saraswati plasto dpr august

8/22/2019 Saraswati plasto DPR August

1/205

M/c No. Product Name

Order

Quantity

(In pcs)

Total Qty.

Produced

pcs

Balanced

need to

produced

(pcs)

cycle

Time

(Sec)

EBM-1 250ml round bottle TSL yellow 24500 25200 -700 24

EBM-2 1 ltr cobra Bottle Mono 220970 170810 50160 29

EBM-3 50ml FAME bottle 14660 -14660 19

100ml Fame Bottle 14548 -14548 19

250ml Confidor Super Bottle 960 -960 24

EBM-4 3 ltr Jery Can 5000 4680 320 45

EBM-5 1 ltr Triangular Bottle Blue 35000 34008 992 31

EBM-6 1 ltr Anupam coex Bottle 234000 35634 198366 30

ASB1 120ml round PET bottle 300000 220220 79780 12.6

ASB-3 1 ltr Magister Bottle 60000 17700 42300 26.2

IM-1 RD 15 juniar Base 350000 31500 318500 24

IM-2 50mm KR logo white cap 20000 13000 7000 27.2

50mm KR logo blue cap 30000 16000 14000 27.2

IM-3 30ml Raft Measuring cup 90000 100000 -10000 19

30ml Flat measuring cup 50000 42500 7500 19

IM-4 10ml corogon cap pearl white 1000000 138000 862000 24

IM-5 46mm Plain cap 50000 43000 7000 19

25ml Plain measuring cup 100000 12000 88000 19

IM-6 53mm cobra cap 700000 590400 109600 30

IM-7 RD jr Lid 500000 174400 325600 16

IM-8

m easur ng cup w

logo 100000 140000 -40000 16.5

IM-9 53mm Anupam starp 200000 90000 110000 19

IM-11

m corogon easur ng cup

TP violet 1000000 211500 788500 17

IM-12

m easur ng cup w

logo 200000 295700 -95700 19.5

IM-12 53mm Anupam Cap 200000 102000 98000 27

Date: 29/7/2013


2/205

Wadding M/c-1 28mm confidor cap

Wadding M/c-2 50mm KR logo blue cap

50mm Green Planet Cap

53mm cobra cap

Wadding M/c-3 53mm Anupam cap

Wadding m/c-5 10ml corogon cap

Wadding M/c -6 94mm Anupam cap

Wadding m/c no.7 46mm Plain cap

manual assembly threded plug

53mm anupam cap packing

53mm Anupam cap assembly

50mm Pursuite cap assembly

94mm Anupam Cap assembly

RD jr Lid & Base Assembly

Sr. No. Raw Material Name Grade Qty Kg

HDPE B52A003OtherItems

HDPE B56003

polybag

45*45

HDPE E5201S 7000

shipper

555

MB TSL Yellow 9682 25 Ovensack

MB Blue 29443 25 325 shiper

HDPE 50ma180 200

510

shippers

PP 3530 1500 10 x 1 ltr

ASPET 21c 1150

465

shipper 3

ply

PP H110MA 625

shipper

600 x 430

ASPET 20C 1150

40 x

250ml

PP srm100nc 1075 20 x 500

TotalRaw Material Reconcilation :


3/205

PA 200

Admer 100


4/205

weight

(Grams)

No. of

Cavity Grade Color Target

Actual

Production in

Pcs

Producti

on In

Kgs

Opening

RM

Balance

RM

issue

details

37 8 B52A003 tsl yellow 19200 16380 606 63 1150

110 8 B52A003 Natural 23834 18570 2043 32 2500

16 4 B52A003 golden 6063 3572 57

21 4 B52A003 golden 6063 3460 73

42 4 B52A003 white 2400 960 40 165 500

250 2 B52A003 white 1920 1080 270 28 500

110 4 B52A003 blue 11148 6318 695 155 700

100 8 B52A003 tsl yellow 23040 18474 1847 266 2000

13.25 5 20C amber 8571 8008 106 35 1150

65.5 6 ASPET Blue 19786 17700 1159 45 1150

9.6 6 H110MA white 17280 15750 151.2 14 150

10.5 8 MI3530 white 3176 3000 31.5

10.5 8 MI3530 blue 21176 16000 168.0 18 200

7 14 C blue 7958 7500 52.5

7 14 C blue 55705 42500 297.5 15 350

2.56 32 H110MA pearl white 115200 78000 199.7 9 300

8 8 MI3530 white 4547 2800 22.4

3.5 8 MI3530 Natural 13642 12000 42.0 43 200

13.5 16 MI3530 c blue 46080 30600 413.1 10 550

6.66

H110MA blue32400 24000 158.4 9 275

3.6 15 C Natural 78545 56000 201.6 1 275

3.8 8 50mA180 white 36379 20000 76.0 14 100

2 32 C tp violet 162635 141000 282.0 19 300

6.5 8 C trans 35446 30000 195.0 11 300

19 8 MI3530 yellow 25600 18000 342.0 0 400

Daily Production Report bottling pla


5/205

white 30000

blue 6000

white 18000

white 8100

yellow 10800

Violet 48000

yellow 10000

white 19600

12000

2924

3000

3570

1344

7000

777798 772010 9530 952 13050

Qty

Wad

Receivedin Pcs size QTY issued

100 bayer logo 46.4 20000

600 bayer logo 29.6

2 roll

mayer

plain 46.4 22100

200 dupont 19.2

wad 43.4

500 DX excel 46.4 20000

400

mayer

plain 34.5

20 board 46.4

dupont 19.2 110000

rallis 46.4

% of Wastage

% of wastage whichcan not used


6/205


7/205

Total

closing

balance

Regrind

generate

d kg

Regrind

/

reproces

s used

Lumps

(Kg)

Plan

Hour

Mold

change

& Other

BD time

Efficean

cy

1213 601 8.51 8.5 6 16 8 85%

2532 486 20.9 20.9 3.7 24 78%

0 5.44 5.4 8 59%

0 6.3 6.3 8 57%

665 485 37.38 37.4 9.6 4 12 40%

528 253 31.25 31.3 5 12 56%

855 153 25.3 25.3 7.5 24 57%

2266 411 45 45.0 8 24 80%

1185 1078 3.0475 3.0 1 6 93%

1195 36 7.86 7.9 24 89%

164 13 5.376 5.4 16 8 91%

0 2.1 2.1 3 94%

218 13 1.26 1.3 6 20 76%

0 1.61 1.6 3 94%

365 12 2.1 2.1 3 21 76%

309 109 0.8704 0.9 24 68%

0 1.92 1.9 3 62%

243 178 1.575 1.6 9 12 88%

560 147 3.3075 3.3 24 66%

284 126 1.32 1.3 24 74%276 74 2.412 2.4 24 71%

114 38 0.532 0.5 24 55%

319 37 0.48 0.5 24 87%

311 116 1.625 1.6 24 85%

400 58 3.8 3.8 24 70%

t


8/205

14002 4422 221 221 50

2.8

0.52


9/205


10/205

Mold change/Break down

ay s . rs ue o ower s u own, n n g3AM Mold offloaded for Logo insert changeover.

Day shift 4.00 Hrs BD due to Power shutdown,



Mold change & color cleaning & production starteday s . rs ue o ower s u own, + c

stopped in Night shiftay s m c s oppe . an s ar e rom .

PM due to cable work 8 hrs BD

M/c stopped due to no space to Keep Finish Goods

color changeover to Bluee ec or cy n er o ro en, rep ace mo oa e m c

started

Cavity insert change


2 cavity blocked

Day shift 4.00 Hrs BD due to Power shutdown,ay s m c s oppe . an s ar e rom .

PM due to cable work 8 hrs BDay s m c s oppe . an s ar e rom .

PM due to cable work 8 hrs BD

Mold change & startup


Day shift 4.00 Hrs BD due to Power shutdown,cav y no o so was oc e + ay s . rs

due to Power shutdown,

4 cavity running only

Hot tip cleaning

2 cavity block c# 1, 6


11/205


12/205


Order

Quantity

(In pcs)

Total Qty.

Produced

pcs

Balanced

need to

produced

(pcs)

cycle

Time

(Sec)

EBM-1

250ml Round Natural Bottle

(AB Chem) 10000 10590 -590 24

250ml round Coex PA bottle

white 12000 9000 3000 24

EBM-2 1 ltr cobra Bottle Mono 220970 194390 26580 29

EBM-3 250ml Confidor Super Bottle 75000 11520 63480 24

100ml Confidor super bottle 70000 8820 61180 24

EBM-4 5 Ltr BASF can 15000 1105 13895 45

EBM-5 1 ltr Triangular Bottle Blue 35000 37050 -2050 40

1 ltr Square Bottle pearl

white 12000 280 11720 38

EBM-6 1 ltr Anupam coex Bottle 234000 37788 196212 30

100ml Cobra Bottle Mono 500000 16632 483368 17

IBM-1 10/30ml Corogon Bottle 500000 0 500000 15

ASB-3 1 ltr Magister Bottle 60000 34800 25200 26.2

IM-1 RD 15 juniar Base 350000 49000 301000 24

IM-2 50mm KR logo blue cap 30000 41000 -11000 27.2

IM-3 30ml Flat measuring cup 50000 55000 -5000 19

50mm Pursuite ring 35000 12000 23000 20


IM-5 25ml Plain measuring cup 100000 66000 34000 12.5

IM-6 53mm cobra cap 700000 629100 70900 30

IM-7 RD jr Lid 500000 204150 295850 16

IM-8

logo 100000 170000 -70000 16.5

50mm BASf cap 25000 3250 21750 20

IM-9 53mm Anupam starp 200000 112000 88000 19

IM-11

cup TP violet 1000000 338400 661600 17

Date: 30/7/2013


13/205

IM-12

logo 200000 304700 -104700 19.5

Red (SAC Derabasi) 60000 15000 45000 19.5

IM-12 53mm Anupam Cap 200000 120600 79400 26


28mm folicure cap

Wadding M/c-2 50mm KR logo blue cap

50mm Pursuite cap

53mm cobra cap






assembly

50mm Blue cap assembly



HDPE B52A003

Other

Items

HDPE B56003

polybag

45*45

HDPE E5201S 7000

shipper

555

MB WHITE 10055 25

shipper

465


MB Blue 29443 25 325 shiper

HDPE 50ma180 100

510

shippers

PP 3530 750 10 x 1 ltr

ASPET 21c 1150

465

shipper 3

ply

Total

Raw Material Reconcilation :


