SUMMER INTERSHIP PROJECT

- July 2010

INDEX

Page No.

Chapter 1 Introduction 04

Industry Profile 08

Chapter 2 Organization Structure 11

Chapter 3 Departments 13

1. Tool Department 132. Vendor Department 183. Assembly Department 224. Components manufacturing Department 265. Information Support Group Department 306. Purchase Department 327. Sheet Metal Department 358. Central Stores 39

Chapter 4 Vision / Mission 47

9. Vision Mission statement 48

Chapter 1

INTRODUCTION

ACE DESIGNERS LIMITED PROFILE

The beginning:

M/s Ace Designers ltd was set up in the year 1979 as a machine tool designing Service Company. The company began its foray into manufacturing of machine tools in 1982 when it was commissioned to make a range of special purpose import substitution machine tools.

The Promoters:

Three engineers Mr.A.V.Sathe, Mr.Shrinivas G.Shirgurkar and Mr.B.Machado promoted the company as a partnership. Together, they pooled into their new venture a total of 35 years of machine tool experience, all of it accumulated at the Central Manufacturing Technology Institute, India’s premier center for manufacturing technology and machine tool design. The trio began the venture armed with only their experience, design boards and a few thousands rupees in a garage.

The Journey:

The first product developed by M/s Ace Designers ltd was the Auto Lathe – a multi slide automatic production turning machine, built on the modular concept around the “component to be machined” and supplied as a complete machining solution with the auto components and the two-wheeler industry and the industry leader in its class. Ace started manufacture of CNC Machines in 1986 and their first CNC Chucker LC-16 was adjudged the best-designed machine at the IMTEX 86. “Today Ace Designers are the largest manufacturer of CNC lathes in India with a market share of 50%.

CERTIFICATIONS:

ISO 9001 and 14001 certified company

INFRASTRUCTURE:

1. Innovation Center2. Design

Dedicated home grown R & D team, headed by founder No outside collaborations for talent or technology Strategic strength, driving quick customer response Use of sophisticated design

3. Flow line Assembly Assemble high volume standard machines on conveyor line Extensive standardization Focused Assembly group

4. Spindle room Spindle assembly Spindle testing

KEY COMPONENT MANUFACTURING

1. Mazak five face machining center2. Mazak machining center with palette pool3. Kellenberger spindle grinding4. Favretto bed grinding5. Sheet metal shop

Amada laser cutting machine Robotic welding Amada sheet metal bending machine

6. Automated paint shop Pre-treatment plant Powder coating unit

QUALITY AND TESTING:

1. Assembly practices constantly refined2. Extensive check lists that ensure complete testing of the machines on the

test floor.

HIGH PRODUCTIVITY CMD:

1. Use of TPM-Trak on all machines to automatically measure, track and remediate shop productivity and OEE.

2. Integration of TPM –trak shop floor data to SAP for “shop floor to top floor” visibility (in process).

QUALITY POLICY

It is to continuously aiming at satisfying the customer’s quality expectations. The objective is to provide the customers with a reliable product a cost effective solution to their needs, and to deliver it to the customers on time with the added assurance of prompt services.

Company Wide Initiatives

1. Awards and AccoladesIM TMA – SIEMENS Productivity Summit Award – 1st prize Best Supplier Award – Honda motor cycles secured one of the best company in following 5-s practices.

2. ISO 9001 – Quality management system3. ISO 14001 – Environmental management system4. Business Excellence5. OHSAS18001- occupational Health and safety assessment series.6. 5s – Japanese model for higher productivity and elimination of wastes.

