krishna machine.pptx

8/10/2019 Krishna Machine.pptx

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Machine Utilization at

Krishna Ltd.

Submitted By:-

Roll No: 1401061to 1401080

PGDIE 44th

SECTION- B


2/13

OBJECTIVE OF STUDY:

1. Evaluation of current machine utilization and improvement

2. Future capacity requirements (In view of increase in production)

3. Measures for 2 month stock


3/13

Question: 01

Objectives of the study were met by the

consultant, i.e. (i) The current M/C

utilization, (ii) Improvement suggestions,

(iii) Suggestion for future capacity

requirements & 2 month stock, All are

addressed.

However the study DOES NOT considersome of the important aspects*.

* Same will be discussed in next sections.


4/13

Question: 02(Improvement of Shop Supervision)

Provision can be made, so that all lines receive equal supervision.

(With due consideration to most underutilized line)

Dedicated supervision for each area.

Surprise/Periodic supervision by shop in-charge

Whether supervisors are overloaded ? Needs to be analyzed.

Only improved supervision may not increase the machine utilization.

Human factors for operators, such as motivation etc. need to be

analyzed.


5/13

Question: 02(Improvement of Shop Supervision)

Study

Shop

Supervision

Adequate ?

Study of

probable

reasons

Adequate no. of

supervisor as per

standard ?

Supervisor busy

with other work ?

Dedicated

supervisor foreach area ?

Area is too large

for the supervisor

to handle ?

Higher level

involvement needed.

No. of supervisor

needs to be increased

Target to be given

to supervisors

related to m/c

utilization

Supervisor s are

excessive friendly

with operators ?

Departmental

supervision needed

YES

NO

YESNO

YES

NO

YES

NO

YES

NO

YES

NO

Proper

training to

be given


6/13

Question: 03(Weakness in work sampling study)

Individual machine wise study was not done. Grouped machines were

studied. Which does not give a clear picture about the individual

machine utilization.

Idle due to operator has been given as one of the highest

contributing factor for machine idle time, but break up for the same

was not given.

Standards for machine utilization of similar shops were not

considered.


7/13

Question: 04(Capacity Determination: Option 01)

Annual Demand 2 Month Stock Group I Group II Group III Group IV

Speedometers 203000 33833.33333 62 2097.67 66 2233 82 2774.33 0

Pressure Gauges 212700 35450 24.4 864.98 91 3225.95 0 17.3 613.285

Temperature Gauges 118560 19760 0 0 85 1679.6 0 8.5 167.96

Tachographs/ Speed indicators 20000 3333.333333 151 503.333 150 500 133.7 445.667 21.8 72.6667

Faremeters 4500 750 7.1 5.325 67 50.25 11.7 8.775 0

Cables 300000 50000 66 3300 7 350 0 0

Hub drive 10000 1666.666667 42.6 71 11.2 18.6667 26.4 44 13.6 22.6667

Warning lamp 82560 13760 15 206.4 5.3 72.928 0 5.1 70.176

Total 7048.71Total 8130.39Total 3272.78Total 946.754

Hours / Week 135.552 156.354 62.938 18.2068

No. of Machines 10 13 6 3

OT/Machine/Week 13.5552 12.0272 10.4897 6.06894


8/13


Introduction of 3rdShiftAssumptions:

Working Hours = 8 Hrs

Break = 1 Hr (Considering Night Shift)

No. of

working

days

Daily

working

Hrs

Total

working

Hrs

300 7 2100

Group 1 Group 2 Group 3 Group 4

10 13 6 3

21000 27300 12600 6300

Extra working Hours

Total No. of Machines required

Target time for 2 month inventory (In months)

GroupMachine Hrs Required Available M/C Hrs/Year/Machine 2 4 6 8 10 12

I 7048.705 2100 20 10 7 5 4 3

II 8130.394667 2100 23 12 8 6 5 4

III 3272.775 2100 9 5 3 2 2 2

IV 946.7543333 2100 3 1 1 1 1 1

TOTAL MACHINES 55 28 18 14 11 10

TOTAL OPERATORS 28 18 14 11 10

WAGES (400/Day) Rupees NOTFEASIBLE 1344000 1296000 1344000 1320000 1440000


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Introduction of 3rdShiftComparison of OT and 3rdShift