14/205

PP H110MA 500

shipper

600 x 430

ASPET 20C

40 x

250ml

PP srm100nc 1000 20 x 500

green 13965

silver grey 88901

c blue 80505 25


15/205

weight

(Grams)

No. of


Actual

Production in

Pcs

Production In

Kgs

Opening

RM

Balance

40 8 B52A003 Natural 12000 10590 424

40 8 B52A003 white 12000 9000 360 601

110 8 B52A003 Natural 23834 23580 2594 486

42 4 B52A003 white 14400 10560 444

23 4 B52A003 white 14400 8820 203 485

300 2 B52A003 tsl yellow 1920 1105 332 253

110 4 B52A003 blue 3600 3042 335

100 2 B52A003

Pearl

white 568 280 28 153

100 8 B52A003 tsl yellow 2880 2154 215

21 8 B52A003 Natural 20329 16632 349 411

8 14 B52A003 pearl white 0 0

65.5 6 ASPET Blue 19786 17100 1120 36

9.6 6 H110MA white 21600 17500 168.0 13

10.5 8 MI3530 blue 25412 25000 262.5 13

7 14 SRM100NC blue 13263 12500 87.5

1.8 8 SRM100NC Natural 15840 12000 21.6 12

2.56 32 H110MA pearl white 125673 114000 291.8 109

3.5 8 MI3530 Natural 55296 54000 189.0 178

13.5 16 MI3530 c blue 46080 38700 522.5 147

6.6 6 H110MA blue 32400 29750 196.4 126

3.6 15 SRM100NC Natural 32727 30000 108.0

12.5 4 MI3530 yellow 4320 3250 40.6 74

3.8 8 50mA180 white 36379 22000 83.6 38

2 32 SRM100NC tp violet 162635 126900 253.8 37

Daily Production Report bottling


16/205

6.5 8 SRM100NC trans 10338 9000 58.5

6.5 8 SRM100NC red 16246 15000 97.5 116

19 8 MI3530 yellow 26585 18600 353.4 58

white 40000

green 5000

blue 9000

yellow 5950

white 52200

yellow 23400

Violet 54000

white 33600

5831

4200

9100

12250

750513 885594 9137 3344

Qty

a

Received

in Pcs size QTY issued

bayer logo 46.4 40000

220 bayer logo 29.6

plain 19.8

mayerplain 46.4 22100

150 dupont 19.2

wad 43.4

1000 DX excel 46.4

200

mayer

plain 34.5

% of wastage

not used

% of Wastage


17/205

board 46.4

dupont 19.2 110000

rallis 46.4




18/205

RM

issue

details Total

closing

balance

Regrind

generate

d kg

Regrind

/

reproces

s used

Lumps

(Kg)

Plan

Hour

Mold

change

& Other

BD time Efficeancy

0 0 22.4 22.4 10 88%

1575 2176 1379 29.2 29.2 13 10 4 75%

3000 3486 890 19.8 19.8 2 24 99%

0 0 15.96 16.0 7 24 73%

700 1185 532 48.3 48.3 24 61%

400 653 305 90 90.0 17 12 12 58%

0 30.8 30.8 7 10 85%

700 853 478 18 18.0 5 3 11 49%

0 37.9 37.9 6 3 75%

700 1111 534 16.38 16.4 6 12 9 82%

0 0 0.0 0 #DIV/0!

1150 1186 65 19.65 19.7 1 24 86%

175 188 20 2.304 2.3 24 81%

250 263 0 3.57 3.6 24 98%

0 1.4 1.4 5 94%

125 137 25 1.008 1.0 3 11 8 76%

200 309 17 0.8704 0.9 24 91%

50 228 39 0.805 0.8 24 98%

500 647 124 3.375 3.4 24 84%

150 276 79 1.32 1.3 24 92%

0 0.504 0.5 10 92%

100 174 23 2.5 2.5 3 6 8 75%

50 88 4 0.532 0.5 24 60%

250 287 33 1.12 1.1 24 78%

plant


19/205

0 1.56 1.6 7 87%

75 191 33 2.34 2.3 2 11 6 92%

450 508 155 4.75 4.8 24 70%

10600 13944 4735 376 376 72

which can

0.79

4.9


20/205


21/205


Material Logo insert change & Production startup in night

shift

1 cavity Not coming OK due to Moog problem

Mold change & PDN startup

Mold change & color cleaning of barrel & startup

Mold change & Production startup & color cleaning

Mold change + 1 cavity having mjor flash

1 cavity not ok so it was blocked




22/205

Cavity Plate offloaded & insert change & M/c startup


m/c bearing broken


23/205


Order

Quantity

(In pcs)

Total Qty.

Produced

pcs

Balanced

need to

produced

(pcs)

EBM-1 500ml Coex Bottle Natural 20000 17024 2976

EBM-2 1 ltr cobra Bottle Mono 220970 216930 4040

EBM-3 250ml Confidor Super Bottle 75000 23280 51720

100ml Confidor super bottle 70000 18900 51100

EBM-4 5 Ltr BASF can 15000 3681 11319

EBM-5 1 ltr Square Bottle pearl white 12000 4798 7202

EBM-6 100ml Cobra Bottle Mono 500000 56438 443562

ASB-3 1 ltr Magister Bottle 60000 39960 20040

500ml PET Bottle 30000 9360 20640

IM-1 RD 15 juniar Base 350000 65000 285000

IM-2 50mm KR logo blue cap 30000 42000 -12000

50mm Suzumida cap 30000 17000 13000

IM-3 50mm Pursuite ring 35000 33000 2000

IM-4 10ml corogon cap pearl white 1000000 366000 634000

IM-5 25ml Plain measuring cup 100000 123000 -23000

IM-6 53mm cobra cap 700000 652500 47500

53mm obran cap 50000 21600 28400

IM-7 RD jr Lid 500000 232150 267850

IM-8 50mm BASf cap 25000 16900 8100

IM-9 53mm Anupam starp 200000 134000 66000

IM-11

10ml corogon Measuring cup TP

violet 1000000 488800 511200

Date: 31/7/2013


24/205

IM-12

50ml Plain measuring cup Red

(SAC Derabasi) 60000 48000 12000

IM-12 53mm Anupam Cap 200000 139200 60800


Wadding M/c-2 50mm plain cap white

50mm Pursuite cap

50mm KR logo blue cap

53mm cobra cap


38mm cobra cap white








94mm Anupam cap

22mm Fame cap



HDPE B52A003

HDPE B56003

HDPE E5201S 6000



25/205

MB WHITE 10055 25

MB TSL Yellow 9682 25

MB Blue 29443

HDPE 50ma180 100

PP 3530 1000

PP H110MA 750

ASPET 20C 1150

PP srm100nc 1000

pearl white 20051 25

yellow 12184 25

o blue 14275 25

PA 150

Admer 50


26/205

cycle

Time

(Sec)

weight

(Grams)

No. of


Actual

Production in

Pcs

Production

In Kgs

24 65 8 B52A003 Natural 19200 17024 1107

30 110 8 B52A003 Natural 23040 22540 2479

24 42 4 B52A003 white 14400 11760 494

24 23 4 B52A003 white 14400 10080 232

45 300 2 B52A003 tsl yellow 3840 2576 773

34 100 2 B52A003

Pearl

white 5082 4518 452

17 21 8 B52A003 Natural 40659 39806 836

26.2 65.5 6 ASPET D blue 5771 5160 338

23 46.2 6 ASPET D Blue 10330 9360 432

24 9.6 6 H110MA white 21600 16000 153.6

27.2 10.5 8 MI3530 blue 1059 1000 10.5

27.2 10.5 8 MI3530 white 18000 17000 178.5

19 1.8 8

SRM100N

C Natural 36379 21000 37.8

22 2.56 32 H110MA pearl white 125673 114000 291.8

12 3.5 8 MI3530 Natural 57600 57000 199.5

29.5 13.5 16 MI3530 c blue 23431 23400 315.9

29.5 13.5 16 MI3530 obran 23431 21600 291.6

14 6.6 6 H110MA blue 37029 28000 184.8

24.8 12.5 4 MI3530 yellow 13935 13650 170.6

16 3.8 8 50mA180 white 43200 22000 83.6

17.5 2 32

SRM100N

C tp violet 157989 150400 300.8

Daily Production Report bo


27/205

19.5 6.5 8

SRM100N

C red 35446 33000 214.5

27.8 19 8 MI3530 yellow 24863 18600 353.4

blue 45000

white 14000

yellow 6500

blue 4000

white 17100

yellow 18000

4000

Violet 18000

yellow 7500

white 4200

27000

2210

2210

8941

5600

18430

22750

756356 884915 9930

Other

Items Qty

Wad

Received


polybag

45*45 75 bayer logo 46.4 40000

shipper

555 bayer logo 29.6


28/205

shipper

465 300 plain 19.8

Ovensack 2 roll

mayer

plain 46.4 44200

325 shiper 150 dupont 19.2

50 x

100ml 500 wad 43.4 21300

10 x 1 ltr 2000 DX excel 46.4

shipper

600 x 430 board 46.4

40 x

250ml dupont 19.2 90500

20 x 500 rallis 46.4


29/205

Opening

RM

Balance

RM

issue

details Total

closing

balance

Regrind

generate

d kg

Regrind

/

reproces

s used

Lumps

(Kg)

