level 1! then level 2 and so on.
h0 ead Time and ead Time )ffsettin*F
The )ea1 ime is the time it ta&es to produce or to purchase a part.
The lead time depends onF
; setup time
; production time
; lot si+e
; seDuence of machines on %hich operations are performed
; Dueuin* delays
The 3,!*:asi+g )ea1 ime is the time $et%een placin* an order %ith a vendor and receipt
of the order.
The manufacture or purchase of component items must $e offset $y at least their )ea1
imes to ensure availa$ility of these items for assem$ly into their parent items at the desired
time.
F. CAPACITY PLANNING:
26
The output of Material 7esource Plannin* does not produce an eBecuta$le manufacturin*
plan! $ecause it contains material reDuirement information only $ut does not contain
information a$out the manufacturin* capacity of the plant.
-apacity plannin* is concerned %ith ensurin* the feasi$ility of production plans $y
determinin* resources such as la$or and eDuipment %ith a vie% to developin* %hat is
&no%n as an e6e*,a<)e ma+,0a*,!i+g 3)a+.
The process of capacity plannin* is compleB and involves a num$er of decisionsF
; :Bplorin* overtime / multiple shifts / su$3contractin* options
; ,evelopin* alternative process plans for effective resource utili+ation
; Splittin* lots
; 1ncreasin* or decreasin* employment levels to respond to capacity chan*es
; 1nventory options! $uffer stoc&s
; 1ncreasin* capacity $y addin* capital eDuipment such as machines/eDuipments.
G. ORDER RELEASE:
)nce an eBecuta$le manufacturin* plan is o$tained! orders are released to the shop floor.
)rder release documents includeF
; Part No ! Jty to $e produced of each item.
; B)M is also referred as 7outin* sheets havin* information onF
I operation seDuences!
I %or& centers!
; Standard machine time allo%ed for each operation! etc.
; Appropriate shop floor records such as cards! move cards! and part lists for assem$ly
jo$s /B)M is referred0.
The "!1e! !e)ease tri**ers a num$er of activities at the shop floorF
I Schedulin* of jo$ orders on the %or& centers.
I SeDuencin* of jo$s on a %or& center.
I Allocation of ji*s and fiBture.
I oadin* of %or& centers considerin* optimal process conditions.
I -oordination of material handlin*! stora*e! %arehousin*! and machine tools.
H. SHOP FLOOR SCHEDULING AND CONTROL:
2<
#hen the planned orders are released to the shop floor for manufacturin*! the primary
o$jective is to deliver the product.
I at the ri*ht time!
I in the ri*ht Duantities!
I Meetin* Duality specifications.
But some uneBpected event /machine $rea&do%n for eBample0 may cause delays! the up to
date information from shop floor is send to mana*ement via $rea& do%n memo.
1n order to ta&e action /for e.* chan*in* the schedulin*0! up to date information from the
shop floor is sent to the mana*ement.
A num$er of methods are used for data collection in Astra Metal Systems Pvt. td. areF
I Hand %ritten reports.
I Manual data entry terminals! for enterin* data in eBcel files called #1P files.
The major functions "0 a s:"3C0)""! *"+!") s7sem follo%ed areF
I Schedule jo$ orders on the %or& centers!
I SeDuence the jo$s in order on a %or& center!
I Provide accurate and timely order status information.
The %or& order status information includesF
I order $atch si+es
I jo$ completion
I remainin* jo$s and operations
The %or& order status information is usedF
I To monitor the pro*ress of manufacturin* activities.
I To determine priorities for schedulin* jo$s in the shop in response to chan*es in jo$
order status.
I To maintain and control %or& in process.
I To provide output data for capacity control purposes.
)peration schedulin*F
There are t%o major activities to $e performed %hen 4"!5 "!1e!s are released to the shop
floorF
29
1. The %or& orders are assi*ned to the %or& centers such that due dates are satisfied.
Allocation of jo$s to %or& centers is referred to as ma*:i+e )"a1i+g.
2. The seDuence of each %or& order throu*h each %or& center is determined. This
process is referred to as B"< seF,e+*i+g.
The o$jectives of "3e!ai"+ s*:e1,)i+g areF
; Meetin* due dates.
; Minimi+in* manufacturin* throu*hput time.
; Minimi+in* %or&3in3process.
; MaBimi+in* %or& center utili+ation.
No$ SeDuencin* and Priority 7ulesF
Normally! the total num$er of jo$s eBceeds the num$er of %or& centers. -urrently Astra
Metal Systems Pvt. td. uses com$inations of priority rules li&e S:"!es 3!"*essi+g ime
%herein hi*hest priority is *iven to the jo$ %ith the shortest processin* time. 1n some cases
Ea!)ies 1,e 1ae /:,,0 or Leas s)a*5 rule is *iven the hi*hest priority.
S)a*5 R time remainin* until due date 3 process time remainin*.
More suita$le priority rule for Astra Metal Systems Pvt. td. &ind of entrepreneurship %ill
$e Fi!s C I+ Fi!s C O, /?1?)0. This %ill improve performance in plant operations. Since
too many chan*es lo%ers productivity and even too many chan*es lo%ers one or other
customerEs service level.
J5A1TK ASS57AN-:F
1n Astra Metal Systems Pvt. td. Juality is maintained in t%o %aysF
1. :ach %or&er monitors his %or&S and
2. Periodic inspections are performed $y individuals from the Duality control function
1nspection is necessary at several places in the manufacturin* process! includin*F
1. 1nspection of ra% materials
2. 1nspection of manufactured productF
I Preprocess
I 1n3process
2=
I Post process
1nspection of production process parametersF
; Tools
; ?iBtures
; Production machinery
; Verification/cali$rationF
1. 1nspection fiBtures
2. 1nspection *au*es
6. 1nspection machinery
Juality Assuarnce Process at Astra Metal Systems Pvt. td.
Me:"1")"g7 a+1 P!"*e1,!e "0 A"!5:
1n Astra Metal Systems Pvt. td. the production of hi*h3Duality parts is the company
policy! production operators inspect the parts durin* the production process to ensure that
28
the process is under control. Some operations involve 144T inspection and some use
random samples.
Astra follo%s samplin* $ased inspection %herein randomly a sample is ta&en from a $atch
%hich is representative of the entire $atch. Thus! only the sample is inspected in
determinin* the Duality of the entire $atch. No of samples to $e inspected depends on $atch
si+e. ?or fa$ricated products and $ou*ht out items samplin* plans are desi*ned to avoid
non value added activity.
Machine components reDuired for production process are verified at Juality department! as
an inspection process M/ced components are inspected under sample plan %ith acceptance
Duality limit. The num$ers of inspection samples are eDual to the sample si+e as defined
$elo%. -riteria for acceptin* or rejectin* a lot depends on num$er of non conformin* items!
if they are eDual to the acceptance num$er! full lot is accepta$le su$ject to the functional
fitment acceptance.
Lot size
Sample
size
Acceptan
ce
Rejecti
on
Quantity in
Numbers
2 to 8 2 0 1
9 to 15 3 0 1
1 to 25 5 0 1
2 to 50 8 0 1
51 to 90 13 0 1
91 to 150 20 1 2
151 to 280 32 1 2
281 to 500 50 2 3
501 to 1200 80 3 !
1201 to 3200 125 5
3201 to 10000 200 " 8
?or in3process inspection of Product a*ain samplin* plan is follo%ed throu*hout the
production line. The /SAMP:31U0 ?irst conform Piece %ill $e :Bcludin* of Settin*
Piece/s0. 1f the settin* pieces found to $e Non3 conformin*! it is transferred to Juality
-ustody for further disposition action. Visual characters /li&e dent mar&! $o%! punchin*
mar&! 7ust! #eld distortion! %eld Juality! tapper $end! po%der shade! po%der pattern!
scratch mar&! pin holes and forei*n particle0 are inspected 144T.
2"
Batch Si+e
Sample
s Sample31U Sample32 Sample36 Sample3< Sample39
5p to 19 2 ?irst -onform Piece ast Piece 33 33 33
1= 3 <@ 6 ?irst -onform Piece 94T 144T 33 33
94 and A$ove 9 ?irst -onform Piece 29T 94T 89T 144T
P!"1,*i"+ 3!"*e1,!eF -ustomer *ives orders to PP- for re*ular production! for ne%
parts inDuiry comes throu*h ne% development team to PP- Duotes are sent! on approval of
Duotes! commitment for delivery of proto/samples *iven than samples approval process is
follo%ed $efore ta&in* actual production process.
H"4 is P!"1,*i"+ P)a++i+g 1"+eG: Production plannin* and control /PP-0 department
receives a Production )rder /P)0 that consists of client reDuirements such as product type!
Duantity! revision status! item rate and delivery date. PP- cross verifies Purchase )rder
terms G conditions a*ainst correspondin* Duotation released $y M, / -:) or Previously
a*reed rates as per ?inal Product ist. After revie% of Purchase )rder the same is updated
in data$ase pro*ram and ac&no%led*ement sent to the customer if needed.
PP- controls su$ units such as schedulin*! routin*! ra% material handlin*! and personnel!
etc necessary for the successful completion of the order. #hen a contract affectin* product
parameters is modified! PP- initiate the component Modification process. PP- transmits
the order reDuirements to these su$ units electronically in the form of a production reDuest.
Based on inputs a$out availa$ility of respective resources from various su$ units! PP-
$rea&do%ns the P) into production $atches and lots. -ustomer releases purchase orders
%hich can $e specific Dty %ith tar*et dates or open order %ith monthly or %ee&ly schedule
%hich follo%s from time to time
Mae!ia) De3a!me+:
The material department is responsi$le for material reDuirement plannin* and for providin*
materials such as -7-A! H7-A! Hard%are! M/c items! Po%der! chemicals. ,urin* the
process of P) order $rea&do%n! the main role of the Material department is to determine
the amount of ra% material reDuired to satisfy the P) and chec& for their availa$ility either
via in3house inventory or an eBternal vendor. ,ependin* on the availa$ility of the ra%
material reDuired for production or the due dates as to %hen the procurement %ould $e
complete! the Material department provides the necessary feed$ac& to the schedulin*
department /PP-0.
2@
F,+*i"+a) A!eas "0 Mae!ia) De3a!me+:
Material department has five primary functionsF
I 7a% Material reDuirement computation
I 1nventory Mana*ement
I Vendor Selection
I o*istics
I #arehouse Mana*ement
The P)s /Production )rders0 arrive on the floor at irre*ular intervals and for various types
of products %ith various compositions. The orders are currently processed manually $y a
PP- /Production! Plannin* and -ontrol0 %ho after innumera$le consultations %ith other
departments $rea&s do%n the order into $atches and fi*ures out the $est %ay to produce
the lot %ith the *iven specifications and availa$ility of ra% materials. Since the iterative
process and manual schedulin* of the orders is time consumin* and depends on real time
information! it invaria$ly results in a hapha+ard schedulin* and delays in finishin* an order.
-urrently Astra is implementin* :7P module. This module %ill $e inte*rated %ith the
overall production order information system at a later sta*e.
:Bpected $enefits of the ne% :7P Module are follo%in*F
I Juic&er cycle time
I 1ncreased productivity
I a$or savin*s
I :fficient schedulin*
I :liminate $ottle nec&s and ma&e $etter use of machine time
I #aste prevention and efficient use of ra% material
I 1mproved morale / 7educed stress
:7P Module %ill ena$le Astra Metal Systems Pvt. td. employees toF
I -alculate the amount of ra% material reDuired to complete a P)
I .enerate reports of ra% material inventory across all the 5nits
I .enerate list of approved vendors
I -ompare different vendors from the list and select vendors $ased on price! lead
time! and Duality
64
I .enerate purchase orders to vendors
I :ffective mana*ement of contractin* process
I ,evelop user *uidelines and policies
I :nsure secure authori+ed user access
I Protect vendor and customer information
Astra Metal Systems Pvt. td. follo%s J"< "! ,+i 3!"1,*i"+ of production system
%herein production is initiated as per customer specifications! each $atch or order consists
of a small lot of products and may $e different from other $atches. 1t is fleBi$le and can $e
adapted to chan*es in product desi*n and order si+e %ithout much inconvenience. 1n this
system varied products are produced a*ainst specific orders.
Production as a System
1nputs 1nputs 1nputs 1nputs
)utputs )utputs
)utputs )utputs
-onversion -onversion
Su$system Su$system
-onversion -onversion
Su$system Su$system
Production System Production System
-ontrol -ontrol
Su$system Su$system
-ontrol -ontrol
Su$system Su$system
61
Astra Metal Systems Pvt. td. ?ollo%s B"<<i+g 3!"1,*i"+ ma+,0a*,!i+g 3!"*ess
%herein one or fe% units of the products are produced as per the reDuirement and
specifications *iven $y customer via Purchase order and ,ra%in*s respectively. Production
is to meet the delivery schedule and costs are fiBed prior to the contract. 1n this! limited
Duantities of each of the different types of products are manufactured on same set of
machines. ,ifferent products are produced separately one after the other.
T!a+s0"!mai"+ P!"*ess
I+3, P!"*ess O,3,
Materials Manufacturin* A37ay M/cOs
Machines Assem$lin* ATM M/cOs
Man / %or&ers Transportin* Cios&s
Money / capital Storin* Services
1nformation -onsultin*
62
ProcessF A series of activities that ta&es an input adds value to it and produces an output for
a customer
Production Plannin* and -ontrol /PP-0 is a process that comprises the performance of
some criticalS functions on either side! vi+.! plannin* as %ell as control. ?i*ure PP- Process
Production Plannin* and control