PRODUCT PROFILE:

1. Jobber Series Jobber XL Jobber Jr Super Jobber

2. Premium Series μ Turn LT -2 Xl

3. Chucker Series Vertical Turret Series VTL – 30 VTL – 40

4. Large Series LT – 30 LT – 25

5. Flexible, Premium and High-Tech (vantage series) Machines with y axis and sub spindle

6. Cost Effective Flat Bed Chukers7. Turn Mill Series

8. Sub Spindle Machines9. Automation Machines10. Machining Centers11. Cylindrical Grinding12. Turrets, ATC’s and Tooling Productivity Measurement TPM-Trak

OEE and Machine Monitoring Services13. Complete Turning Solutions

CUSTOMERS1. ASEA BROWN BOVERI2. BAJAJ AUTO3. CROMPTON GREAVES4. ENGINE VALVES5. INA BEARINGS – GERMANY ,USA & UK6. KAR MOBILES7. KIRLOSKAR OIL ENGINES 8. GABRIEL INDIA9. GL REXROTH10. GODREJ GE11. HERO HONDA 12. HONDA MOTOR CYCLE & SCOOTERS(I)13. HINDUSTHAN MOTORS14. KENNAMETAL WIDIA15. MICO16. MUNJAL SHOWA17. TVS MOTORCYCLES18. SANDVIK ASIA 19. SUPER AUTO FORGE 20. SRIRAM GROUP21. NRB BEARINGS22. LUCAS TVS

INDUSTRY PROFILE

INDIAN MACHINE TOOLS INDUSTRY

BACKGROUND AND HISTORICAL TRENDS:

The Machine Tools industry in India dates back to the second world. Due to non availability of imported machine tools, a few British owned general engineering firms took up their manufacture in India. This was followed by the start of Industrialization in a series of five year plans. The process of planning in the Economy resulted in a second phase of machine tools manufacturing with public sector invest in machine tools (HMT LTD 1953). These two initial phases of development of the Indian machines tools industry saw the production of general purpose machine tools most of which were produced under technical assistance from foreign collaborators .

The 1960’s marked the third phase of the machine tools industry. During this phase, the range of products witnessed rapid growth and various types of machine tools including SPM’s were manufactured.

The fourth phase began in the mid 1980’s, which saw the entry of Japanese machine tools makers in the Indian market through licensing arrangements

The fifth and current phase began in the early 1990’s after the liberalization of the Indian economy .with the expanding market share of the bigger companies and the public sector giants shrinking ,the smaller companies were rising .In- house designing capability, entrepreneurial spirit ,greater technology friendliness ,operational flexibility and lean management ,combined to give a greater competitive edge to the smaller companies set up by technocrats , resulting in a significant shift in machine tools production to these medium sized companies . However, these companies produced sophisticated machines and machines of higher capacity either singly, or in small number.

Machine tools are Heavy, power driven machinery and equipment that perform specific actions on materials like metal and plastic. The most common jobs these machines are used for include material removal ( turning , milling , drilling , grinding , laser cutting ) ;material forming ( bending , joining ) ; and “work loading” (chucks , fixtures , clamps ) . The majority of this equipment is technical in nature, with computer numerical control (CNC) or programmable logic control (PLC) built in.

The tooling and machining industry is critical to our country’s economic health as it makes possible the existence of virtually every other manufacturing industry. Tooling is the means of Production. “ Special “ tooling , such as dies and moulds, is custom designed and made to manufacture specific

products , generally in quantity , and to desired levels of uniformity , accuracy , interchange ability , and quality. Machining involves the use of a wide variety of machine tools to cut or form material, usually metal, to precise shapes and dimensions.

The machine tool industry initially was not self sufficient. The policy regime compelled broad range import substitution regardless of its high costs. Soon the firms were in a hurry to replace imported machine tools and imported technology regardless of market size .The smaller domestic firms copied the technology of simpler machine. As a result, the industry produced a broad range of machine tools on a small scale. A small number of bigger firms imported technology employed for design and production; excessive in-house production, poor subcontracting, poor domestic transfer of technology as there was limited use of engineers and engineering technique ,Indian engineers were acknowledged for their talent , but were mostly used for import substitution and product development ,not to build overall competitiveness .poor domestic technology development and transfer meant good machines built at a high cost and poor quality machines , built at a low cost. Neither was exportable to the discerning, competitive markets of the west.

Being an integral sector, growth of the machine tool industry has an immense bearing on the entire economy especially India’s manufacturing industry. It is even more crucial for the development of the country’s strategic segments such as defense, railways, space and atomic energy.