Plan

Hour

Mold

change

& Other

BD time

1379 1000 2379 1259 80.6 80.6 13.5 16 8

890 2400 3290 808 5.5 5.5 2.6 24

0 0 0 9.24 9.2 4.9 24

532 700 1232 497 50.14 50.1 4 24

305 700 1005 212 66 66.0 20 24

478 650 1128 669 19.5 19.5 7 24

534 800 1334 493 7.35 7.4 4.9 24

0 19.65 19.7 7

65 1150 1215 442 11.55 11.6 3 11 6

20 150 170 16 2.88 2.9 24

0 0 3.57 3.6 1

0 200 200 6 2.1 2.1 5 17 6

25 50 75 37 1.404 1.4 24

17 300 317 26 1.152 1.2 24

39 200 239 40 0.42 0.4 24

0 4.59 4.6 12

124 600 724 110 2.16 2.2 7 12

79 200 279 94 1.782 1.8 24

23 200 223 52 1.5 1.5 24

4 100 104 21 0.532 0.5 24

33 300 333 32 1.12 1.1 24

tling plant


30/205

33 200 233 19 2.34 2.3 24

155 425 580 226 4.75 4.8 24

4735 10325 15060 5059 300 300 72

% of Wastage 3.7

% of wastage which

can not used 0.72


31/205


32/205

Efficeancy Mold change/Break down

89% Mold change & Production startup & color cleaning

98%

82% M/c stopped for 1 hrs for loader connection

70% 1 cavity Not coming OK due to Moog problem

67% Frequent stopage of m/c

89%

98%

89%

91%Mold change & PDN startup + Night shift Chiller flange

open corrected & started

74%

94%

94% Cavity insert change & Barrel color cleaning & startup

58% 1 cavity having mjor flash

91%

99%

100%

92% color change

76%

98% Mold change & PDN startup

51% 4 cavity running only

95%


33/205

93% Cavity Plate offloaded & insert change & M/c startup

75% 2 cavity block c# 1, 6


34/205


Order

Quantity

(In pcs)

Total Qty.

Produced

pcs

Balanced

need to

produced

(pcs)

cycle

Time

(Sec)

weight

(Grams)

EBM-1

500ml Coex Bottle

Natural 20000 18240 1760 24 65

1 ltr Round Coex Bottle 20000 7254 12746 32 115

EBM-2 1 ltr cobra Bottle Mono 220970 237700 -16730 30 110

EBM-3

250ml Confidor Super

Bottle 75000 36000 39000 24 42

100ml Confidor super

bottle 70000 28980 41020 24 23

EBM-4 5 Ltr BASF can 15000 6962 8038 45 305

EBM-5

1 ltr Square Bottle

pearl white 12000 9790 2210 34 100

EBM-6

100ml Cobra Bottle

Mono 500000 102438 397562 15 21

ASB-3 500ml PET Bottle 30000 29160 840 23 46.2

IM-1 RD 15 juniar Base 350000 84250 265750 24 9.6

IM-2 50mm Suzumida cap 30000 39000 -9000 27.2 10.5

IM-3 50mm Pursuite ring 35000 37250 -2250 19 1.8

10ml Camel Cap 100000 -100000 18 1.5

IM-4 10ml corogon cap pearl 1000000 466000 534000 22 2.56

IM-5 25ml Plain measuring c 100000 129000 -29000 12 3.5

IM-6 53mm obran cap 50000 65700 -15700 29.5 13.5

IM-7 RD jr Lid 500000 244400 255600 14 6.6

32ml Confidor super

Measuring cup 25000 7500 17500 14 4.2

IM-8 50mm BASf cap 25000 29900 -4900 24.8 12.5

IM-9 53mm Anupam starp 200000 152000 48000 16 3.8

Date: 1/8/2013


35/205

IM-11

Measuring cup TP

violet 1000000 611000 389000 17.5 2

IM-12

cup Red (SAC

Derabasi) 60000 76000 -16000 19.5 6.5

50ml Plain Measuring

cup 60000 6000 54000 19.5 6.5

IM-12 53mm Anupam Cap 200000 157200 42800 27.8 19



50mm Pursuite cap


53mm cobra cap

Wadding M/c-3 38mm cobra cap white

Wadding M/c-4 10ml camel cap



manual

assembly threded plug

53mm anupam cappacking

53mm Anupam cap

assembly

50mm Pursuite cap

assembly

RD jr Lid & Base

Assembly


HDPE B52A003

Other

Items Qty

HDPE B56003

polybag

45*45 100

HDPE E5201S 6000

shipper

555



36/205

MB WHITE 10055 25

shipper

465

pearl white t1

Shipper

510 200

MB TSL Yellow 9682 Ovensack

MB Blue 29443 325 shiper

HDPE 50ma180

50 x

100ml 500

PP 3530 625 10 x 1 ltr 1000

ASPET 21c

465

shipper 3

ply 150

PP H110MA 600

shipper

600 x 430

ASPET 20C 1150

40 x

250ml

PP srm100nc 500 20 x 500

green 13965

silver grey 88901

PA 75

Admer 50

red 6213 25


37/205

No. of


Actual

Production

in Pcs

Production

In Kgs

Opening

RM

Balance

RM

issue

details Total

8 B52A003 Natural 2400 1216 79

8 B52A003 white 12600 7254 834 1259 350 1609

8 B52A003 Natural 23040 20770 2285 808 2500 3308

4 B52A003 white 14400 12720 534 0 0

4 B52A003 white 14400 10080 232 497 800 1297

2 B52A003 tsl yellow 3840 3281 1001 212 1000 1212

2 B52A003

Pearl

white 5082 4992 499 669 500 1169

8 B52A003 Natural 46080 46000 966 493 1000 1493

6 ASPET D Blue 22539 19800 915 442 1150 1592

6 H110MA white 21600 19250 184.8 16 175 191

8 MI3530 white 25412 22000 231.0 6 225 231

8

SRM100N

C Natural 4547 4250 7.7 0 0

32 H110MA red 108800 100000 150.0 37 150 187

32 H110MA pearl white 125673 100000 256.0 26 250 276

8 MI3530 Natural 7200 6000 21.0 40 0 40

16 MI3530 obran 46861 44100 595.4 110 500 610

6 H110MA blue 15429 12250 80.9 0 0

6

SRM100N

C blue 9257 7500 31.5 94 25 119

4 MI3530 yellow 13935 13000 162.5 52 125 177

8 50mA180 white 43200 18000 68.4 21 50 71

Daily Production Report bottling plant


38/205

32

SRM100N

C tp violet 157989 122200 244.4 32 225 257

8

SRM100N

C red 28062 28000 182.0 0 0

8

SRM100N

C red 7385 6000 39.0 19 25 44

8 MI3530 yellow 24863 18000 342.0 226 0 226

blue 45000

white 17000

yellow 9750

blue 11000

ob blue 9900

46000

Po red 70000

Violet 12000

yellow 11500

24000

2261

2261

7497

15750

784594 930582 9941 5059 9050 14109

a

Received


bayer logo 46.4

bayer logo 29.6

% of Wastage

% of wastage which

can not used


39/205

plain 19.8

46.4

mayer

plain 46.4

dupont 19.2

wad 43.4

DX excel 46.4

mayer

plain 34.5

board 46.4

dupont 19.2

rallis 46.4




40/205

closing

balance

Regrind

generated

kg

Regrind /

reprocess

used

Lumps

(Kg)

Plan

Hour

Mold

change

& Other

BD time Efficeancy

36.4 36.4 2 51%

684 126.5 126.5 11.8 14 8 58%

1019 26.4 26.4 4.5 24 90%

0 16.38 16.4 6.5 24 88%

522 25.3 25.3 3 24 70%

196 38.735 38.7 14.5 24 85%

667 34 34.0 2.6 24 98%

525 4.62 4.6 2.5 24 100%

673 15.246 15.2 4 24 88%

6 2.112 2.1 24 89%

0 1.365 1.4 24 87%

0 0.612 0.6 3 93%

24 0.66 0.7 5.7 17 4 92%

20 0.8448 0.8 24 80%

19 0.42 0.4 3 83%

15 3.105 3.1 24 94%

0 1.32 1.3 10 79%

0 1.428 1.4 6.8 6 8 81%

15 2.75 2.8 24 93%

2 0.532 0.5 24 42%


41/205

13 0.6 0.6 24 77%

0 1.56 1.6 19 100%

0 1.95 182.0 3 5 81%

0 3.99 120.0 24 72%

4399 347 643 65

4.1

0.65


42/205


43/205


mold change & PDN startup + left side blow

pin get bend in night shift 4 hrs BD

M/c stopped for 1 hrs for loader connection


Cavity insert change & Barrel color cleaning &

startup

1 cavity having major flash

mold change & PDN startup

M/c stopped

Mold change & PDn started



44/205

Frequent cavity blockage

color change


m/c bearing broken


45/205


Order

Quantity

(In pcs)

Total

Qty.

Produce

d pcs

Balance

d need

to

produce

d (pcs)

cycle

Time

(Sec)

weight

(Grams)