P!"*ess La7", C 4"!5 !a8e)s " 1e1i*ae1 3!"*ess *e+e!s
P,+*:i+g
Assem<)7
H Tes
Be+1i+g
P"41e!*"ai+g Fa<!i*ai"+
P!"*ess La7",
66
Production Plannin* Production -ontrol

Plannin* ,ispatchin*

7outin* ?ollo%in* up

oadin* 1nspection

Schedulin* -orrective

P!"1,*i"+ P)a++i+g a+1 C"+!") F,+*i"+s
All of the four $asic phases of control of manufacture are easily identified in production
plannin* and control. The plan for the processin* of materials throu*h the plant is
esta$lished $y the functions of process plannin*! loadin*! and schedulin*. The function of
dispatchin* puts the plan into effectS that is! operations are started in accordance %ith the
plan. Actual performance is then compared to the planned performance! and! %hen
reDuired! corrective action is ta&en. 1n some instances re3plannin* is necessary to ensure the
effective utili+ation of the manufacturin* facilities and personnel.
A. P!"1,*i"+ P)a++i+g:
Production plannin* may $e defined as the techniDue of foreseein* every step in a lon*
series of separate operations! each step to $e ta&en at the ri*ht time and in the ri*ht place
and each operation to $e performed in maBimum efficiency. 1t helps to %or& out the
Duantity of material manpo%er! machine and money reDuires for producin* predetermined
level of output in *iven period of time.
/a0 P!"*ess P)a++i+g -R",i+g.: The determination of %here each operation on a
component part! su$assem$ly! or assem$ly is to $e performed results in a route for the
movement of a manufacturin* lot throu*h the factory. Prior determination of these
routes is carried out $y ne% product development team. 5nder this! the operations!
their path and seDuence are esta$lished. The main aim of routin* is to determine the
$est and cheapest seDuence of operations and to ensure that this seDuence is strictly
follo%ed. 7outin* procedure involves follo%in* different activities.
/10 An analysis of the article to determine %hat to ma&e and %hat to $uy.
6<
/20 To determine the Duality and type of material
/60 ,eterminin* the manufacturin* operations and their seDuence.
/<0 A determination of lot si+es
/90 ,etermination of scrap factors
/=0 An analysis of cost of the product
/$0 L"a1i+g: )nce the route has $een esta$lished! the %or& reDuired is loaded a*ainst the
selected machine or %or&station. The total time reDuired to perform the operation is
computed $y multiplyin* the unit operation times *iven on the standard process sheet
$y the num$er of parts to $e processed. This total time is then added to the %or&
already planned for the %or&station. This is the function of loadin*! and it results in a
ta$ulated list or chart sho%in* the planned utili+ation of the machines or %or&stations
in the plant. The neBt step is the eBecution of the schedule plan as per the route chal&ed
out it includes the assi*nment of the %or& to the operators at their machines or %or&
places.
So oadin* determines %ho %ill do the %or& as 7outin* determines %here and
Schedulin* determines %hen it shall $e done.
/c0 S*:e1,)i+g: Schedulin* is the last of the plannin* functions. 1t determines %hen an
operation is to $e performed! or %hen %or& is to $e completedS the difference lies in the
detail of the schedulin* procedure. 1n Astra de3centrali+ed schedulin* system is
follo%ed %here all process plannin*! loadin*! and schedulin* for the units are done in
main unit the details of the schedule may specify the startin* and finishin* time for an
operation. And accordin*ly location PP- %ith the help of production supervisor
schedules on day to day $asis to meet completion time for the %or& in a *iven
department.
1t means %or&in* out of time that should $e reDuired to perform each operation and
also the time necessary to perform the entire series as routed! ma&in* allo%ances for all
factors concerned. 1t mainly concerns %ith time element and priorities of a jo$.
The pattern of schedulin* differs from one jo$ to another %hich is eBplained as $elo%F
69
I Mase! S*:e1,)eF Schedulin* usually starts %ith preparation of master schedule %hich
is monthly! $ro&en do%n to %ee&ly production reDuirement for each product for a
definite time period! $y havin* this as a runnin* record of total production reDuirements
the PP- is in $etter position to shift the production from one product to another as per
the chan*ed production reDuirements. This forms a $ase for all su$seDuent schedulin*
activities. A master schedule is follo%ed $y operator schedule %hich fiBes total time
reDuired to do a piece of %or& %ith a *iven machine or %hich sho%s the time reDuired
to do each detailed operation of a *iven jo$ %ith a *iven machine or process.
I P!"1,*i"+ s*:e1,)eF The main aim is to schedule that amount of %or& %hich can
easily $e handled $y one unit %ithout interference. To sta$ili+e or avoid freDuent
chan*es in location of manufacturin* any product! at the initial period i.e at the time of
prototype itself feasi$ility study is carried out and as far as possi$le %here all the
processEs can $e done in totality that location is selected as manufacturin* unit for that
*iven product. 1tEs not independent decision as it ta&es into account follo%in* factors.
/10 Physical plant facilities of the type reDuired to process the material $ein* scheduled.
i&e some jo$s may reDuire laser cuttin* %hich in availa$le only %ith one unit out of 6
Astra 5nits.
/20 Personnel %ho possess the desired s&ills and eBperience to operate the eDuipment
and perform the type of %or& involved.
/60 Necessary materials and purchased parts.
S*:e1,)i+g "0 J"< "!1e! ma+,0a*,!i+gF Schedulin* is of utmost importance as it
$rin*s out efficiency in the operations and reduces cost price. Astra PP- $asically
maintains different types of schedules to have a close scrutiny of all sta*es namely an
enDuiry schedule! a production schedule! a shop schedule out of a$ove three! a shop
schedule is the most important as it ena$les to see at a *lance.
1. The total load on any section.
2. The operational seDuence.
6. The sta*e! %hich any jo$ has reached.
C"m<i+i+g F,+*i"+s: #hile it is easy to define '%here( as process plannin*! 'ho%
much %or&( as loadin*! and '%hen as schedulin*! in actual operations these three
functions are often com$ined and performed concurrently. )$viously! it is desira$le that
6=
a minimum of chan*es $e made after schedules are esta$lished. This o$jective can $e
approached if the amount of %or& scheduled for the unit or department is eDual to or
sli*htly *reater than the manufacturin* cycle. ?or optimum control! it should never $e
less than the manufacturin* cycle.
B. P!"1,*i"+ *"+!"):
Production control is the process of plannin* production in advance of operations!
esta$lishin* the eBtract route of each individual item part or assem$ly! settin*! startin*
and finishin* for each important item! assem$ly or the finishin* production and
releasin* the necessary orders as %ell as initiatin* the necessary follo%3up to have the
smooth function. The production control is of complicated nature. The production
plannin* and control department can function at its $est only %hen the production
mana*er! the purchase mana*er! the personnel mana*er and the financial controller
assist in plannin* production activities.
a. Dis3a*:i+g: Authori+in* the start of an operation on the shop floor is the function of
dispatchin*. This ?unction may $e centrali+ed or decentrali+ed. 1n Astra said function is
,e3centrali+ed %herein production supervisors are authori+ed to start each of the
machine operations $ased on the routin* and schedulin* of the %or& throu*h his
department. ,ispatchin* involves issue of production orders for startin* the operations.
Necessary authority and conformation is *iven forF
1. Movement of materials to different %or&stations.
2. Movement of tools and fiBtures necessary for each operation.
6. Be*innin* of %or& on each operation.
<. 7ecordin* of time and cost involved in each operation.
9. Movement of %or& from one operation to another in accordance %ith the route
sheet.
=. 1nspectin* or supervision of %or&
,ispatchin* is an important step as it translates production plans into production.
<. Re3"!i+g "! F"))"4 I ,3 : 1n Astra this function is carried on daily $asis %hich starts
%ith production meetin* %ith necessary departments li&e Press Shop! ?a$ Shop!
Po%der -oatin*! )ffloadin*! Purchase! Maintenance Juality and PP-. The
manufacturin* activity of a plant is said to $e 'in control( %hen the actual performance
68
is %ithin the o$jectives of the planned performance. #hen jo$s are started and
completed on schedule! there should $e very little! if any! concern a$out the meetin* of
commitments. :very production pro*ramme involves determination of the pro*ress of
%or&! removin* $ottlenec&s in the flo% of %or& and ensurin* that the productive
operations are ta&in* place in accordance %ith the plans. i&e mornin* meetin* concern
in3char*e in respective department monitors/revie%s dayEs production at the end of
shift. 1t spots delays or deviations from the production plans. 1t helps to reveal detects
in routin* and schedulin*! misunderstandin* of orders and instruction! under loadin* or
overloadin* of %or& etc. All pro$lems or deviations are investi*ated and remedial
measures are underta&en to ensure the completion of %or& $y the planned date!
currently measures li&e providin* necessary ji*s G fiBtures! identifyin* unnecessary
activities and eliminatin* them alon* %ith overtime %or&in* is emphasised.
*. C"!!e*i8e A*i"+: This is the &eystone of any production plannin* and control
activity. 1f all processes are on schedule that means in all pro$a$ility production is not
$ein* scheduled to its optimum productive capacity. #ith an optimum schedule!
manufacturin* delays are the rule! not the eBception. As a -orrective action in Astra
activities of adjustin* the route! reschedulin* of %or&! repairs and maintenance of
machinery or eDuipment! control over inventories is initiated. Alternate methods li&e
overtime! increase in %or& force is ta&en to handle pea& loads.
1. I+s3e*i"+: This is mainly to ensure the Duality of *oods. 1t can $e reDuired as effective
a*ency of production control. To move to%ards %orld class manufacturin* unit Astra is
in the process of im$i$in* this inspection process in the $lood of producer /operator0.
As such necessary on*oin* trainin* are provided operators.
e. ReC3)a++i+g: 7e3plannin* is not corrective action. 7e3plannin* revises routes! loads!
and schedules! a ne% plan is developed. Astra $ein* jo$ shopper and have vide variety
products and lar*e customer $ase this function is often reDuired. -han*es in customer
reDuirements! machine $rea&do%ns! a$senteeism! material shorta*es or any other
factors affectin* the day to day %or&in* often indicate that a re3plannin* is needed.
As in many manufacturin* industries today! Astra is under increasin* pressure to transform
$usinesses from ma&e3to3forecast /$ased on the predictions *iven $y customers0 to small
$atch made3to3order /MT)0 production. The emphasis is also stron* on just3in3time
6"
deliveries and minimal stoc&holdin* throu*hout the manufacturin* process. The customer
no%adays eBpects a fast delivery of Duality products that are ali*ned %ith current trends.
?leBi$ility on the shop floor is $ecomin* essential and attitudes have had to chan*e from
pre3set machine runs for producin* and stoc&in* to a ne% ean approach of ma&in* only
%hat can $e sold.
#ithin our or*ani+ation it %as %idely reco*ni+ed that the performance of production
systems is not only determined $y the %ay the production system is controlled $ut also $y
its or*ani+ational desi*n. And as a measure to try and improve performance de3centrali+ed
plannin* came into eBistence %herein for all 6 units! plans are released $y central PP- and
$ased on central PP- plans! location PP- at each unit does function of controllin* the
production $y simultaneously implementin* plannin* and control systems and utili+in*
or*ani+ational measures. Not%ithstandin* its importance! the field of production and
operations mana*ement still lac&s. )ne of the reasons for this shortcomin* seems to $e a
lac& of understandin* ho% plannin* and control systems interact %ithin or*ani+ational
plant.
)ur )r*anisation %as eBamined durin* a continuous period of siB months. After this
intensive research period! all 6 units %ere follo%ed durin* a period of one year. ,urin* this
period developments re*ardin* the plannin* and control system and the or*anisational
desi*n of the production and distri$ution system %ere o$served. The si+e of the firm is /
194 employees0. All distinctive functional areas li&e production! sales! procurement eBisted
G only mar&etin* did not eBist.
,ata %as *athered $y studyin* internal reports! visitin* and o$servin* meetin*s! and $y
means of /semi0 structured intervie%s. 1n all cases plannin*! production! materials and
lo*istics employees %ere intervie%ed for several times. #ithin each or*anisation the
employees $ein* intervie%ed consisted of employees %or&in* at $oth the lo%er! middle and
hi*her mana*ement levels. Both the /semi30 structured intervie%s and the Duestionnaires