Month Required GR 1 GR 2 GR 3 GR 4 Total CostOT Cost (2 times of

Normal wage)

4 10 12 5 1 1344000

1939862.9

6 7 8 3 1 1296000

8 5 6 2 1 1344000

10 4 5 2 1 1320000

12 3 4 2 1 1440000

Over time 7048.7 8130.4 3272.8 946.75


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ANNUAL DEMAND CALCULATION

Annual Demand Group I Group II Group III Group IV

Speedometers 203000 62 12586 66 13398 82 16646 0

Pressure Gauges 212700 24.4 5189.88 91 19355.7 0 17.3 3679.71

Temperature Gauges 118560 0 0 85 10077.6 0 8.5 1007.76

Tachographs/ Speed indicators 20000 151 3020 150 3000 133.7 2674 21.8 436

Faremeters 4500 7.1 31.95 67 301.5 11.7 52.65 0

Cables 300000 66 19800 7 2100 0 0

Hub drive 10000 42.6 426 11.2 112 26.4 264 13.6 136

Warning lamp 82560 15 1238.4 5.3 437.568 0 5.1 421.056

Total 42292.2 Total 48782.4 Total 19636.7 Total 5680.53

Total Available Hrs/Mc/Yr 4500 4500 4500 4500

No. of Machines 10 13 6 3

OT/Machine/Week 45000 58500 27000 13500

Allowance 0.16 0.22 0.2 0.15

Available Time 37800 45630 21600 11475

Shortage 4492.23 3152.37 -1963.4 -5794.5

Annual Demand


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Total No. of Machines required

Target time for 2 month inventory (In months)

Group

Machine HrsRequired for 2

month stock

Shortage for

annual demand

Net M/C hrs

requiredAvailable M/C Hrs/Year/Machine 2 4 6 8 10 12

I 7049 4492 11541 2100 33 16 11 8 7 5

II 8130 3152 11283 2100 32 16 11 8 6 5

III 3273 -1963 1309 2100 4 2 1 1 1 1

IV 947 -5794 -4848 2100 0 0 0 0 0 0

TOTAL MACHINES 69 34 23 17 14 11

TOTAL OPERATORS 17 14 11

WAGES (400/Day) Rupees NOT FEASIBLENOT FEASIBLE NOT FEASIBLE 1632000 16800001584000

Month

RequiredGR 1 GR 2 GR 3 GR 4 Total Cost

OT Cost (2 times

of Normal wage)

4 0 0 0 0 NA 2413200

6 0 0 0 0 NA 2413200

8 5 6 2 1 1632000 2413200

10 4 5 2 1 1680000 2403200

12 3 4 2 1 1584000 241320011541 11282 1309 0

Total cost comparison (Considering all demand)


12/13

Question: 05Scheduling

Backward scheduling

Determining a production schedule by working backwards from

the due date (or time) to the start date (or time).

Simultaneously computing the materials and time required at

every operation or stage.

Different heuristics like branch and bound technique can be used.

As per the target date set by the sales departments, the job

priorities will be set wrt the manufacturing lead time and the

penalties associated with it.


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Question: 06Trivial and Useful Suggestion

Following recommendations were found to be trivial:-

Shop supervision to be improved. (Because, strict supervision may not

always contribute to higher utilization. And can cause union problem.)

Gear up maintenance effort. (Instead of increasing maintenance activities,

change the maintenance system. Can deploy TPM, preventive maintenance.)

Piece rate incentive scheme. (It is not considered as a fair method as it is

directly output depended. All the jobs do not have equal cycle time. Better

alternatives are available like a) Halsey plan b) Rowan plan c) Emerson plan)

Useful solutions:-

1. Dedicated PPC department.

2. Maintaining buffer stock.

3. Use of lead time cards.

krishna machine.pptx

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