EBM-1 1 ltr Round Coex Bottle 20000 20982 -982 32 115

250ml Cobra Bottle Monolayer 200000 560 199440 24 37

EBM-2 1 ltr cobra Bottle Mono 220970 240240 -19270 30 110

500ml Cobra Bottle 200000 19980 180020 24 57

EBM-3 250ml Confidor Super Bottle 75000 48960 26040 24 42

100ml Confidor super bottle 70000 39690 30310 24 23

EBM-4 5 Ltr BASF can 15000 10362 4638 45 305

EBM-5 1 ltr Square Bottle pearl white 12000 15484 -3484 30 100

EBM-6 100ml Cobra Bottle Mono 500000 147762 352238 15 21

ASB-3 500ml PET opaqe green bottle 30000 15600 14400 23.5 46.2

IM-1 RD 15 juniar Base 350000 105250 244750 24 9.6

IM-2 50mm Suzumida cap 30000 60000 -30000 27.2 10.5

IM-3 10ml Camel Cap 300000 250000 50000 16 1.5

IM-4 10ml corogon cap pearl white 1000000 576000 424000 22 2.56

IM-5 25ml Plain measuring cup 100000 0 100000 12 3.5

IM-6 53mm obran cap 50000 111600 -61600 29.5 13.5

IM-7

Measuring cup 25000 32500 -7500 18 4.2

IM-8 50mm BASf cap 25000 42250 -17250 24.8 12.5

IM-9 53mm Anupam starp 200000 0 200000 16 3.8

IM-11

TP violet 1000000 690900 309100 17.5 2

IM-12 50ml Plain Measuring cup 60000 76500 -16500 19.5 6.5

IM-12 53mm Anupam Cap 200000 160800 39200 27.8 19



53mm cobra cap


Date: 2/8/2013


46/205



Wadding m/c no.7 46mm plain cap

37mm white cap





Almix cap wadding



HDPE B52A003 6250

Other

Items Qty

HDPE B56003

polybag

45*45 75

MB WHITE 10055 100

shipper

465

orange 9.18E+08

shipper

590 50

pearl white t1Shipper510


MB Blue 29443 325 shiper 150

HDPE 50ma180

20 x 500

shipper 1000

PP 3530 1000 10 x 1 ltr 100

ASPET 21c 1150

465

shipper 3

ply

PP H110MA 750

shipper

600 x 430

ASPET 20C

40 x

250ml

PP srm100nc 710 20 x 500

silver grey 88901

white t5 25

PA 75



47/205

Admer 50


48/205

No. of


Actual

Production

in Pcs

Producti

on In

Kgs

Opening

RM

Balance

RM

issue

details Total

8 B52A003 white 15300 13728 1579 0 0

8 B52A003 Natural 1200 560 21 684 2000 2684

8 B52A003 Natural 2880 2540 279 0 0

8 B52A003 Natural 21600 19980 1139 1019 1500 2519

4 B52A003 white 14400 12960 544 0 0

4 B52A003 white 14400 10710 246 522 400 922

2 B52A003 tsl yellow 3840 3400 1037 196 1000 1196

2 B52A003

white 5760 5694 569 667 500 1167

8 B52A003 Natural 46080 45324 952 525 1075 1600

6 ASPET op green 16545 15600 721 673 1150 1823

6 H110MA white 21600 21000 201.6 6 200 206

8 MI3530 white 25412 21000 220.5 0 225 225

32 H110MA red 172800 150000 225.0 24 225 249

32 H110MA pearl white 125673 110000 281.6 20 300 320

8 MI3530 Natural 0 0 0.0 19 19

16 MI3530 obran 46861 45900 619.7 15 625 640

6 C blue 28800 25000 105.0 0 125 125

4 MI3530 yellow 13935 12350 154.4 15 150 165

8 50mA180 white 0 0 0.0 2 0 2

32 C tp violet 157989 130000 260.0 13 250 263

8 C red 35446 35400 230.1 0 250 250

8 MI3530 yellow 4144 3600 68.4 0 135 135

blue 30000

white 18000

ob blue 28800

68000

Daily Production Report bottling plant


49/205

Po red 175000

Violet 36000

white 2800

6000

30000

4590

5600

5200

6000

14000

774664 1114736 9453 4399 10110 14509

a

Received



plain 19.8

camel 22.6

ep wad 22.6 220000

mayer

plain 46.4 44200

dupont 19.2

wad 43.4

DX excel 46.4

mayer

plain 34.5

board 46.4

dupont 19.2 41000

rallis 46.4


% of Wastage

% of wastage which

can not used


50/205


51/205

closing

balance

Regrind

generate

d kg

Regrind

/

reproces

s used

Lumps

(Kg)

Plan

Hour

Mold

change

& Other

BD time

Efficean

cy

0 87.4 87.4 8.5 17 90%

1070 32.19 32.2 6.5 1 6 47%

0 61.6 61.6 5.5 3 88%

1087 22.8 22.8 7.8 18 3 93%

0 15.12 15.1 3.6 24 90%

123 6.9 6.9 4.5 24 74%

145 79.3 79.3 14.6 24 89%

593 34 34.0 5 24 99%

644 8.4 8.4 3.7 24 98%

1096 15.708 15.7 6.5 18 6 94%

5 2.208 2.2 24 97%

5 2.31 2.3 24 83%

24 0.36 0.4 24 87%

38 0.768 0.8 24 88%

19 0 0.0 0 #DIV/0!

20 3.105 3.1 24 98%

20 0.504 0.5 24 87%

10 2.5 2.5 24 89%

2 0 0.0 0 #DIV/0!

3 0.4 0.4 24 82%

20 0.845 0.8 24 100%

67 3.8 3.8 4 87%


52/205

4989 380 380 66

4.7

0.70


53/205


54/205


Mold change & PDN startup.

mold change & PDN startup.


day shift color trial & PDN startup from 2PM.

M/c stopped

M/c stopped

M/c stopped


55/205

m/c bearing broken


56/205


Order

Quantity

(In pcs)

Total Qty.

Produced

pcs

Balanced

need to

produced

(pcs)

cycle

Time

(Sec)

EBM-1

Monolayer 200000 30440 169560 21

EBM-2 500ml Cobra Bottle 200000 52410 147590 21

EBM-3

Bottle 75000 60000 15000 24


EBM-4 5 Ltr BASF can 15000 11892 3108 45

EBM-5

white 12000 16810 -4810 30

1 ltr Triangular Bottle 20000 2520 17480 32

EBM-6 100ml Cobra Bottle Mono 500000 193346 306654 15

ASB-3

bottle 30000 30240 -240 23.5

500ml Blue Bottle 30000 34320 -4320 23.5

IM-1 RD 15 juniar Base 350000 124500 225500 24

IM-2 50mm Suzumida cap 30000 61000 -31000 27.2

50mm chambal cap 30000 16000 14000 27.2

IM-3 10ml Camel Cap 300000 450000 -150000 13

IM-4 10ml corogon cap pearl whit 1000000 681000 319000 22

IM-6 53mm obran cap 50000 155700 -105700 29.5

IM-7

Measuring cup 25000 62500 -37500 16

IM-8 50mm BASf cap 25000 55900 -30900 24.8

IM-9 38mm cobra cap 200000 14000 186000 30

IM-11

cup TP violet 1000000 813100 186900 17.5

IM-12 50ml Plain Measuring cup 60000 76500 -16500 19.5

IM-12 53mm Anupam Cap 200000 0 200000 27.8



50mm Pursuite cap

53mm cobra cap

Date: 3/8/2013


57/205

53mm cobra cap




37mm white cap


assembly

Almix cap wadding



HDPE B52A003 4000

Other

Items

HDPE B56003

polybag

45*45

HDPE E5201S

shipper

555

MB WHITE 10055 75

shipper

465

orange 9.18E+08

shipper

590

pearl white t1

Shipper

510



HDPE 50ma180

20 x 500

shipper

PP 3530 750 10 x 1 ltr

ASPET 21c 1150

465

shipper 3

ply

PP H110MA 500

shipper

600 x 430

ASPET 20C

40 x

250ml

PP srm100nc 20 x 500

green 13965



58/205

silver grey 88901

red 29020

golden t3 25

white t5

pearl white 20051

crimson 13315yellow 12184

c blue 80505

o blue 14275

pearl blue 133101

blue 24577

yellow 1786

PA

Admer

red 6213

pearl blue 28760

p blue 41954034

yellow 12180

HDPE b5500

red 11155

orange 30444

green 15404


59/205

weight

(Grams)

No. of


Actual

Production in

Pcs

Production In

Kgs

Opening

RM Balance

37 8 B52A003 Natural 32914 29880 1106 1070

58 8 B52A003 Natural 32914 32430 1881 1087

42 4 B52A003 white 14400 11040 464 0

23 4 B52A003 white 14400 10080 232 123

305 2 B52A003 tsl yellow 1920 1530 467 145

100 2 B52A003

ear

white 1440 1326 133

110 2 B52A003 white 2700 2520 277 593

21 8 B52A003 Natural 46080 45584 957 644

46.2 6 ASPET op green 16545 14640 676

46.2 6 ASPET blue 5515 5160 238 1096

9.6 6 H110MA white 21600 19250 184.8 5

10.5 8 MI3530 white 2118 1000 10.5

10.5 8 MI3530 white 16941 16000 168.0 5

1.5 32 H110MA red 212677 200000 300.0 24

2.56 32 H110MA pearl white 125673 105000 268.8 38

13.5 16 MI3530 obran 46861 44100 595.4 39

4.2 6 C blue 32400 30000 126.0 20

12.5 4 MI3530 yellow 13935 13650 170.6 10

6.8 32 MI3530 golden 23040 14000 95.2 2

2 32 C tp violet 157989 122200 244.4 3

6.5 8 C red 35446 35100 228.2 20

19 8 MI3530 yellow 0 0 0.0 67

blue 55000

white 15730

yellow 3250

c blue 18900

Daily Production Report bottli


60/205

ob blue 16200

58000

Po red 155000

Violet 36000

16000

45000

3400

12000

10500

857508 1199470 8822 4990

Qty

Wad

Received


75 bayer logo 46.4 42750

bayer logo 29.6

plain 19.8

camel 22.6

300 ep wad 22.6 220000

mayer

plain 46.4 22100

100 dupont 19.2

1500 wad 43.4

DX excel 46.4

200

mayer

plain 34.5 39600

board 46.4

526 dupont 19.2

rallis 46.4

bayer logo 26.4

% of Wastage

% of wastage

not used


61/205



62/205

RM

issue

details Total

closing

balance

Regrind

generated

kg

Regrind /

reprocess

used

Lumps

(Kg)

Plan

Hour

Mold

change &

Other BD

time

Efficean

cy

500 1570 455 16.65 16.7 8.9 24 91%

900 1987 98 17.4 17.4 7.7 24 99%

0 0 9.66 9.7 12 24 77%

600 723 8 25.3 25.3 8 24 70%

500 645 162 70.15 70.2 16 12 80%

0 0 34 34.0 6 92%

500 1093 675 33 33.0 8 12 693%

1075 1719 759 6.3 6.3 2.6 24 99%

0 10.626 10.6 18 88%

1150 2246 1325 30.954 31.0 6.5 6 94%

200 205 20 2.88 2.9 24 89%

0 1.26 1.3 2 47%

175 180 1 2.1 2.1 16 6 94%

300 324 24 0.45 0.5 24 94%

250 288 19 0.8704 0.9 24 84%

550 589 0 3.105 9.1 24 94%

0 20 0 0.84 107.0 24 93%

0 10 0 1.5 162.0 24 98%

0 2 0 2.04 95.0 6 18 61%

0 3 0 0.4 242.0 24 77%

0 20 0 0.78 209.0 24 99%

0 67 67 0 0.0 0 #DIV/0!

ng plant


63/205

6700 11690 3613 270 1086 70

3.9

hich can

0.79


64/205


65/205



Night shift M/c stopped due to no place to keep the Finished Goods


color change

Cavity insert change & PDN startup


M/c stopped


66/205

m/c bearing broken


67/205


Order

Quantity

(In pcs)

Total

Qty.