%ere conducted.
1n all case studies some participative research elements %ere included. These included
Duestions li&eF do %e need a lo*istical or materials mana*ement department! ho% can
conflicts $et%een Production! Sales and o*istics $e reduced! are there any co3ordination
pro$lems $et%een Purchasin*! Production and Sales and if! ho% can they $e solved! and
6@
last $ut not leastF are interfaces %ithin the company $et%een functional areas mana*ed
properly. ?rom this evaluation in all units an improvement and reor*anisation process needs
to $e conducted.
Questions #nit 1 #nit 2 #nit 3
$o% can con&icts bet%een
'ro(uction) Sales an( Lo*istics be
re(uce(+
better
,ommunicati
on) nee(s
Re(esi*n
or*anization
structure
nee(s
re(esi*n
or*anizati
on
structure
Re(e-ne
responsibilit
ies an(
aut$orities
are t$ere any co.or(ination
problems bet%een 'urc$asin*)
'ro(uction an( Sales+ /es /es /es
i0) $o% can t$ey be sol1e(+
2R') Lean
process 2R' 2R'
(o %e nee( a lo*istical or
materials mana*ement
(epartment+ 3aterials 3aterials 3aterials
Are inter0aces %it$in t$e company
bet%een 0unctional areas mana*e(
properly+ No No No
P!"1,*i"+ De3a!me+s -P!"*ess.:
P!ess S:"3
I Punchin*
I Bendin*
I 1nsertin*
Fa<!i*ai"+
I #eldin*
I ,rillin*
I Sanderin*
S,!0a*e 0i+is:i+g
I Po%der -oatin*
I Pre3treatment
P!ess S:"3:
Astra $ein* $asically sheet metal manufacturin* unit! -A,3-AM systems are %idely used.
Typically! sheetmetal parts are produced $y a num$er of different 2, and 6, operations. 1n
this study! %e only consider the cuttin* and $endin* process. Startin* from a flat $lan&! a
suita$le cuttin* process %ill $e chosen to produce the 2, part. Since material is an
<4
important cost component! optimi+ation of this process %ill $e driven $y the need to
decrease the scrap percenta*e. Nestin* al*orithms! implemented in computer systems! is
used to *roup a num$er of parts %ith the same thic&ness on a sin*le sheet. 1f the reDuired
end product is a 6, part! air $endin* %ill $e applied. The $endin* process is la$or intensive
and reDuires an operator continuously. The production time of a 6, part is influenced $y
the num$er of time3consumin* setups $et%een parts. A part reDuires a certain production
layout! i.e. a seDuence of punch3die com$inations positioned on the press $ra&e.
1nterchan*in* production layouts is time consumin* and thus needs to $e avoided as much
as possi$le. Plannin* of the air $endin* process is still hi*hly eBperience3$ased.
Here focus is on an inte*rated approach for production plannin* of sheet metal parts for
turret punch press /cuttin*0 and press $ra&e /air $endin*0.
S:ee mea) "3e!ai"+s: "3imi9ai"+ "0 :e 1isi+* 3!"*esses
Sheet metal operationsF Sheet metal operations are used to transform a flat $lan& into 2,
or 6, o$jects $y applyin* different processesF punchin*! cuttin*! $endin*! %eldin*! po%der
coatin*! platin*! etc. The thic&ness typically varies $et%een 4." and 9 mm. 1n the first step!
a cut to si+e sheet or standard si+e sheet %ill $e punched on turret punch press /TPP0 or cut
%ith the laser! resultin* in a 2, intermediate or end product.
1f 6, parts are reDuired! air $endin* is used. By applyin* a vertical force! the sheet is
forced into a die. ,ependin* on the ma*nitude of this force! the $end an*le %ill vary. :ach
$end line reDuires a certain toolset. Such toolset comprises a punch and a die! positioned on
the press $ra&e. ?or $endin* one part! often consistin* of multiple $end lines! different
toolsets mi*ht $e needed.
Those sets %ill all $e positioned on the press $ra&e! resultin* in a production layout.
-han*in* production layouts is time consumin* and should $e avoided as much as possi$le.
The operatorEs eBperience plays an important role in reducin* the num$er of tool chan*es
at the press $ra&e.
?i*ure displays the different sheet metal operations.
<1
T,!!e P,+*: P!ess -C,i+g.: Nesi+g "0 :e "!1e!s
-urrently! Astra manufacture ta&es production $atch si+e %ith smaller lot si+es than $efore.
To decrease the costs for sheet metal punchin* or laser cuttin*! nestin* is applied. -urrently
nestin* is $asically done to produce items %ith minimum $atch si+es that too under same
product $rand and same customer.
?uture nestin* plans %ill imply com$inin* multiple orders of the same material on a sheet!
such that the amount of %aste material is reduced. This can $e of different product and
different customers.
The pro$lem of com$inin* different parts on a sheet is &no%n as the cuttin* stoc& Pro$lem.
1n the first sta*e the parts are en*a*ed in minimum area rectan*ular modules either sin*ly
or in com$ination %ith other parts. 1n the second sta*e! those modules are *rouped on a
sheet! minimi+in* the %aste material. An important remar& is the fact that these
simplifications can create additional %aste material. Parallelo*ram shaped parts can ideally
$e nested %ithout any %aste material.
An instruction to punchin* operator is *iven usin* No$ )rder for pro*ram to $e punched G
shall chec& for the follo%in* parametersF
1. Pro*ram No
<2
2. -A, ?ile Name
6. Sheet Si+e
<. Sheet thic&ness
9. Material used
=. NoEs of sheets to $e punched
8. No$ description G Si*nature
". Special 1nstructions
Punchin* operator than chec&s the Tools indicated in the Pro*ram to $e punched G note
do%n the correct die clearances *iven G direction of Tool loadin*. Tool loadin* %ith
proper direction and proper clearance is initiated for that particular thic&ness.
P,+*: T"") Basi*s
Toolin* for a punch press consists of a punch! die and stripper. The punch is located in a
*uide mechanism that fits in the turret on a turret punch press. Turrets hold a variety of
tools and indeB to $rin* different punch tools into the %or& +one of the machine.
:ach punch tool has a correspondin* die that is located under the machine toolOs %or&ta$le.
The si+e and shape of the hole created in the sheet metal is determined $y the *eometry of
the punch. -learance $et%een the punch and die is adjusted to reflect the material
thic&ness.
#hen the punch press is actuated! a ram descends! causin* the punch to &noc& out the
material creatin* a slu*. The die is desi*ned to allo% the slu* to fall throu*h. The stripper
holds the sheet metal in place until the punch is fully %ithdra%n from the sheet.
Most sheet metal punch tools used in shops today are self3strippin*. 1nstead of usin* the
ram to push the punch throu*h the material and pull it out! these tools are $uilt %ith an
internal sprin* that automatically retracts the punch. The ram then only needs to %or& in
one direction. This saves cycle time and %ear on the turret punch press.
T"") Li0e
The punchin* process *enerates heat. There is friction $et%een the punch and the *uide
assem$ly as the punch reciprocates %ithin its $ushin*s. Modern turret punch presses are
capa$le of 1!444 stro&es per minute. Most punch presses are eDuipped %ith! or have
availa$le! an automatic oil lu$rication system. 1t supplies an air3oil mist throu*h ports in the
<6
*uide assem$ly to lu$ricate the movin* parts in the tool. This si*nificantly eBtends the life
of %ear parts %ithin the punch tool.
Be+1i+g: Mi+imi9ai"+ "0 :e +,m<e! "0 se,3s
?or the $endin* operation! production time minimi+ation is reDuired. After careful studies
of dra%in* proper tools are selected accordin* to the sheet thic&ness! $end shape and
$endin* len*th.
7elationship $et%een Sheet Thic&ness /t0 and V3%idth
S:ee :i*5+ess $.=C#.% mm (.$C? mm @C&$ mm &# mm "! m"!e
V3%idth =t "t 14t 12t
V3)penin* selections normally should $e as per the standards i.e for material thic&ness less
then 6mm it should $e =BT! and for 6mm to <mm its "BT /TRthic&ness of the sheet0
Selection of Punch and ,ieEs -om$ination is done such that components are $ent %ith
minimum noEs of Tool Set upEs! also as far as possi$le ,ie removal is avoided %hile
seDuencin* of $ends.
RECOMENDED VCOPENING DIES TO BE USED FOR BENDING.
Re*"m. Mi+ Be+ F)a+ges A*:ie8e1.-mm. "+ Di00. P,+*:es.
S:.T:5s.VCOPEN #&$ -$.?!. '&=-&.=!. '=#&=-&.=!. '$?-$.?!. '>&=&-&.=!.
4." = < 9 9 9 9
1 = < 9 9 9 9
1.2 " =.2 8.2 8.2 8.2 8.2
1.9 14 8 " " " "
1." 12 @ 14 14 14 14
2 12 @ 14 14 14 14
2.9 1= 11.9 12.9 12.9 12.9 12.9
6 1= 12 16 16 16 NA
< 29 1".9 1".9 1".9 1".9 NA
Blan& are chec&ed and ensured there are no $urrs in the supportin* area /$ac& *au*e0. Tool
ori*in point is set $y *ivin* adeDuate pressure. ?ormula R maB pressure / "69 B punch
len*th. /MaB pressure ; 8.1/"69 mm0 -N- pro*ramme is corrected to *ive enou*h feed
speed V?SW! $ac& *au*e retract len*th and ,3aBis movement.
<<
Actual $endin* is done and dimensions are chec&ed in each cycle! pro*ramme is corrected
only in the case of dimension variation. This pro*ramme is saved for $atch production.
,imensions related to $endin*! are %ritten do%n in $endin* report re*ister. Parts are
chec&ed after predefined $atch to avoid any sort of deviation from dra%in* specifications.
After completin* $endin* operation of $atch! the part are moved to neBt station $ased on
route! herein process locations are defined to store the material from %here neBt station
collects material for further processin*. Parts are identified %ith %hite ta*Es filled %ith data
li&e part no! part description! Dty! date of production.
?or the production plannin* model some important data reDuirements need to $e fulfilled.
?irst! the partsE characteristics! sheetsE characteristics and the production layouts are
needed. The partEs characteristics and the sheetEs dimensions can $e eBtracted from the Bill
of Material. The production layout is determined $ased on the press $ra&e operatorEs
eBperience. All data is put in datasheets to $e lin&ed %ith the plannin* model.
Second! the Punchin* times and the $endin* times are needed. The Punchin* times are
determined usin* Soft%are output! %hile the $endin* times are determined $y means of a
time3motion study.
F,+*i"+i+g "0 P!ess S:"3:
Press3Shop 1n char*e plans production as per %ee&ly plan released $y PP-. This is $ro&en
do%n to daily plan for /Turret Punch! Press3Bra&e! 1nsertin* respectively0. Shift 1n3char*e
chec&s for the manpo%er! material G machine availa$ility.
Pro*ram for punchin* is made ready as per daily production plan G same is do%nloaded on
m/c $ased on No$ order slip %hich is issued to operator. )perator chec&s for tools that are
reDuired to process the do%nloaded pro*ram G accordin*ly load the Turret.
Su$seDuent to punchin* and prior to $endin* the $lan&ed material is made $urr free to
avoid any hindrances %hile $endin* )n Press3Bra&e! $ased on the process seDuence tool
set up is carried out and accordin*ly jo$s are processed.
<9
?irst piece inspection is carried out G relevant data is recorded in in3process inspection
re*ister /JA Maps0. 1f any variation in product characteristics is noticed than it is corrected
G jo$ are re3inspected G a*ain re3relevant data is recorded in in3process inspection re*ister.
After the first piece is accepted! production is carried out as per process seDuence. The
inspection of the products is done at freDuency defined for monitorin* G measurement of
product. Material to $e moved to concerned department for further processin* is moved as
per $elo% movement note
1. To stores /for further processin*0F3 material movement note start %ith PS3 follo%ed
$y increasin* serial no. if moved from Bendin* and TS if moved after punchin*
2. To stores /,ispatch0F3 material movement note start %ith P,3 follo%ed $y
increasin* serial no. if moved from Bendin* and T, if moved after punchin*
6. To ?a$rication ShopF3 material movement note start %ith P?3 follo%ed $y
increasin* serial no. if moved after $endin* and T? if moved after punchin*
<. To Po%der -oatin* ShopF3 material movement note start %ith PP3 follo%ed $y
increasin* serial no. if moved after $endin* and TP if moved after punchin*
1n3process rejections that occur in the process are entered in inspection re*ister and
controlled as per set procedures for controllin* N- /Non conformin*0 items. An operator
does the inspection for parameters identified in dra%in*s! and in case of non3conformities
necessary disposition and corrective actions are initiated.
Fa<!i*ai"+:
?a$rications involvin* sheet metal! plate or pipes %hich are commonly %elded $y an arc
process. The most %idely used %eldin* processes rely on fusion of the components at the
joint line. 1n fusion %eldin*! a heat source melts the metal to form a $rid*e $et%een the
components. T%o of the most important processes use a *as shield to protect the %eld
metal from atmospheric contamination.
M1. / MA. / T1. %eldin* principles .as shielded metal arc %eldin* is a semi3automatic
process %hich is suita$le for $oth manual and mechanised operation.
1t is &no%n $y a variety of namesF
M1. 3 Metal 1nert .as! MA. 3 Metal Active .as! -ar$on ,ioBide / Ar*on
<=
A lo% volta*e /1".<4V0! hi*h current /=4.944A0 arc $et%een the end of a %ire electrode
and the %or& provides the heat needed for the %eldin* operation. The arc and the %eld are
protected from atmospheric contamination $y a *as shield.
Time study of fa$rication process is carried out to facilitate eBecution of fa$rication activity.
Srl
Part no ,escription Jty
Time in minutes