Produce

d pcs

Balanced

need to

produced

(pcs)

cycle

Time

(Sec)

EBM-1 250ml Cobra Bottle Monolayer 200000 66000 134000 19.5


EBM-3 250ml Confidor Super Bottle 75000 63120 11880 24


50ml confidor super Bottle 45000 4000 41000 24

100ml Round White Bottle 0 0 24

EBM-4 5 Ltr BASF can 15000 0 15000 45

EBM-5 1 ltr Triangular Bottle 20000 10368 9632 36

EBM-6 100ml Cobra Bottle Mono 500000 199360 300640 15

100ml Fame Bottle 260000 36960 223040 15

IBM-1 10/30ml Corogon Bottle 500000 500000 15

ASB-3 500ml Blue Bottle 30000 45000 -15000 23.5

IM-1 RD 15 juniar Base 350000 147250 202750 22

IM-2 50mm Kr Logo white cap 25000 16000 9000 27.2

50mm chambal cap 30000 19000 11000 27.2

IM-3 10ml Camel Cap 300000 470000 -170000 13

10ml Camel Cap 300000 175000 125000 13


IM-5 46mm Plain white cap 50000 26400 23600 18

IM-6 53mm obran cap 50000 159300 -109300 29.5

53mm Cobra Cap 1000000 39600 960400 29.5

IM-7

cup 25000 90000 -65000 16

IM-8 50mm BASf cap 25000 25000 24.8

IM-9 38mm cobra cap 200000 84000 116000 28

IM-11

10ml corogon Measuring cup TP

violet 1000000 827200 172800 17.5


IM-12 53mm Anupam Cap 200000 200000 27.8

Date: 4/8/2013


68/205


28mm Folicure cap

Wadding M/c-2 50mm chambal cap

50mm white cap Kr logo


53mm cobra cap

53mm cobra cap

Wadding M/c-3 38mm cobra cap





37mm white cap





Almix cap wadding

22mm Fame cap



HDPE B52A003 5000

Other

Items

HDPE B56003

polybag

45*45

HDPE E5201S

shipper

555

MB WHITE 10055 25

shipper

465

orange 9.18E+08

shipper

590

pearl white t1

Shipper

510




69/205


HDPE 50ma180

20 x 500

shipper

PP 3530 1250 10 x 1 ltr

ASPET 21c

465

shipper 3

ply

PP H110MA 625

shipper

600 x 430

ASPET 20C

40 x

250ml

PP srm100nc 500 20 x 500

green 13965

silver grey 88901

red 29020

golden t3 50white t5

pearl white 20051

crimson 13315

yellow 12184

c blue 80505 25

o blue 14275

pearl blue 133101

blue 24577

yellow 1786

PA

Admer

red 6213

pearl blue 28760

p blue 41954034

yellow 12180

HDPE b5500

red 11155

orange 30444

green 15404


70/205

weight

(Grams)

No. of


Actual

Production

in Pcs

Producti

on In

Kgs

Opening

RM

Balance

RM

issue

details

37 8 B52A003 Natural 35446 35560 1316 455 1300

58 8 B52A003 Natural 32914 32120 1863 98 2275

42 4 B52A003 white 4200 3120 131 0

23 4 B52A003 white 4200 3780 87 0

18 4 B52A003 white 4200 3780 68

21 4 B52A003 white 4200 3780 79 8 500

300 2 B52A003 tsl yellow 1920 0 0 162 0

110 4 B52A003 white 9600 7848 863 675 500

21 8 B52A003 Natural 7680 6014 126

21 8 B52A003 Golden 38400 36960 776 759 500


46.2 6 ASPET blue 11030 10680 493 1325

9.6 6 H110MA white 23564 22750 218.4 20 200

10.5 8 MI3530 white 16941 16000 168.0

10.5 8 MI3530 white 3176 3000 31.5 1 200

1.5 32 H110MA red 26585 20000 30.0

1.5 32 H110MA L yellow 186092 175000 262.5 24 300

2.56 32 H110MA pearl white 125673 109000 279.0 19 300

8.5 8 MI3530 white 28800 26400 224.4 0 225

13.5 16 MI3530 obran 3905 3600 48.6 0

13.5 16 MI3530 obran 42956 39600 534.6 0 600

4.2 6 C blue 32400 27500 115.5 0 125

12.5 4 MI3530 yellow 0 0.0 0

6.8 32 MI3530 golden 98743 70000 476.0 0 450

2 32

SRM100N

C tp violet 19749 14100 28.2 0 0

6.5 8 C red 35446 33000 214.5 0 0

19 8 MI3530 yellow 0 0.0 67 0



71/205

blue 40000

green 15000

white 18000

white 12000

blue 7730

c blue

ob blue 15300

blue 68000

Po red 60000

Violet 30000

yellow

white

42000

10500

797820 1022122 8434 3613 7475

Qty

a

Received


25 bayer logo 46.4

bayer logo 29.6

plain 19.8

230 camel 22.6

ep wad 22.6 110000

mayer

plain 46.4 21100

% of Wastage

% of wastage which

can not used


72/205

100 dupont 19.2

1600 wad 43.4

DX excel 46.4

mayer

plain 34.5

board 46.4

dupont 19.2

rallis 46.4




73/205

Total

closing

balance

Rejectio

n in pcs

Regrind

generate

d kg

Regrind

/

reproces

s used

Lumps

(Kg)

Plan

Hour

Mold

change

& Other

BD time

Efficean

cy

1755 433 90 3.33 3.3 5.9 24 100%

2373 503 120 6.96 7.0 7.6 24 98%

0 0 200 8.4 8.4 8 7 74%

0 0 320 7.36 7.4 6 7 90%

0 0 400 7.2 7.2 4 7 10 90%

508 110 450 9.45 9.5 7 7 90%

162 162 0 0 0.0 12 0%

1175 303 450 49.5 49.5 8.5 24 82%

0 0 600 12.6 12.6 5 4 78%

1259 344 450 9.45 9.5 8 20 96%

0 0 0.0 0 #DIV/0!

1325 828 340 15.708 15.7 3 12 97%

220 2 120 1.152 1.2 24 97%

0 80 0.84 0.8 16 94%

201 2 230 2.415 2.4 3 5 94%

0 0 500 0.75 0.8 3 75%

324 26 780 1.17 1.2 5 21 94%

319 40 230 0.5888 0.6 24 87%

225 1 120 1.02 1.0 18 6 92%

0 0 230 3.105 3.1 2 92%

600 11 400 5.4 5.4 5.5 22 92%

125 10 230 0.966 1.0 24 85%

0 0 0 0.0 0 #DIV/0!

450 0 340 2.312 28.3 24 71%

0 0 220 0.44 28.4 3 71%

0 0 120 0.78 215.3 24 93%

67 67 0 0 0.0 0 #DIV/0!

t


74/205

11088 2842 7020 151 419 74

2.7

0.87


75/205


76/205


open + weight adjustment problem solved

Finished Goods

color change to golden

Night shift M/c stopped

Cavity insert change & PDN startup

Color change to L yellow

PDN startup

Color change

M/c stopped

Hot tip cleaning in day shift

M/c stopped

M/c stopped


77/205

m/c bearing broken


78/205


Order

Quantity

(In pcs)

Total

Qty.

Produce

d pcs

Balance

d need

to

produce

d (pcs)

cycle

Time

(Sec)

EBM-1 250ml Cobra Bottle Monolayer 200000 102680 97320 18


EBM-3 50ml confidor super Bottle 45000 22000 23000 19

100ml Round White Bottle 17248 -17248 19

EBM-4 3 ltr Jery Can 2000 792 1208 45

EBM-5 1 ltr Triangular Bottle 20000 16764 3236 36

EBM-6 100ml Fame Bottle 260000 76294 183706 16


ASB-3 500ml Blue Bottle 30000 0 30000 23.5

IM-1 RD 15 juniar Base 350000 168250 181750 22

IM-2 50mm Kr Logo white cap 25000 40000 -15000 27.2

IM-3 10ml Camel Cap 300000 220000 80000 13

10ml Camel Cap 300000 110000 190000 13


22mm Fame cap 500000 90000 410000 22

IM-5 46mm Plain white cap 50000 41400 8600 18

46mm Plain Yellow cap 15000 18000 -3000 18

IM-6 53mm Cobra Cap 1000000 81000 919000 29.5

IM-7

32ml Confidor super Measuring

cup 25000 100000 -75000 16

30ml Raft Measuring cup 50000 25000 25000 20

IM-8 50mm BASf cap 25000 25000 24.8

IM-9 38mm cobra cap 200000 156000 44000 28

IM-1110ml corogon Measuring cup TPviolet 1000000 0 1000000 17.5


IM-12 53mm Anupam Cap 200000 0 200000 27.8

Wadding M/c-1 28mm Folicure cap

Wadding M/c-2 50mm Rallis cap


Date: 5/8/2013


79/205


53mm cobra cap

53mm cobra cap






37mm white cap




50mm Pursuite cap assemblyAlmix cap wadding

22mm Fame cap



HDPE B52A003 4000

Other

Items

HDPE B56003

polybag

45*45

HDPE E5201S

shipper

555

MB WHITE 10055 25

shipper

465

orange 9.18E+08

shipper

590

pearl white t1

Shipper

510



HDPE 50ma180

20 x 500

shipper

PP 3530 1250 10 x 1 ltr

ASPET 21c

465

shipper 3

ply



80/205

PP H110MA 625

shipper

600 x 430

ASPET 20C

40 x

250ml

PP srm100nc 250 20 x 500

green 13965

silver grey 88901

red 29020

golden t3 50

white t5

pearl white 20051

crimson 13315

yellow 12184

c blue 80505

o blue 14275

pearl blue 133101blue 24577

yellow 1786

PA

Admer

red 6213

pearl blue 28760

p blue 41954034

yellow 12180

HDPE b5500

red 11155

orange 30444

green 15404


81/205

weight

(Grams)

No. of


Actual

Production in

Pcs

Producti

on In

Kgs

Opening

RM

Balance

RM

issue

details

37 8 B52A003 Natural 38400 36680 1357 433 1000

58 8 B52A003 Natural 32914 31388 1821 503 1450

18 4 B52A003 white 18189 18000 324 0

21 4 B52A003 white 18189 14784 310 110 550

255 2 B52A003 white 960 792 202 162 100

110 4 B52A003 white 9600 6396 704 303 450

21 8 B52A003 Golden 43200 39334 826 344 500


46.2 6 ASPET blue 0 0 828

9.6 6 H110MA white 23564 21000 201.6 2 200

10.5 8 MI3530 white 25412 24000 252.0 2 250

1.5 32 H110MA L yellow 53169 45000 67.5 0

1.5 32 H110MA Black 159508 110000 165.0 26 225

2.56 32 H110MA pearl white 10473 10000 25.6

2.56 32 H110MA golden 94255 90000 230.4 40 225

8.5 8 MI3530 white 17600 15000 127.5

8.5 8 MI3530 yellow 20800 18000 153.0 1 275

13.5 16 MI3530 c blue 46861 41400 558.9 11 550

4.2 6

SRM100N

C blue 10800 10000 42.0

7 16 C blue 28800 25000 175.0 10 150

12.5 4 MI3530 yellow 0 0.0 0

6.8 32 MI3530 golden 98743 72000 489.6 0 275

2 32SRM100N

C tp violet 0 0 0.0 0 0

6.5 8 C red 35446 33000 214.5 67 0

19 8 MI3530 yellow 0 0 0.0 0 0

green 50000

red 9000

white 21000

Daily Production Report bottling p


82/205

blue

c blue 20700

ob blue 1800

blue 60000

black 95000

Violet 24000

yellow

yellow 5600

27000

8400

2100

3500

786883 989874 8246 2842 6200

Qty

a

Received


bayer logo 46.4

300 bayer logo 29.6

plain 19.8

100 camel 22.6

ep wad 22.6

2 rollmayerplain 46.4 44200

dupont 19.2

1500 wad 43.4

200 DX excel 46.4

mayer

plain 34.5

% of Wastage

% of wastage which

can not used


83/205

board 46.4

dupont 19.2

rallis 46.4

bayer logo 26.4

bayer logo 29.6


84/205

Total

closing

balance

Rejectio

n in pcs

Regrind

generate

d kg

Regrind

/

reproces

s used

Lumps

(Kg)

Plan

Hour

Mold

change

& Other

BD time Efficeancy

1433 68 450 16.65 16.7 8.7 24 96%

1953 123 340 19.72 19.7 9.8 24 95%

0 0 700 12.6 12.6 7.5 24 99%

660 13 340 7.14 7.1 5.5 24 81%

262 42 340 86.7 86.7 18 6 83%

753 38 780 85.8 85.8 11.5 24 67%

844 12 560 11.76 11.8 5.5 24 91%

0 0 0.0 0 #DIV/0!

828 828 0 0.0 0 #DIV/0!

202 0 270 2.592 2.6 24 89%

252 0 120 1.26 1.3 24 94%

0 0 700 1.05 1.1 6 85%

251 16 2300 3.45 3.5 3 18 69%

0 560 1.4336 1.4 1 2 95%

265 0 760 1.9456 1.9 8 18 4 95%

0 230 1.955 2.0 11 85%

276 0 300 2.55 9.6 2 13 87%

561 2 240 3.24 3.2 24 88%

0 200 0.84 0.8 8 93%

160 -64 540 3.78 3.8 6 10 6 87%

0 0 0 0 0.0 0 #DIV/0!

275 0 430 2.924 218.0 24 73%

0 0 0 0 0.0 0 0 #DIV/0!

67 0 120 0.78 149.0 24 93%

0 0 0 0 0.0 0 #DIV/0!

lant


85/205

9042 1079 10280 268 639 87

4.3

1.05


86/205


87/205


Mold change & PDN startup in night shift

color line problem, uneven flow, weight varation.

M/c stopped

color change & tip cleaning

Mold change & Barrel cleaning and PDN startup

color change & PDN startup

Color change

Mold change & PDn startup

M/c stopped


M/c stopped

M/c stopped


88/205


89/205


Order

Quantity

(In pcs)

Total

Qty.

Produce

d pcs

Balance

d need

to

produce

d (pcs)

cycle

Time

(Sec)

weight

(Grams)

EBM-1 250ml Cobra Bottle Monolayer 200000 136280 63720 19 37

EBM-2 500ml Cobra Bottle 200000 131518 68482 21.5 58r oun o e w ec

ring 30000 6396 23604 30 100

EBM-3 50ml confidor super Bottle 45000 40000 5000 19 18

100ml Round White Bottle 35112 -35112 19 18

EBM-4 3 ltr Jery Can 2000 2040 -40 45 255

EBM-5 1 ltr Triangular Bottle 20000 18948 1052 36 100m quare o e w ew

Strip 13000 1560 11440 30 62

EBM-6 100ml Fame Bottle 260000 78758 181242 16 21

400ml Anupam bottle 60000 16300 43700 24 48


ASB-3

m rans reen o e

(Anuproduct) 20000 10200 9800 23.5 46.2

IM-1 RD 15 juniar Base 350000 192750 157250 21 9.6

IM-2 50mm Kr Logo white cap 25000 45000 -20000 26 10.5

50mm Kr Logo cap 25000 19000 6000 26 10.5

IM-3 10ml Camel Cap 300000 265000 35000 13 1.5

IM-4 22mm Fame cap 500000 220000 280000 20 2.56

IM-5 46mm Plain white cap 50000 62400 -12400 18 8.5

46mm plain green cap 10000 12600 -2600 18 8.5

IM-6 53mm Cobra Cap 1000000 94500 905500 29.5 13.5

53mm Cobra Cap 1000000 18900 981100 29.5 13.5

IM-7 30ml Raft Measuring cup 50000 50000 0 20 7

RD Jr Lid Mold 350000 5250 344750 20 6.6

IM-8 50mm BASf cap 25000 0 25000 24.8 12.5

Date: 6/8/2013


90/205

IM-9 38mm cobra cap 200000 198000 2000 28 6.8

IM-11

m corogon easur ng cup

TP violet 1000000 1000000 17.5 2

IM-12 50ml Plain Measuring cup 60000 175500 -115500 19.5 6.5

IM-12 53mm Anupam Cap 200000 200000 27.8 19

Wadding M/c-1 28mm Folicure cap

22mm Fame cap

Wadding M/c-2 50mm Rallis cap



50mm Plain white cap

50mm Blue cap

53mm cobra cap



10ml camel cap




46mm Plain Cap Green




50mm Blue Cap Assembly

Almix cap wadding

22mm Fame cap





91/205

HDPE B52A003 5000

Other

Items Qty

HDPE B56003

polybag

45*45 50

HDPE E5201S

shipper

555

MB WHITE 10055 50shipper465

orange 9.18E+08

shipper

590 360

pearl white t1

Shipper

510 200



HDPE 50ma180

20 x 500

shipper 1500

PP 3530 1250 10 x 1 ltr

RELPET 5841J 1100

465

shipper 3

ply

PP H110MA 500

shipper

600 x 430

ASPET 20C

40 x

250ml

PP srm100nc 475 20 x 500

green 13965

silver grey 88901

red 29020

golden t3

white 10055 25

pearl white 20051

crimson 13315

yellow 12184

c blue 80505

o blue 14275

pearl blue 133101

blue 4183916 13.7

yellow 1786

PA

Admer

red 6213

pearl blue 28760

p blue 41954034

yellow 12180


92/205

HDPE b5500

red 11155

orange 30444

green 15404


93/205

No. of


Actual

Production

in Pcs

Producti

on In

Kgs

Opening

RM

Balance

RM

issue

details Total

8 B52A003 Natural 36379 33600 1243 68 1200 1268

8 B52A003 Natural 17414 15600 905 0 0

8 B52A003 Natural 6720 6396 640 123 1450 1573

4 B52A003 white 18189 18000 324 0 0 0

4 B52A003 white 18189 17864 322 13 700 713

2 B52A003 white 1440 1248 318 42 300 342

4 B52A003 white 2400 2184 218 0 0 0

2 B52A003 pearl white 1920 1560 97 38 350 388

8 B52A003 Golden 3600 2464 52 0 0 0

8 B52A003 tsl yellow 19200 16300 782 12 1050 1062

14 B52A003 pearl white 0 0 0

6 ASPET blue 11030 10200 471 828 1100 1928

6 H110MA white 24686 24500 235.2 0 250 250

8 MI3530 white 5538 5000 52.5 0 0

8 MI3530 Blue 19938 19000 199.5 0 275 275

32 H110MA Black 212677 155000 232.5 16 225 241

32 H110MA golden 138240 130000 332.8 0 350 350

8 MI3530 white 24000 21000 178.5 0 0 0

8 MI3530 yellow 14400 12600 107.1 0 300 300

16 MI3530 c blue 17573 13500 182.3 0

16 MI3530 c blue 29288 18900 255.2 2 500 502

16 C blue 28800 25000 175.0 0 0

6 C blue 6480 5250 34.7 0 225 225

4 MI3530 yellow 0 0 0.0 0 0



94/205

32 MI3530 golden 98743 42000 285.6 0 300 300

32 C tp violet 0 0.0 0 0

8 C red 35446 33000 214.5 0 88.7 89

8 MI3530 yellow 0 0.0 0 0

green 5000

golden 32062

red 1000

white 7000

blue 18000

white 2000

blue 11050

white 1800

blue 46000

black 80000

L yellow 120000

Violet 48000

yellow

white 19600

green 12600

6000

8636

9000

14000

3500

792291 1075414 7857 1142 8664 9806

% of Wastage


95/205

Wad

Received


bayer logo 46.4

bayer logo 29.6

plain 19.8

camel 22.6

ep wad 22.6 220000

mayer

plain 46.4

dupont 19.2

wad 43.4 42600

DX excel 46.4

mayer

plain 34.5

board 46.4

dupont 19.2 110000

rallis 46.4

bayer logo 26.4


% of wastage which

can not used


96/205


97/205

closing

balance

Rejectio

n in pcs

Regrind

generate

d kg

Regrind

/

reproces

s used

Lumps

(Kg)

Plan

Hour

Mold

change

& Other

BD time Efficeancy

21 290 10.73 10.7 3.6 24 92%

0 100 5.8 5.8 4.6 13 90%

18 800 80 80.0 6 7 4 95%

0 400 7.2 7.2 24 99%

63 345 6.21 6.2 3.8 24 98%

14 160 40.8 40.8 10 9 87%

0 500 50 50.0 10 6 91%

57 200 12.4 12.4 6 8 10 81%

0 100 2.1 2.1 2.2 2 68%

220 400 19.2 19.2 6 16 6 85%

0 0.0 0 #DIV/0!