Total
Time
#
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mins
Product MM2.9
1 9<2411" 441 ?ront -over 1 " 3333 3333 @ 14 3333 3333 3333 3333 28
2 9<2414@ 441 Top Panel -omplete 1 " 3333 3333 19 19 3333 3333 3333 3333 6"
6 9<12<64 441 -ap -omplete 1
14
3333 3333 19
1=
3333 3333 3333 3333 <1
< 9<12<11 441 Tan& Housin* -omplete 1
<9
24
19 64
64 3333 3333 24 24 1"4
9 9<24169 441
-olumn -ap
1
9
3333 3333 "
12
3333
9
3333 3333 64
= 9<24119 441
-assette BoB
1
9
3333 3333 19
19
3333 3333 3333 3333 69
8 9<21=9@ 441
#heel .uard
1
19
3333 3333 12
1"
3333 3333 3333 3333 <9
" 9<12<21 441 Top Plate -omplete 1
14
3333 3333
"
= 3333 3333 3333 3333 2<
@ 9<16=61 442 inverter $ase tray 1 33333 6 33333 @ 29 9 14 3333 3333 92
14 9<12<2@ 441 -over -omplete 1
9
33333 33333 =
"
3333
9
3333 3333 2<
F,+*i"+i+g "0 Fa< S:"3:
Based on time study production is line up for neBt day. #herein daily Production line3up
for man G machine /-)2 #eldin*! Spot %eldin*! ,rillin*! Sanderin*! etc.0 is monitored
and measured.
<8
?a$3Shop 1n char*e plans production as per %ee&ly plan released $y PP-. This is $ro&en
do%n to daily plan for /#eldin*! ,rillin*! Sanderin*! ,e$urrin*! fillin*! $uffin*0. Shift 1n3
char*e chec&s for the manpo%er! material G machine availa$ility.
Visual inspection for Duality of fa$rication is carried out $y operators themselves $efore
movin* said item to neBt station. 1n case of detection of any visual defects! the shift
supervisor initiates necessary disposition and corrective action.
?irst piece is verified for conformity as per the procedure for monitorin* G measurement of
product! and then the production is $e carried out as per process seDuence /route0. Here
a*ain similar to Press Shop material movement method is follo%ed for identifyin*
movement from fa$rication to other department! %here in T is placed %ith ? /for ?a$0
P"41e! C"ai+g:
Po%der coatin* is $y far the youn*est of the surface finishin* techniDues in common use
today. 1t %as first used in Australia a$out 1@=8. Po%der coatin* is the techniDue of
applyin* dry paint to a part. The final cured coatin* is the same as a 23pac& %et paint. 1n
normal %et paintin* such as house paints! the solids are in suspension in a liDuid carrier!
%hich must evaporate $efore the solid paint coatin* is produced.
1n po%der coatin*! the po%dered paint may $e applied $y either of t%o techniDues.
I The item is lo%ered into a fluidised $ed of the po%der! %hich may or may not $e
electrostatically char*ed! /Astra does not have this set up0 )7
I The po%dered paint is electro3statically char*ed and sprayed onto the part. Astra
uses this method.
The part is then placed in an oven and the po%der particles melt and coalesce to form a
continuous film.
There are t%o main types of po%der availa$le to the surface finisherF
I Thermoplastic po%ders that %ill re3melt %hen heated! and
<"
I Thermosettin* po%ders that %ill not re3melt upon reheatin*. ,urin* the curin*
process /in the oven0 a chemical cross3lin&in* reaction is tri**ered at the curin*
temperature and it is this chemical reaction %hich *ives the po%der coatin* many of
its desira$le properties.
P!e3a!ai"+ 0"! P"41e! *"ai+g:
The $asis of any *ood coatin* is preparation. The vast majority of po%der coatin* failures
can $e traced to a lac& of a suita$le preparation. The preparation treatment is different for
different materials. 1n *eneral! for all applications the preparation treatment for aluminium
is as follo%sF
-lean )r -lean
7inse 7inse
:tch :tch
7inse 7inse
-hromate Phosphate
7inse 7inse
,emin 7inse ,emin 7inse
)ils and *reases are removed in %ea& al&ali or neutral deter*ent solutions and the surface is
etched to remove heavy oBides. After rinsin*! the aluminium is dipped into a chromate or
phosphate solution to form a conversion coatin* on the aluminium. This film is chemically
attached to the aluminium. After rinsin* the aluminium is finally rinsed in demineralised
%ater.
The conversion coatin* has t%o functionsF
I 1t presents a surface to the po%der %hich favours adhesion more than the oBides
that form very readily on aluminium surfaces! and
I 1t reduces the incidence of under film corrosion.
The use of demineralised %ater reduces the presence of chemical salts on the aluminium
surface.
?or steel the preparation Astra has set up hot treatment plant %hich $asically follo% as per
$elo% flo%.
Srl Description Vol Time Temp. Points Ph.
1 ,e*reasin* 93=T 19 min. =4389
4
- @4 3114 3
2 #ater 7inse
3
1 min 7T
4
- 3 =38
6 ,erustin* 19324T 14 min 7T
4
- 19 324 3
<@
< #ater 7inse
3
1 min 7T
4
- 3 =38
9 Activation 4.4"T 1 min. 7T
4
- 3 A$ove @
= Phosphatin* 9T 938 min <"399
4
- 2@ 361 3
8 #ater 7inse 3 1 min 7T
4
- 3 =38
" Passivation 4.429T 1 min. =4389
4
- 3 <3=