1454 190 8.778 8.8 3 12 12 92%

15 80 0.768 0.8 24 99%

130 1.365 1.4 5 90%

20 200 2.1 2.1 3.5 18 1 95%

8 760 1.14 1.1 24 73%

17 450 1.152 1.2 24 94%

200 1.7 1.7 15 88%

9 130 1.105 1.1 5 9 2 88%

200 2.7 2.7 9 77%

57 220 2.97 3.0 7.6 15 65%

0 120 0.84 0.8 10 87%

14 230 1.518 1.5 1 6 8 81%

0 0 0 0.0 0 #DIV/0!

t


98/205

14 670 4.556 4.6 24 43%

0 0 0.0 0 #DIV/0!

0 220 1.43 127.4 24 93%

0 0 0.0 0 #DIV/0!

2002 7095 267 393 72

4.3


99/205

0.92


100/205


101/205


Air Membrane change in Day shift BD- 1 Hrs.

Mold change & PDN started

comp e e o o oa e or c angeover c

stopped in Night shift

o c ange o or r a ecyc e ex ru er es

cleaning

mold change & PDN startup

Night shift Loader suction problem M/c stopped 1 hrs.

M/c stoppedo oa e s ar e a er comp e ng m c

stopped

Mold insert change & PDN startup


color change & PDN startup

Day shift Toshiba Eng is Working 2 hrs BD


2 cavity block

Mold change & PDn startup

M/c stopped


102/205

ay s u r ca on a ram pro em m c s oppe o p

cleaning

M/c stopped

M/c stopped


103/205


Order

Quantity

(In pcs)

Total Qty.

Produced

pcs

Balanced

need to

produced

(pcs)

EBM-1 250ml Cobra Bottle Monolayer 200000 141040 58960

250ML Cobra Coex Bottle Blue 81565171

(Himat Nagar) 25000 19320 5680

EBM-2 1 ltr Round Bottle with Neck ring 30000 28470 1530

EBM-3 50ml confidor super Bottle 45000 51000 -6000

100ml Round White Bottle 0 42504 -42504

100Ml confidor Super Bottle 40000 2400 37600

EBM-4 5 ltr BASF jery Can (BASF Panoli) 2500 1105 1395

EBM-5 500ml Square Bottle with View Strip 13000 8160 4840

EBM-6

Bottle, Logo,HDPE, 0,4L, y, IN (Anupam)

67638678 60000 42796 17204

IBM-1 10ml Fame Bottle 500000 37855 462145

ASB-3

500ml White PET Bottle (Modern

Insecticide) 10000 11520 -1520

IM-1 RD 15 juniar Base 350000 219000 131000

IM-2 50mm Kr Logo cap 50000 41000 9000

IM-3 10ml Camel Cap 300000 400000 -100000IM-4 22mm Fame cap 500000 370000 130000

IM-5 46mm Plain white cap 50000 100200 -50200

IM-6 53mm Cobra Cap 50000 36000 14000

35ml cobra Measuring cup 432000 10000 422000

IM-7 RD Jr Lid 350000 36750 313250

IM-8 20ml Rallis measuring cup 100000 42000 58000

IM-9 38mm cobra cap 200000 254000 -54000

IM-11 10ml corogon Measuring cup TP violet 1000000 1000000

IM-12 50ml Plain Measuring cup 60000 207000 -147000

IM-12 53mm Anupam Cap 200000 200000

Wadding M/c-1 22mm Fame cap

Wadding M/c-2 50mm Plain cap



Date: 7/8/2013


104/205

50mm Green Planet cap

50mm pursuite cap

53mm cobra cap



10ml camel cap







50mm Blue Cap AssemblyAlmix cap wadding

22mm Fame cap



HDPE B52A003 5000

HDPE B56003

HDPE E5201S 500

MB WHITE 10055 25

orange 9.18E+08

pearl white t1

MB TSL Yellow 9682 25

MB Blue 29443

HDPE 50ma180

PP 3530 1500

RELPET 5841J



105/205

PP H110MA 750

ASPET 20C

PP srm100nc 250

green 13965

silver grey 88901

red 29020

golden t3

white 10055 25

white t5 25

crimson 13315

yellow 12184

c blue 80505

o blue 14275

pearl blue 133101blue 4183916

yellow 1786

EVOH 100

Admer 75

red 6213

pearl blue 28760

p blue 41954034

yellow 12180

HDPE b5500

red 11155

orange 30444

green 15404


106/205

cycle

Time

(Sec)

weight

(Grams)

No. of


Actual

Production

in Pcs

Production

In Kgs

19 37 8 B52A003 Natural 6063 4760 176

24 37 8 B52A003 blue 21600 19320 715

30 100 8 B52A003 Natural 23040 22074 2207

22 18 4 B52A003 white 11782 11000 198

22 22 4 B52A003 white 7855 7392 163

22 23 4 B52A003 white 3927 2400 55

45 305 2 B52A003 white 1280 1105 337

24 64 2 B52A003 pearl white 7200 6600 422

24 48 8 B52A003 tsl yellow 28800 26496 1272

15 5.5 14 B52A003 golden 40320 37855 208

23.5 35.5 6 ASPET white 12868 11520 409

19.5 9.6 6 H110MA white 26585 26250 252.0

26 10.5 8 MI3530 Blue 26585 22000 231.0

13 1.5 32 H110MA Black 212677 135000 202.518 2.56 32 H110MA golden 153600 150000 384.0

18 8.5 8 MI3530 white 38400 37800 321.3

29.5 13.5 16 MI3530 white 21478 17100 230.9

20 4.5 32 C Trans 11520 10000 45.0

16 6.6 6 C blue 32400 31500 207.9

20 3.6 16 C Trans 46080 42000 151.2

28 6.8 32 MI3530 golden 98743 56000 380.8

17.5 2 32 C tp violet 0 0 0.0

19.5 6.5 8 C red 35446 31500 204.8

27.8 19 8 MI3530 yellow 0 0 0.0

golden 40000

white 1300

white

blue 25000

Daily Production Report


107/205

white 9500

yellow 1300

white

Golden 16000

black 55000

L yellow 142000

Violet 48000

yellow

white 42000

21000

2000

7000

10500

868248 1130272 8774

Other

Items Qty

a

Received

in Pcs size QTY issuedpolybag

45*45 50 bayer logo 46.4

shipper

555 bayer logo 29.6

shipper

465 plain 19.8

shipper

590 100 camel 22.6

Shipper

510 ep wad 22.6 110000

Ovensackmayerplain 46.4 66300

325 shiper dupont 19.2

20 x 500

shipper wad 43.4 42600

10 x 1 ltr DX excel 46.4

465

shipper 3

ply 150

mayer

plain 34.5


108/205

shipper

600 x 430 20 board 46.4

40 x

250ml dupont 19.2

20 x 500 rallis 46.4

bayer logo 26.4



109/205

Opening RM

Balance

RM

issue

details Total

closing

balance

Rejectio

n in pcs

Regrind

generate

d kg

Regrind

/

reproces

s used

Lumps

(Kg)

Plan

Hour

0 340 12.58 12.6 3 4

21 1000 1021 118 780 28.86 28.9 8.8 18

18 2200 2218 5 970 97 97.0 6 24

0 0 0 340 6.12 6.1 18

0 0 450 9.9 9.9 12

63 400 463 40 780 17.94 17.9 8 6

14 350 364 8 230 70.15 70.2 19 8

57 400 457 29 780 49.92 49.9 5.5 24

220 1125 1345 66 560 26.88 26.9 7 24

0 225 225 13 340 1.87 1.9 4 12

1454 0 1454 1042 560 19.88 19.9 3 14

15 250 265 13 80 0.768 0.8 24

20 225 245 14 230 2.415 2.4 24

8 100 108 0 240 0.36 95.0 2417 400 417 33 400 1.024 1.0 24

9 325 334 13 240 2.04 2.0 24

0 0 0 0 1200 16.2 16.2 11

57 275 332 52 650 2.925 2.9 5 2

14 200 214 6 240 1.584 1.6 24

0 175 175 22 340 1.224 1.2 2 16

14 375 389 9 670 4.556 4.6 24

0 0 0 0 0.0 0

0 225 225 20 450 2.925 2.9 24

0 0 0 0 0.0 0

bottling plant


110/205

2002 8250 10252 1501 10870 377 472 71

% of Wastage 5.1

% of wastage which can

not used 0.81


111/205


112/205

Mold

change

& Other

BD time Efficeancy Mold change/Break down

79%

2 89% COEX started + @ 6Am Hydraulic hose pipe burst

96%

93%

94%

6 61%

loaded

16 86%.

Day shift Recycle layer extruder open and clean the

92%

92%

94% mold change & PDN startup

10 90%Mold change & PDN startup, PDN completed M/c

stopped

99%

83%

63% Hot tip cleaning in day shift +100% Regrind usages98%

98%

80%

11 87%,

MCB change in Night Shift

97% Mold change & PDn startup

8 91% Mold loaded & PDN started

57%

tip cleaning

#DIV/0! M/c stopped

89%

#DIV/0! M/c stopped


113/205


114/205


Order

Quantity

(In pcs)

Total Qty.