The *rain refiner is used after acid cleanin* of steel surfaces and $efore +inc phosphatin*!
other%ise the +inc phosphate coatin*s produced %ill $e very coarse %ith lo% adhesion. The
po%der coatin* applied to a coarse phosphate %ill produce rou*h coatin*s /a little li&e
PsandpaperP0 and possess lo% adhesion.
H"4 is i 1"+e CC e)e*!"sai* s3!a7G
The po%der is applied %ith an electrostatic spray *un to a part that is at earth /or *round0
potential.
Before the po%der is sent to the *un it is fluidisedF
I to separate the individual *rains of po%der and so improve the electrostatic char*e
that can $e applied to the po%der and
I so that the po%der flo%s more easily to the *un.
Because the po%der particles are electrostatically char*ed! the po%der %raps around to the
$ac& of the part as it passes $y to%ards the air off ta&e system. The po%der %ill remain
attached to the part as lon* as some of the electrostatic char*e remains on the po%der. To
o$tain the final solid! tou*h! a$rasion resistant coatin* the po%der coated items are placed
in an oven and heated to temperatures that ran*e from 1=4 to 214 de*rees - /dependin* on
the po%der0. 5nder the influence of heat a thermosettin* po%der *oes throu*h < sta*es to
full cure. M:T! ?)#! .:! -57:. The final coatin* is continuous and %ill vary from
hi*h *loss to flat matt dependin* on the desi*n of the po%der $y the supplier.
P"41e! *"ai+g g,+s
There are at least three types of electrostatic *uns in useF
I -orona char*in* *uns %here electric po%er is used to *enerate the electrostatic
char*e. -orona *uns are either internal or eBternal char*in*.
94
I Tri$o char*in* *uns %here the electrostatic char*e is *enerated $y friction $et%een
the po%der and the *un $arrel.
I PBellP char*in* *uns %here the po%der is char*ed $y $ein* Pflun*P from the
perimeter of the P$ellP
Not all po%der is applied usin* *uns. )ne system ma&es use of electrostatic tunnels.
F,+*i"+i+g "0 S,!0a*e C"ai+g S:"3:
i&e functionin* of Press Shop and ?a$3Shop! functionin* of surface coatin* is also
initiated $ased on production plans released $y PP- as per %ee&ly plan. This is $ro&en
do%n to daily plan for /treatment and po%der coatin*0. Shift 1n3char*e chec&s for the
manpo%er! material G machine availa$ility. Time study of po%der coatin* process is done
to facilitate eBecution of po%der coatin* activity.
S!) Pa! +" Des*!i3i"+ 27
Time i+ mi+,es
T"a)
Time
M
a
s
5
i
+
g

C
"
a
i
+
g

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1 9<12<11 441 Tan& Housin* -omplete 1
14
9
9 33333
94 84
2 9<12<21 441 Top Plate -omplete 1
33333 33333 33333 33333
14 14
6 9<12<2@ 441 -over -omplete 1
33333
< 1 9
33333
14
< 9<12<64 441 -ap -omplete 1
33333
6
33333
6
33333
=
9 9<2414@ 441 Top Panel -omplete 1 2 9 33333 8 6 18
= 9<24119 441
-assette BoB
1
33333
9
33333
9
33333
14
8 9<2411" 441 ?ront -over 1 2 9 2 " 6 24
" 9<24169 441 -olumn -ap 1 33333 9 33333 < 33333 @
@ 9<21=9@ 441 #heel .uard 1 33333 < 33333 = 33333 14
P!e T!eame+ P!"*ess C"+!")
Before loadin* material in treatment $ath! Pre3treatment parameters li&e Pointa*e /
Temperature / pH are chec&ed as per %or& and said data is recorded in -hemical Test
7eport 7e*ister.
91
Pre3treatment is carried out $y loadin* jo$s inside $as&et! loadin* of jo$s is done &eepin* in
mind %ater/chemicals should not accumulate on jo$. Than the jo$s are inspected for oil
mar&s G rust! if needed jo$s are retreated.
No$s %ith overlappin* surface are heated in oven for temperature $et%een 194 to 244X-
$efore coatin*. After heatin* the jo$s in oven! they are inspected for -hemical :ntrapment
G oil! only -hemical/)il free material is ta&en for coatin*. No$s %ith -hemical :ntrapment
G oil are treated a*ain. No$s %ithout any overlappin* surface need not $e heated in oven
$efore coatin*! instead they are &ept for air dryin* G are coated &eepin* in one of the
criteria of coatin* treated jo$s %ithin 2< hours to avoid any undue effect on coated jo$s.
P"41e! C"ai+g P!"*ess C"+!"): Before start of coatin*! Po%der -oatin* .uns are
chec&ed for char*ea$ility G flo% of po%der. No$s %hich reDuire earthin* or $earin* surface
for rollers are mas&ed %ith ru$$er sleeves or mas&in* tapes. -oated jo$s are inspected for
any visual defects G ,?T! and same is recorded in inspection re*ister. ?urther activities li&e
touch/re3tappin*/cleanin* are carried out $efore movin* the jo$s to concerned department.
Surface coatin* process is validated $y pre3treatin* and phosphatin* 9 nos of -7-A test
specimen of si+e 84.4 B 1<4.4 B 1.4 m.m. Test specimen is coated in the po%der coatin*
$ooth %ith 2 ; 6 passes to achieve the reDuired 144 Y ,?T. Than the panels are $a&ed at
1"4 ; 1@4 X- for a period of 24 ; 64 minutes. Test Panels are allo%ed to cool to the room
temperature and send for third party analysis %herever reDuired. -urrently Astra conducts
$elo% mentioned tests.
S!) C:a!a*e!s Sa+1a!1 Va),e Re0 Sa+1a!1
Va)i1i7
Pe!i"1
1 1mpact Stren*th 144C*;mZ<4/<4[ ASTM ,28@< /@9 Ball\9/"P = Months
2 -onical Mandrel " m.m. ASTM , 9223B / ,1N 96192 = Months
6 Bend 1/<P ,1N 9619= = Months
< Salt Spray 7esistance 1444 Hrs ASTM B 118 = Months
9 -ross -ut Adhesion .t R 4/144 ASTM , 669@ / ,1N 96191 ,aily
The inspection of the products is done as per set procedures for monitorin* G
measurement of product. ?inal rejections that occur in the process are entered in inspection
re*ister. ?inished Material is moved to either dispatch department or for further assem$ly!
as such for Astra ?a$ricated Material /includin* in3house G material received from
92
vendors0 material movement note starts %ith ?P-3 follo%ed $y increasin* serial no! and for
No$ %or& items /i.e customer supplied items0 material movement note starts %ith NP-3
follo%ed $y increasin* serial no! for ?urther ProcessEs li&e assem$ly /carried out in3house
or off3loadin*0 material movement note start %ith 1P-3 follo%ed $y increasin* serial no.
PRODUCTION PLANNING AND CONTROL
Presently Astra Metal Systems Pvt. td. as&s for production lead time of < to = %ee&s as
such starts production of < %ee&s $efore the planned completion date.
The $asic control pro$lem is that the capacity need in different phases of production
chan*es a$ruptly as demand fluctuates. The Supervisors try to solve the pro$lem $y
maBimi+in* capacity in all production phases $y shufflin* the Dueue in order to minimi+e
setups. ot si+e is &ept rather lar*e for the same reason. Shufflin* causeEs variation in
Dueuin* times to *ro% and therefore throu*hput times *ro%. Prioriti+in* is used amply for
late jo$s. The effect is that lots pro*ress throu*h production Duite randomly and lead times
are lon*. There is a lar*e amount of %or& in process and the need for capacity fluctuates a
lot.
Fi+a+*e
De3a!me+
H,ma+ Res",!*e
De3a!me+
Ra4 Mae!ia)s
S"!es
Mae!ia)s
Ma+ageme+
Di8isi"+
Ne4 P!"1,*
De8e)"3me+
Ma!5ei+g
De3a!me+
C,s"me!
Ve+1"!;
S,33)ie!s
P!"1,*i"+
De3a!me+
-S:"3 0)""!.
2,a)i7 Ass,!a+*e
De3a!me+
Sa)es
De3a!me+
A Bird view of Production System
96
1deally! the plannin* and control method should level the need for capacity in a %ay that
allo%s for Duic& and predicta$le completion of each %or& phase and simultaneously results
in adeDuate capacity utili+ation. The company has developed $ufferin*! orderin*! and
forecastin* methods to*ether %ith its customers in order to level demand. Ho%ever! the
demand for products produced $y Astra is hi*hly varia$le and difficult to forecast and
therefore also $ufferin* is ris&y not only $ecause of increase in inventory level $ut more
over may result in o$solescence.
The production schedulin* policy used in Astra Metal Systems Pvt. td.! is $ased on a
system %here monthly demands are divided into short periods in %hich a predetermined
amount of each product is produced. Althou*h this policy is appropriate for the fleBi$ility
of the schedulin*! it may cause production of a$undant num$ers of setup %aste. The reason
of this is that as period of schedulin* plan $ecomes smaller! the num$er of machine
adjustments $ecomes hi*her! %hich in turn increases the num$er of setup %aste.
Therefore! the schedulin* periods and num$er of setup %aste are inversely proportional. 1f
lon*er schedulin* periods are chosen! then the production of setup %astes %ill $e decreased
$ut the fleBi$ility of the schedulin* %ill $e lost and ne% costs such as inventory holdin*
costs %ill appear. )n the other hand! if the schedulin* period is shortened! then the
schedulin* %ill $e more fleBi$le and the num$er of setup %aste %ill increase. ?or this
reason! there is a need to find out an optimum schedulin* plan ta&in* into account the
%aste production.
Production plannin* and control can $e vie%ed vertically in a top3do%n! hierarchical
fashion. Ho%ever! reDuires stron* cooperation hori+ontally across the functional
disciplines.
Re)ai"+s:i3 <e4ee+ 3)a++i+g a+1 i+8e+"!7:
1n any manufacturin* enterprise production is the drivin* force to %hich most other
functions react. This is particularly true %ith inventoriesS they eBist $ecause of the needs of
production. The ultimate o$jective of PP-! li&e that of all other manufacturin* controls! is
to contri$ute to the profits of the enterprise. As %ith inventory mana*ement and control!
this is accomplished $y &eepin* the customers satisfied throu*h the meetin* of delivery
schedules. Specific o$jectives of PP- are to esta$lish routes and schedules for %or& that
9<
%ill ensure the optimum utili+ation of materials! %or&ers! and machines and to provide the
means for ensurin* the operation of the plant in accordance %ith these plans.
T73es "0 I+8e+"!ies:
i&e any other industry Astra Metal Systems Pvt. td. also has different &ind of inventory
throu*hout its manufacturin* process. Astra maintains inventory in terms of stoc& of some
&ind of physical commodity li&e ra% materials! component parts! supplies G consuma$le
stores! %or&3in3pro*ress G finished *oods. The analysis of the cost structure of many of the
product reveals that inventories cost ran*e from 89T to "9T of the product cost. Thus
inventories indicate a major of application of financial resources G efficient inventory
control can contri$ute su$stantially to the profita$ility of the $usiness.
The Principal Types of 1nventories are F
1NP5T Production 1nventory
P7)-:SS 1n3process 1nventory
)5TP5T ?inished 1nventory
1. Production Inventories: 1tems %hich *o into the final products! ra% materials and
$ou*ht out components. Astra $ein* $asically sheet metal fa$rication unit stoc& of -7-A!
SS or .P sheets is a must to start first operation of cuttin*. )n an avera*e Astra maintains
] 94 tons of ra% material in sheet form at any *iven time.
2. Maintenance! 7epair and )peratin* 1nventoriesF 1tems %hich do not form a part of final
Product $ut are consumed in a prod. Processes spare parts! -onsuma$le items etc.
3. In Process Inventories: #or&3in3pro*ress items %hich are partly manufactured and
A%ait the neBt sta*e in process.
4. ?inished .oods 1nventories completed products ready for dispatch.
5. Miscellaneous Inventories: #hich arise out of the a$ove four types of inventory scrap!
Surplus and o$solete items %hich are not to $e disposed off.
As a step to%ards %orld class manufacturin* unit Astra is $een practisin* 9S for Duite a
fe% years.
99
Operate to the standard Operate to the standard
Heres what 5-S means:
Sort
Separate %hat is needed and %hat is not needed! and &eep only those
thin*s that are needed in the %or&place. ,iscard unnecessary items.
Set-In-Order
Neatly place and identify needed %or& items. ,esi*nate a place for
everythin* so that anyone can find it. Al%ays put thin*s $ac& in their
desi*nated spots.
Shine
-lean up. Al%ays maintain a clean and shiny %or& place. 1dentify %hy
thin*s are *ettin* dirty.
Standardize
Become a role model for adherin* to the standards of the first three SEs
and encoura*e others to follo% them. Ma&e rules and procedures to
promote a *ood %or& environment until the first three SEs $ecome every$odyEs second
nature.
Sustain
Maintain and practice the first four SEs. Be thorou*h in strai*htenin* up!
puttin* thin*s in order and cleanin*.
ean manufacturin* is certainly an effective strate*y $ut some principles such as one piece
flo%! ta&t time! level schedulin* and Can$an all $rea& do%n for intermittent production
hi*h miB and lo% volume supplies. The need of a pull system to &eep shop floor under
control. 1n a pull environment! in contrast to push systems! orders are released to factory
only %hen the total %or&load does not eBceed a predetermined level. Besides the
manufacturin* efficiency! the company must ma&e availa$le a suita$le production plannin*
and control system in order to meet their customerEs needs. The constant meetin* due dates
%ill *ive to the relia$le supplier a very important competitive advanta*e.
Lea+ Ma+,0a*,!i+g
9=
ean manufacturin* is a multidimensional approach that encompasses a %ide variety of
mana*ement practices! includin* N1T! Duality systems! %or& team! cellular manufacturin*!
Can$an! Juality -ircles! etc. in an inte*rated system. The core thrust of M is that these
practices can %or& syner*istically to create a streamline! hi*h Duality system and produce at
the pace of customer demand %ith no %aste.
ean Manufacturin* $rin* a$out a chan*e in the approach to dynamic environment!
populari+in* the idea of incorporatin* fleBi$ility in manufacturin* system %ithout
sacrificin* the efficiency. The strate*ic approach of use $uffers in human and other
resources to deal %ith uncertainties is less attractive choice for companies operatin* on M
$asis! thus necessitatin* findin* %ays to achieve manufacturin* fleBi$ility.
Manufacturin* fleBi$ility means havin* the a$ility to rapidly increase or decrease
production level! or to shift production capacity Duic&ly from one product to another. Such
fleBi$ility is achieved throu*h fleBi$le plants! processes! and %or&ers! as %ell as throu*h
strate*ies that use the capacity of other or*ani+ations. The main features of the lean
manufacturin* %hich help meet this o$jective include set3up reduction! multi3s&illed
%or&ers! preventive maintenance! and cellular layout.
ean manufacturin* represents a more fundamental frame%or& for enhancin* efficiency
throu*h elimination of %astes. Seven %astes identified under lean manufacturin* that needs
to $e eliminated are Motion! #aitin*! )verproduction! Processin*! ,efects! 1nventory and
Transportation. Production is lean if it is accomplished %ith minimal cost. The less o$vious
source of cost is varia$ility. This can ta&e many forms! includin* varia$ility in process time!
delivery time! yield rates! demand rates! etc.
S"me E6am3)es "0 Aase a As!a
I #aitin* for parts
I -ountin* parts
I Multiple inspections
I )ver3runs in production
I Movin* parts over lon* distances
I Storin* and retrievin* inventory
I oo&in* for tools
98
I Machine $rea&do%n
I 7e%or&
Lea+ ma+,0a*,!i+g im3)eme+ai"+
As an implementation strate*y manufacturin* process redesi*nin* on the $asis of lean
manufacturin* principles is started. M System implementation process %as started
%herein ?irst step adopted %as chan*es in company culture and *ets people commitment
for sustainin* the chan*e to%ard lean. After that! process flo%! %or& method and
production times are under the process of revision. The main issue that Astra is facin* is
simplifyin* the shop floor! developin* multis&illed %or&ers and set3up reduction. ?illin*
lines $ecame more fleBi$le %hich could %or& %ith a lar*e variety of product in small
Duantities.
As a step to%ards improvin* throu*hput time thin&in* process is initiated at all levels li&e
chan*es are made in the set3up procedure to reduce si*nificantly the set3up time. Trainin*
of %or&ers is initiated to handle multiples machines $rin*in* more fleBi$ility for the shop
floor. Thou*ht process of productive maintenance is &ic& started aimin* to *uarantee hi*her
process relia$ility. The achievements that are tar*eted to achieve after implementin* lean
tools includes plant efficiency improvement! setup time and delivery lead time reduction.
ean -oncept implementation in process...
A:a Is Va),eG
I PValueP is %hat the customer is $uyin*
I Al%ays thin& first a$out the end3customer
; #ho is the customer^
9"
; #hat are they $uyin*^
I ,escri$e value usin* the customersO %ords
A:a Is Va),e S!eam A+a)7sisG
I Plannin* tool to optimi+e results of eliminatin* %aste
To $e*in %ith! $ein* ean manufacturin* needs a cultural chan*e in thou*ht processes!
thin&in* approach! etc. :mployees of Astra needed trainin* on said matter as such
consultants %ere approached and selected one of the prominent leadin* consultant in sad
field. Than the process of trainin*s $e*ins! after $rief trainin*s on manufacturin* #astes G
VSM teams %ere formed at all 6 locations %ith *roup of 14312 mem$ers and each team
selected an item from final product list as a case study.