Produced

pcs

Balanced

need to

produced

(pcs)

cycle

Time

(Sec)

EBM-1

250ML Cobra Coex Bottle

Blue 81565171 (Himat Nagar) 25000 25760 -760 24

1 ltr Round Bottle White @ 95

gram 30000 6240 23760 28

EBM-2

r oun o e w ec

ring 30000 30654 -654 30

1 ltr round Bottle with Neck

ring white 10000 11622 -1622 29

1 ltr cobra Bottle Mono 95

Gram 58470 2800 55670 29

EBM-3 50ml confidor super Bottle 45000 66000 -21000 22

100Ml confidor Super Bottle 40000 17400 22600 22

EBM-4

5 ltr BASF jery Can (BASF

Panoli) 2500 3944 -1444 48

EBM-5

m quare o e w

View Strip 13000 14520 -1520 24

EBM-6

Bottle, Logo,HDPE, 0,4L, y, IN

(Anupam) 67638678 60000 62641 -2641 24

IBM-1 10ml Fame Bottle 500000 117055 382945 15

ASB-3

m e o e

(Modern Insecticide) 10000 10000 23.5

IM-1 RD 15 juniar Base 350000 238250 111750 19.5IM-2 50mm Kr Logo cap 50000 65000 -15000 26

IM-3 10ml Camel Cap 300000 430000 -130000 13

80ml cobra measuring cup 35000 -35000 18

IM-4 22mm Fame cap 500000 500000 0 18

IM-5 46mm Plain white cap 50000 142200 -92200 16.4

IM-6 35ml cobra Measuring cup 432000 127500 304500 20

IM-7 RD Jr Lid 350000 66750 283250 16

IM-8 20ml Rallis measuring cup 100000 108500 -8500 20

IM-9 38mm cobra cap 200000 318000 -118000 28

IM-11

10ml corogon Measuring cup

TP violet 1000000 1000000 17.5

IM-12 50ml Plain Measuring cup 60000 214500 -154500 19

50ml Rallis Measuring cup 200000 25500 174500 19

IM-12 53mm Anupam Cap 200000 200000 27.8

Wadding M/c-1 22mm Fame cap

Date: 8/8/2013


115/205

Wadding M/c-2 50mm Plain cap



50mm Green Planet cap

50mm pursuite cap

53mm cobra cap

Wadding M/c-3 53mm Anupam Cap


10ml camel cap

10ml camel cap

10ml camel cap

10ml camel cap

10ml camel cap

10ml camel capWadding m/c-5 10ml corogon cap


no.7 46mm plain cap

assembly threded plug




HDPE B52A003 5000

Other

Items

HDPE B56003

polybag

45*45

HDPE E5201S 500

shipper

555

MB WHITE 10055 75

shipper

465

orange 9.18E+08

shipper

590

pearl white t1

Shipper

510



HDPE 50ma180

20 x 500

shipper



116/205

PP 3530 1000 10 x 1 ltr

RELPET 5841J

465

shipper 3

ply

PP H110MA 75

shipper

600 x 430

ASPET 20C

40 x

250mlPP srm100nc 1500 20 x 500

green 13965

silver grey 88901

red 29020

golden t3

white 10055

white t5

crimson 13315

yellow 12184

c blue 80505

o blue 14275

pearl blue 133101

blue 4183916

yellow 1786

PA 50

Admer 25

red 6213

pearl blue 28760

p blue 41954034yellow 12180

HDPE b5500

red 11155

orange 30444

green 15404


117/205

weight

(Grams)

No. of


Actual

Production

in Pcs

Producti

on In

Kgs

Opening

RM

Balance

RM

issue

details

37 8 B52A003 blue 7200 6440 238

96 8 B52A003 white 8229 6240 599 118 750

100 8 B52A003 Natural 2880 2184 218

96 8 B52A003 white 12910 11622 1116

96 8 B52A003 Natural 2979 2800 269 5 1650

18 4 B52A003 white 15709 15000 270 0

23 4 B52A003 white 15709 15000 345 40 600

305 2 B52A003 white 3600 2839 866 8 875

64 2 B52A003 pearl white 7200 6360 407 29 400

48 8 B52A003 tsl yellow 28800 19845 953 66 925

5.5 14 B52A003 golden 80640 79200 436 13 500

35.5 6 ASPET white 0 0 1042 0

9.6 6 H110MA white 21046 19250 184.8 13 17510.5 8 MI3530 Blue 26585 24000 252.0 14 250

1.5 32 H110MA Black 35446 30000 45.0 0

7.5 16 SRM100NC Trans 38400 35000 262.5 0 325

2.56 32 H110MA golden 153600 130000 332.8 33 300

8.5 8 MI3530 white 42146 42000 357.0 13 350

4.5 32 SRM100NC Trans 138240 117500 528.8 52 500

6.6 6 SRM100NC blue 32400 30000 198.0 6 200

3.6 16 SRM100NC Trans 69120 66500 239.4 22 225

6.8 32 MI3530 golden 98743 64000 435.2 9 250

2 32 SRM100NC tp violet 0 0.0 0 0

6.5 8 SRM100NC Trans 7579 7500 48.8

6.5 8 SRM100NC Trans 25768 25500 165.8 20 0

19 8 MI3530 yellow 0 0 0.0 0 0

golden 40000

Daily Production Report bottling


118/205

white

white

blue 20000

white

yellow 7150

white

yellow 28200

black 55000

white 10000

po green 10000

l green 10000

po red 15000

co blue 15000

brown 20000Violet 6000

yellow

white 29800

36000

9826

7000

874930 1077756 8766 1501 8275

Qty

a

Received


bayer logo 46.4

bayer logo 29.6

300 plain 19.8

130 camel 22.6

200 ep wad 22.6 110000

mayer

plain 46.4 22100

dupont 19.2

wad 43.4 42600

% of Wastage

% of wastage which

can not used


119/205

DX excel 46.4

mayer

plain 34.5

board 46.4

dupont 19.2rallis 46.4

bayer logo 26.4

bayer logo 19.8


120/205

Total

closing

balance

Rejectio

n in pcs

Regrind

generate

d kg

Regrind

/

reproces

s used

Lumps

(Kg)

Plan

Hour

Mold

change

& Other

BD time

Efficean

cy

0 0 300 11.1 11.1 6.8 6 89%

868 19 360 34.56 34.6 4.9 8 10 76%

0 50 5 5.0 3 76%

0 150 14.4 14.4 10 13 90%

1655 36 180 17.28 17.3 6 3 5 94%

0 0 200 3.6 3.6 7.8 24 95%

640 17 170 3.91 3.9 24 95%

883 0 290 88.45 88.5 17.2 24 79%

429 16 271 17.344 17.3 5.9 24 88%

991 24 600 28.8 28.8 14.2 24 69%

513 75 1000 5.5 5.5 2 24 98%

1042 1042 0 0.0 0 #DIV/0!

188 3 340 3.264 3.3 19 5 91%264 12 200 2.1 2.1 24 90%

0 760 1.14 1.1 4 85%

325 10 900 6.75 6.8 8 12 8 91%

333 1 210 0.5376 0.5 24 85%

363 6 80 0.68 0.7 24 100%

552 23 120 0.54 0.5 24 85%

206 8 95 0.627 0.6 24 93%

247 5 120 0.432 0.4 2 24 96%

259 0 340 2.312 180.0 24 65%

0 0 0 0.0 0 #DIV/0!

0 200 1.3 1.3 5 99%

20 0 230 1.495 195.5 17 2 99%

0 0 0 0 0.0 0 #DIV/0!

plant


121/205

9776 1296 7166 251 623 85

3.8

0.97


122/205


123/205


@ 6Am Hydraulic hose pipe burst

startup+ 4 hrs Mold change delay due to no place to keep

finished goods.

color changeover


Frequent stopage of M/c due to melt pressre high problem

Day shift Mold cooling problem till 3Pm & Night shift 4 nos. die

pin removed & changes due to leakage of material

M/c stopped

loaded & started

mold change & startup

Fermomatic Eng working on machine

M/c stopped

Insert change & PDN started

M/c stopped


124/205


125/205


Order

Quantity

(In pcs)

Total

Qty.

Produce

d pcs

Balance

d need

to

produce

d (pcs)

cycle

Time

(Sec)

weight

(Grams)

EBM-1

1 ltr Round Bottle (Krishi

Rasayan) 30000 22776 7224 29 96

EBM-2

r co ra o e ono

Layer 58470 26310 32160 27 96

EBM-3 50ml confidor super Bottle 45000 82000 -37000 21 18

100Ml confidor Super Bottle 40000 33000 7000 21 23

EBM-4

5 ltr BASF jery Can (BASF

Panoli) 2500 4454 -1954 48 305

5 ltr BASF Can COEX PAStromp 900 901 -1 48 305

EBM-5

500ml Square Bottle with

View Strip 13000 15600 -2600 24 64

100ml Square Bottle With

View Strip 35000 2880 32120 24 25

EBM-6

Bottle, Logo,HDPE, 0,4L, y,

IN (Anupam) 67638678 60000 87283 -27283 24 48

IBM-1 10ml Fame Bottle 500000 196255 303745 15 5.5

ASB-3

500ml White PET Bottle

(Modern Insecticide) 10000 0 10000 23.5 35.5

IM-1 RD 15 juniar Base 350000 245250 104750 19.5 9.6

50mm Green Planet cap 50000 9000 41000 28 10.5

IM-2 50mm Kr Logo cap 50000 66200 -16200 26 10.5

10ml camel cap black 200000 85000 115000 14 1.5

IM-3 80ml cobra measuring cup 300000 95000 205000 20 7.5

IM-4 22mm Fame cap 500000 640000 -140000 18 2.56

IM-5 46mm Plain white cap 50000 177200 -127200 17 8.5

IM-6 35ml cobra Measuring cup 432000 252500 179500 17 4.5

IM-7 RD Jr Lid 350000 78750 271250 14

saraswati plasto dpr august

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