This case study is of a product %hich is reDuired $y one of the most valua$le customer of
Astra %ho is %ith Astra from incorporation period rather Astra %as started to support said
customer. The main o$jective is to analy+e ho% lean manufacturin* can $e effectively
implemented on MT) strate*y! includin* the PP- system reDuirements.
Ae 4i)) 1is*,ss *ase s,17 "0 VSM 0"! Si+g)e Ta+5 H",si+g..
#e carried out value stream mappin* ri*ht from receipt of purchase order to dispatch of
product to customer. Team of 14 mem$ers %as formed %hich included at3least one
personnel from PP-! Production! Purchase! :Bcise! H7! Stores! Maintenance! Juality.
Team selected a leader to *uide the team %ith valua$le support of lean consultant. #e
selected MM2.9 sin*le tan& Housin* for Value Stream analysis.
?irst noted do%n all the processes that are involved ri*ht from receipt of purchase order
from customer to delivery of product. Here process flo% alon* %ith information flo% is
mapped on A2 si+e. 5sin* lean manufacturin* flo% sym$ols. -alculated Total Product
-ycle timeF ,etail off3line activities that are Non3Value added activities>
Than statement statin* the scope of the project is defined. Than all VA ratio calculations
%ere done to find out %hich process to $e prioriti+ed for eliminatin* non3value added
9@
activities! alon* %ith present order to delivery time and its correspondin* VA time is
%or&out.
?rom $elo% value stream mappin* it %as identified that %aitin* time amounts to 94<=4
mins eDuals to ] 69 days %here as actual cycle time is 1@9" mins eDuals to ] 1 and half
day for a $atch of 14 nos. Similarly results of all the team indentified %aitin* time a most
dan*erous manufacturin* %aste.
To conclude %ith it %as realised and understood $y all team mem$ers that %aitin* time is
the most dan*erous manufacturin* %aste so all team needs to %or& to%ards eliminatin*
this %aitin* %aste. As such a first step to%ards elimination of %aste in the form of %aitin*!
production lot %ere $ro&en do%n to smaller $atch si+e! *ivin* scope for line $alancin* at
every sta*e. Herein concept of releasin* production plans for month is chan*ed to releasin*
%ee&ly production plans %ith priority %ise ?1?).
Va),e S!eam Ma33i+g "0 MM #.= Si+g)e Ta+5 H",si+g -i+ a<,)a! 0"!m.
Batch Si+eF 14 Nos
-ycle
Time
No )f
Men Transportation ,istance
#aitin*
Time
Tool
Set 5p
Mins Nos Mins in Mts Mins Mins
Supplier To Astra 7a% Material 124 24444 241=4
Punchin* 16 2 1.9 9 144"4 12
,e$urin* <9 1 2 = 2""4 2
Bendin* 69 1 2 < 1<<4 19
Ta* #eldin* 19 1 2 12 2""4 94
1nternal -orner #eldin* 94 1 4 4 4 4
?ull #eldin* 94 1 4 4 4 4
Sanderin* 124 1 9 <4 4 <
?rame #eldin* 24 1 9 29 144"4 <2.9
?ame Sanderin* 94 1 2 < 4 1
Ta* #eldin* ?rame And Tan&
Housin* 19 1 9 <4 <24 99
,rillin* "4 1 14 24 1<<4 94
Tappin* 144 1 4 4 24
?ull #eld #ith Template 244 1 14 24 1<<4 94
M/- 1tem #eld 1<4 1 4 4 =9
Spatter 7emoval 94 1 14 2 124
Sanderin* 69 1 14 2 2<4 9
ea&a*e Test 94 1 9 9 1<<4 144
Bend 7emoval 94 1 14 1 4
=4
1nspection 7eport And No$
Num$erin* 94 1 4 1<<4
Pretreatment 94 6 14 94 2""4 =4
Pre3Heatin* 19 4 2 14 <9
Mas&in* 144 1 2 14 =4
Po%der -oatin* 94 6 29 9 =4 64
)ven -urin* <9 4 2 9 =4
,e3mas&in* And -leanin* 644 1 14 14 =4
ead Pastin* 144 1 6 4 1<<4 144
Varnishin* 94 1 4 1<<4
7e3Tappin* 94 1 9 2 6=4
1nspection 64 1 9 2 =4
?inished .ood Stora*e 1 9 9 144"4 9
?inished .oods oadin* And
,ispatch 1 9 14 19
Astra To -ustomer ,oor 9 1944
T"a) &@=? (' &=?.= &>@= =$'%$ %%%.=
Time -i+ 1a7s. &.' $.& &.# (=.$ $.=
After completion of VSM chart and calculation of VA and NVA time neBt step %as flo%
dia*rams %ere dra%n related to only production process. #hile dra%in* flo% dia*ram of
process its related process time and NVA processes are also identified.
1n ?lo% dia*rams elements related to %aitin* time %ere eliminated and only value added
/VA0 and non value added /NVA0 activities %ere dra%n %ith respective process time.
=1
?rom a$ove findin* processes li&e /Pre3treatment!Pre3heatin* and )ven currin* since more
than one jo$ is processed in one cycle0 %hich %ere carried out in $atch %ere eleminated for
time $ein*. Than processes %hich %ere in t%o di*its fi*ures i.e 14 mins or more than 14
mins %ere identifed for further study for eleminatin* NVAEs %ithin the processes. )ut of
29 activities " activities %hich reDuired processin* time in dou$le di*it %ere considered for
further action.
=2
Srl Activity Time
1 ,emas&in* And cleanin* 64
2 ?ull %eldin* 24
6 Varnishin* 1"
< M/c item %eldin* 1<
9 Sanderin* 12
= ead pastin* 14
8 Mas&in* 14
" Tappin* 14
@ ,rillin* "
Ta&in* activity %hich needs hi*hest cycle time for further study to atleast $rin* do%n said
cycle time to neBt hi*ht cycle time i.e nearer to cycle time for full %eldin* /24mins0
:very process has VA and NVA activities identifyin* and cuttin* do%n NVA is the neBt step
for %hich commonly 5sed Tools for Pro$lem Solvin* and -ontinuous 1mprovement are
made into use.
?irst tool used to identify VA and NVA %as ?ish Bone dia*ram or cause3and3effect dia*ram
is dra%n identifyin* all possi$le causes to eliminate Non Value Added /NVA0 activities
%ithin /micro level0 process.
=6
Brain stormin* tool is used to identify possi$le causes %hile dra%in* fish $one dia*ram.
Herein each team mem$er starts *ivin* root cause %hich are than *rouped accordin*ly
under Man! Machine! Method or material /discipline of only one at a time0 %ith at3least 6
rounds for each mem$er %here in minimum 6 causes are identified $y each mem$er! same is
continued till mem$ers do not have any more points. #hile doin* this activity team does
not ar*ue on %hether points that one mem$er has *iven is ri*ht or %ron*.
)nce these possi$le causes are identified than collectively neBt round of $rain stormin* is
done %here in mem$erEs de$ate on each points and accordin*ly decide on valid and non3
valid causes! non3valid causes are stri&eout.
All other causes %hich are a*reed up on neBt step is to chal& out action plan! herein there
may $e more than one action plan for one possi$le cause %hich than are assi*ned usin* 6#
G 1H concept /#ho! #hen! #hat and Ho%0.
Than team identifies '%ho %ill $e doin* that tas& he/she may $e %ithin the VSM team or
outside one team %hich depends on need of activity. Belo% is Action Plan initiated for
,emas&in* G -leanin* %hich need 64 mins.
,emas&in* And -leanin* ta&es 64 mins /Hi*h NVA0

Sr
l -auses -orrective Action #ho #hen
Man 1 -hitchattin* %hile demas&in*
:ducate %or&ers %herein they
can have their discussions
durin* tea! lunch $rea&s. Manju
613
,ec
2 5ntrained Person
6
:Bcess use of mas&in* tape and
paper
-han*e the process of
mas&in* itself. 5se sheet
metal plates G scre%s
ti*htened usin* $attery
operated scre% drivers!
instead of paper G mas&in*
tape! than define ne% revised
%or& instructions for carin*
out mas&in* G demas&in* 7ohit 243,ec
< )perator does demas&in* slo%ly
9 ,istractin* %or&place surroundin*

Machine 1 1mproper i*htin*

Material 1
.lue remains after removin* the
mas&in* tape
chan*e of process addressOs
this point 7ohit 243,ec
2 Poor Duality of mas&in* tape
6 Mas&in* tape is used chan*e of process addressEs 7ohit 243,ec
< Mas&in* tape cuts %hile removin* chan*e of process addressEs 7ohit 243,ec
9 Smooth cloth is used
=<

Method 1 Manual removal of mas&in* tape
2 &erosene Applin* chan*e of process addressEs 7ohit 243,ec
6
More contact area of jo$ surface
and mas&in*
< Paper is used
9
Holdin* of jo$ is reDd %ith one
hand %hile demas&in*
= No time standard
8 1mproper tools used for demas&in* chan*e of process addressEs 7ohit 243,ec
"
Proper seDuence fro removin* the
tape is not used
@ ,emas&in* is done after coolin* chan*e of process addressEs 7ohit 243,ec
14 #ron* shape of paper is used chan*e of process addressEs 7ohit 243,ec
11 #or& place or*ani+ation
12
.lue stic&s to the hand of operator
and *ets transferred on the jo$
%hich a*ain needs to $e cleaned
Similarly $rain stormin* is follo%ed $y action plan for ?ull %eldin*! Varnishin*! M/c item
%eldin*! Sanderin*! ead pastin*! Mas&in* and Tappin*. ,ay to day follo% up is done for
the action plans so as to ma&e sure that tar*et dates for implementation are not defaulted.
#hile doin* $rain stormin* and action plans VA and NVAEs are monitored and measured.
All data related to fact findin*s are collected filed for future reference alon* %ith any other
relevant information! photo*raphs etc. #ith each improvement action plan implementation
VA calculations are done to trac& %hether team is movin* in ri*ht direction or not.
7esults of VSM study %as its on*oin* continual improvement process! most of the actions
that are su**ested and implemented a*ainst said product are also applica$le *lo$ally for the
product ran*e that Astra manufactures for different customers. i&e for e.*. one of the
cause for more cycle time for full %eldin* %as unor*anised %or&place as such team %or&ed
out on ne% layout %hich is not only applica$le for product %hich %as ta&en for case study!
said action %as also applica$le for entire ran*e of product that Astra manufactures in3
house.
Fa*"!s A00e*i+g P!"1,*i"+ P)a++i+g a+1 C"+!")
F"!e*as gi8e+ <7 *,s"me!s: 1ts value to production plannin* and control is that it %ill
indicate future trends in demand for product that needs to $e supplied. #or& shift policies!
plans for an increase or decrease in manufacturin* activity! or possi$le plant eBpansions
=9
may often $e $ased upon the customer forecasts and in turn affect the plannin* of the
production plannin* and control *roup.
Sa)es O!1e!: This is the second of the five classes of orders. 1t is a re%rite of the customer
order specifyin* %hat they %ant in terms of product and Duantity and authori+in* shipment
of the *oods to the customer.
S"*5 O!1e! -B,00e! s"*5i+g.: This third class of order is not al%ays used. 1t is
particularly ta&en in conjunction %ith customer.
S:"3 O!1e!: This fourth class of order deals %ith the manufacture of component parts.
?orecasts *iven $y customers! sales orders! and stoc& orders /$uffer stoc&s0 are for the
finished product.
Sa+1a!1 P!"*ess s:ee: This form is prepared $y process en*ineerin* and it is the source
of $asic data as to the type of machine to $e used! the time reDuired for processin* and the
seDuence of operations in the manufacture of the product. 7outin* and schedulin* of shop
orders! as %ell as loadin* of %or&stations in advance of schedulin*! depend on up3to3date
standard process sheets $ein* availa$le to the production plannin* and control *roup.
E+gi+ee!i+g S3e*i0i*ai"+s: Blueprints and $ills of materials are used $y production
plannin* and control %hen they $ecome a component part of the pac&a*ed instructions
issued to the shop throu*h the control office. )ne *ood plannin* procedure is to
accumulate all necessary data for a shop order in a sin*le pac&a*e the standard process
sheet! the $lueprint! the $ill of material /if an assem$ly operation is involved0! the route
sheet! and possi$ly the schedule for the production of the order.
R",e S:ee: This is the form on %hich the route of a shop order is indicated. 1n practice!
this form is *enerally com$ined %ith one of the other forms in the system. ?or eBample! the
shop order! the standard process sheet! and the route sheet are often one piece of paper3
usually called the shop order or he manufacturin* order.
J"< Ti*5es: This is the fifth and last type of order in a manufacturin* situation. No$ tic&ets
authori+e the performance of individual operations in the manufacturin* process.
==
Ce+!a)i9e1 P!"1,*i"+ P)a++i+g a+1 C"+!")F -entrali+ation or decentrali+ation of
duties of the production control staff depends upon the desi*n of the production plannin*
and control system. 1n a completely centrali+ed setup! determination of shippin* promisesS
analysis of sales! stoc&! and shop ordersS preparation of routes! load charts! and schedule
chartsS and dispatchin* of %or& to the shop complete %ith jo$ tic&ets and all other
necessary paper %ould $e accomplished $y a central production plannin* and control unit.
1n addition! as %or& is completed! a careful analysis of the actual performance %ould $e
made! and if corrective action %ere reDuired! it %ould $e initiated $y this *roup.
De*e+!a)i9e1 P!"1,*i"+ P)a++i+g a+1 C"+!"): No matter ho% *eneral the plannin*
may $e under central PP-! the plan must eventually $e developed into a detailed plan on
the shop floor. As such Astra is endeavourin* to ma&e each foreman a mana*er of his o%n
departmental operation.
Meas,!eme+ "0 E00e*i8e+ess: 1n determinin* the effectiveness of a production plannin*
and control system! Astra has Duite a fe% pro$lems. The &ey criterion mi*ht %ell $e
%hether or not shippin* promises are $ein* &ept ; the percenta*e of the order shipped on
time. This! ho%ever! %ould not $e a true criterion if eBcessive overtime of eBpeditin* costs
%ere involved in *ettin* any of these orders shipped.
=8
Res,)s a+1 a+a)7sis "0 :e *ase s,1ies:
To a certain de*ree! production activities are repetitive and often lar*ely predicta$le. No
a**re*ated production plan... No eBplicit overall control concept... A$sence of priorities in
allocatin* production capacities... insta$ility in the production plannin*... a lar*e no of rush
orders... uncertainties in the production... fra*mented allocation of authorities and
responsi$ilities %ith respect to production and distri$ution.... Personal conflicts and domain
discussions $et%een PP- and other ,epts. Hi*h de*ree of de3concentration %ith respect to
plannin* activities.... 1n practice! ho%ever! 6units solved conflictin* issues $et%een
Production and Purchase or PP- $y applyin* a functional hierarchy and not $y some
inte*ratin* mechanism $et%een the parties involved. 1t is noticed that the de*ree of
inte*ration $et%een functional areas in Astra is much lo%er than one %ould eBpect.
1t is interestin* to note that there is necessity for improvin* the overall performance in
terms of decreasin* costs! shortenin* delivery times! improvin* delivery relia$ility! Duality
and customer service. ?rom this! chan*in* the plannin* and control as %ell as the
or*anisational desi*n of the production system should $e re*arded as a potential
opportunity to contri$ute to this improvement.
7esults of VSM study %as its on*oin* continual improvement process! most of the actions
that are su**ested and implemented a*ainst said product are also applica$le *lo$ally for the
="
product ran*e that Astra manufactures for different customers. i&e for e.*. one of the
cause for more cycle time for full %eldin* %as unor*anised %or&place as such team %or&ed
out on ne% layout %hich is not only applica$le for product %hich %as ta&en for case study!
said action %as also applica$le for entire ran*e of product that Astra manufactures in3
house.
Fi+1i+gs, I+0e!e+*es a+1 Re*"mme+1ai"+s:
Some of the chan*es need to $e initiated for $etter co3ordination! communication!
inte*ration! follo%3up action. Meetin* %ith respect to certain predefined points needs to $e
eBecuted at the start and end of shift on daily $asis %ith shift operators and shift in3char*e!
than on daily $asis %ith departmental heads to analyse and resolve day to day issues! and
finally %ith functional heads on future *oal/ o$jectives on %ee&ly $asis.
1. Shift Be*innin* G Shift :nd / -han*e Meetin*
a. Participants F
i. Shift )perators G Shift 1n char*e
$. Time G ,uration F
i. 9314mins
c. A*enda F
i. Production in last Shift
ii. .ap in actual Production G plan
iii. Pro$lems encountered in the previous shift
iv. Production Plan for the neBt shift
v. Availa$le Manpo%er
vi. -han*e )ver reDuirements
vii. Preventive Maintenance Plans
viii. House Ceepin*
iB. Any )ther Planned Stoppa*e
=@
2. ,aily #or& Mana*ement Meetin* $y ,epartment head
a. Participants F
i. Shift 1n char*e
ii. PP-
iii. Maintenance
iv. ,ispatch
v. Purchase/Stores
vi. Juality
i. 24364mins
c. A*enda F
i. Productivity evel G rejection status of day $efore
ii. ,ayEs Plan considerin*! *aps in plan v/s actual of day $efore
iii. ?reDuency G duration of m/c maintenance G their countermeasures
iv. ,ispatch plan
v. Juality pro$lems/ customer complaints G their counter measures
vi. .ap Analysis for Production /maintenance/ dispatch /chan*e over time
6. #ee&ly meetin* of ,epartmental Heads
a. Participants F
i. Shift 1n char*e
ii. PP-
iii. Maintenance
iv. Purchase/Stores
v. Juality
i. =4389mins
c. A*enda F
i. Productivity in terms of stro&es/minute! stro&es/person! spots per person
G efficiency
ii. Juality coverin* in process rejection in PPM of the Press shop!
?a$rication shop G Po%der coatin*. Qero ,efects.
iii. -ustomer -omplaints
84
iv. ,elivery Performance %.r.t -ustomer schedule
v. ,o%ntime due to m/c Brea&do%n
vi. A$senteeism
vii. )vertime #or&in*
viii. Vendor Performance %.r.t Juality G delivery
iB. -apacity 5tili+ation
B. #or&place 1mprovements! 9S Audit results
Bi. Safety3Accidents
Bii. :mployee developments! :mployee .rievances! Trainin* imparted G
employee Participation in su**estions
Biii. 1mprovements in the Duality system
Biv. 1nventories
Bv. -ustomer satisfaction internal/:Bternal
Bvi. -ontinual 1mprovements
1n order to reach the *oals set! production should $e made more predicta$le. The proposed
remedies areF
After the initial Dueue arran*ement in the $e*innin* of production! the Dueue order should
only $e reor*ani+ed in one %ell thou*ht control point. 1n other places prioriti+in* or
shufflin* orders should $e avoided.
Stoc& should $e used in order to level capacity need and provide fast service. 1nstead of the
current practice of havin* lots of %or& in process every%here in production! stoc& should
$e &ept as final stoc& or as $uffer stoc&. Smaller $atches should $e used in order to level
capacity need. Small $atches also allo% concurrent processin* and therefore shorten
throu*hput time.
The simulation model should $e used for ans%erin* Duestions li&eF
#hich one of the alternative points should $e chosen as the Dueue reor*ani+in* point^
Ho% %ell do the alternative schedulin* and Dueuin* lo*ics %or& in this case^
#hat is the effect of the proposed stoc& policies on production^
#hat is the effect of smaller $atch si+es and ho% small can the $atches $e^
81
C"+*),si"+s:
The efficiency of Production Plannin* and -ontrol department depends upon the
information it *ets from other departments and the accuracy of such information. To
prepare load and schedule chat! it must &no% the preventive maintenance schedule. To *ive
realistic delivery date! it must &no% the %or& content of each jo$. PP- %hich are *enerally
reDuires the $elo% information. Astra need to have formal departments li&e sales/mar&etin*
and su$ department of PP-.
82
I+0"!mai"+ Deai)s S",!*e De3a!me+ "!igi+ai+g
C"+*e!+i+g i+1i*ae1 I+0"!mai"+
1. Production
pro*ramme.
2. Production
materials
6. Toolin*
<. Juality
Standards
9. )peration
Methods.
=. Path of
Materials.
8. )peration time.
". Schedulin*
@. Pro*ress of
#or&.
1. Juantity to $e manufactured.
2. ,elivery date.
1. Cind and Duality of material.
2. Juantity of material
reDuired
6. Stoc& on hand and
reservations
<. ead time reDuired for
procurement.
1. Standard and special toolin*
1. ,imensional reDuirements.
2. ?inish reDuirements
6. Tolerance reDuirements
<. Hardness desired.
1. )perations and their
seDuence.
2. Machine tool for each
indicated operation
6. Ni*s and fiBtures needed
<. Speeds G ?eeds.
1 ist of )perations and their
SeDuence
2. Alternatives possi$le
1. Setup time and standard time for
each operation
1. Startin* and finishin* dates.
1. #or& -ompleted as on date.
Sales order or )rder
Acceptance
,ra%in*s/Bill of Material
Stoc& -ards
Tool -ard
,ra%in*s
-ustomerEs feed$ac&
Process sheets
-apacity charts
:Bperience
7oute sheets
Plan layout
#or& Measurement data
Machine oad G Scheduled
charts
,aily production reports
/Time tic&et/Perforated slips
Sales
,ra%in* -ontrol
,es&
Stores Purchase
PP- / Prod
,ra%in* -ontrol
des&
Mar&etin* ,ept
PP-
PP-
PP-
,evelopment dept.
P.P.-
Production
Astra need to have $etter control over plannin* %hich is done manually. Because of
compleB nature of process transactions AstraEs needs to have inte*rated :7P system to
avoid conflicts and hierarchical interferences. Astra *oin* ahead %ith implementation of
:7P module for plannin*! follo%in* performance criteria $y %hich production plannin* and
control systems mi*ht $e jud*ed! since all plannin* activity is done usin* %ith data throu*h
eBcel Astra currently measures only $road $ase delivery commitments for the month.
1. 1nventory turnover
2. ,elivery lead time
6. Percent of time meetin* delivery promises
<. Percent of orders reDuirin* 'splits( $ecause of unavaila$le material.
9. Num$er of eBpeditors
=. Avera*e unit cost.
86
S,mma!7:
The rapid *ro%th in the num$er of options provided $y manufacturers/suppliers to their
customers has forced Astra to $e fleBi$le enou*h under hi*h varia$le demand. 1n addition!
the orders should $e shipped %ith hi*her Duality and shorter due3date times.
Astra $ein* $asically jo$ shopper and has lar*e variety of products under um$rella for
different customers! %hich are $ased on customer specifications. There is hi*h variation in
demand and %ith lo% volume orderEs! as such Astra needs to operate accordin* to the
Ma&e3to3)rder /MT)0 strate*y. Astra have to cope %ith unsta$le production schedules and
materials mana*ement due to freDuent chan*es in planned production orders! and a lot of
production process inefficiencies as %ell.
As a conseDuence! the Production Plannin* and -ontrol /PP-0 $ecomes rather compleB
and often $ased on inaccurate data the $i* challen*e for Astra to operate on MT) strate*y
is to meet customer demand on time. To achieve this o$jective! companies have adopted
continuous improvement pro*rams to enhance their manufacturin* process. Ne%
manufacturin* principles such lean manufacturin* /M0 %hich is under %ay of
implementation same have helped Astra to *reat eBtend to reali+e %astes in manufacturin*
and or*anisation is confident to manufacture on MT) $asis $ecause of the reduced lead
time that is achieved even %hen lean implementation is not even half %ay throu*h.
Re0e!e+*es:
)hno! Taiichi. Toyota Prodcution systeF $eyond lar*e3scale production.
Bertrand! N.#.M.! N.-. #ortmann and N. #ijn*aard! /1@@40 Production -ontrol. A
Structural and ,esi*n )riented Approach.
:ilon! Samuel. :lements of Production Plannin* and -ontrol! Bom$ay
7o$otics and computer inte*rated manufacturin*
8<
ist of ,ia*rams 33
.ross 7eDuirements of -omponent 1tems! Juality Assurance Process at Astra Metal
Systems Pvt. td.! Production as a System! Process flo%! Process ayout! ProcessF A series
of activities! PP- Process! ?i*ure displays the different sheet metal operations.
A Bird vie% of Production System! 93S! Some :Bamples of #aste !Value Stream Analysis!
?lo% dia*rams elements related to %aitin* time! fish $one dia*ram for demas&in* and
cleanin*! )r*ani+ational Structure of Astra Metal Systems Pvt. td.!
process determination and its interaction.

ist of Ta$les33
7esource comparison! Bill of Material !-riteria for acceptin* or rejectin* a lot M/-
components!-riteria for acceptin* or rejectin* a lot 1n3house production! Transformation
Process! 7elationship $et%een Sheet Thic&ness /t0 and V3%idth!7ecomended V3)penin*
,ies! Time study of fa$rication process !Preparation for Po%der coatin*! po%der coatin*
preparation flo%! Time study of po%der coatin* !Value Stream Mappin* of MM 2.9 Sin*le
Tan& Housin* !NVAOs %ithin the processes! Action Plan for ,emas&in* G -leanin*!
information reDuired $y PP-
89

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STUDY OF PRODUCTION, PLANNING AND

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