Chapter 2

A. Organization Structure:

Chapter 3

DEPARTMENTS

TOOL DEPARTMENT

OBJECTIVE:To lay down the procedure to be followed in tool room to ensure that the items manufactured conforms to the specified quality requirements as per drawing.

SCOPE: Work holding fixtures Tool holding fixtures & tool holders Prototype & R&D activities ( not for auditing)

RESPONSIBILITY: Chief of tool room shall be responsible for the operation of the system. The tool room executive shall be responsible for day to day activities.

CHIEF OF TECHNOLOGY GROUP

CHIEF OF TOOL ROOM

EXECUTIVE PLANNING (p) EXECUTIVE MANUFACTURING (M)

OPERATIVE = 20

Job Description of Chief of Tool room: Plan & ensure trained man power & machines available for production. Plan resources for long-term & short term. Ensure department is running smoothly. Plan & ensure component are produced with reference to IDS / changed

priorities. Ensure procedures, systems are being followed effectively. Implementation and sustenance of ISO 9001:2008 quality assurance system. Implementation and sustenance of ISO14001:2004 EMS system. Implementation and sustenance of SAP systems. Encourage subordinates for suggestions, etc. Any other activities

JOB DESCRIPTION OF EXECUTIVE PLANNING (P): Receive new drawings/ planned order in SAP as input to the department. Write routing, purchase in for records for outside operations, material BOM in

SAP. Create manual production order for new drawing & convert planned order to

production order. Prepare operation monitoring chart. Plan, procure raw material through vendor department. Plan & execute external activities like material testing etc. Check the department capacity in coordination with executive manufacturing &

plan for outsourcing of operations as & when required. Implementation and sustenance of ISO 9001:2008 quality assurance system. Implementation and sustenance of ISO14001:2004 EMS system. Implementation and sustenance of SAP systems. Any other activity

JOB DESCRIPTION OF MANUFACTURING EXECUTIVE: Receive drawings from executive (p) & raw material from vendor department. Plan & procure any tools, jigs, fixtures, etc whenever necessary. Refer IDS, MOM & oral instruction from department head; load the job to the

machine. Change the priorities as and when required. Check physically capacity f the department, off load few/components/operations

whenever department is over loaded & components are urgently required.

Co-ordinates with other related functions D&D, Purchase, Vendor, Assembly& Tooling& Trials etc for day to day activities.

Organise components for outside operations like heat treatment, blackening, plating, etc.

Raise NCR internal/ external for any deviations in the materials/ components. Implementation and sustenance of ISO 9001:2008 quality assurance system. Implementation and sustenance of ISO14001:2004 EMS system. Implementation and sustenance of SAP systems.

JOB DESCRIPTION OF OPERATIVES: In charge of the specified machine for operation, routine maintenance and up

keeping. Manufacturing of tool room items as per requirements. Taking procession of the required manufacturing documents viz., up to date

drawings for all items. Use necessary jigs & fixtures. Use calibrated gauges & instruments. Self inspection & recording in inspection sheets for critical items & operators. Implementation and sustenance of ISO 9001:2008 quality assurance system. Implementation and sustenance of ISO14001:2004 EMS system. Implementation and sustenance of SAP systems. Involving improvements in process methods through suggestion schemes. Any other activities

JOB DESCRIPTION OF OPERATIVE ASSEMBLY: Collect /move finished components assembly to assembly table. Clean, retag the components. Check/ inspect all operations completed if not raise internal NCR’s. Procure screws / any bought out items from stores. Do assembly of components. Make document for the finished components either in assembly or in individual

condition. Supply finished components to stores with documents in preserved conduction. Ensure these components are received & receipt has been made in SAP. Implementation and sustenance of ISO 9001:2008 quality assurance system. Implementation and sustenance of ISO14001:2004 EMS system. Implementation and sustenance of SAP systems.

TOOL ROOM FUNCTION:

PROCESS INPUT PROCESS OUTPUTMRN Finished work holding componentStandards Updated stockDrawingsBOMQuality Work InstructionApproved Vendor ListProduction order NCR’s if any

RESOURCES REQUIREDERP software packageTrained manpowerOffice equipment & stationaryTools & fixtures MachineryInstruments & gauges VendorStorage facilityOther infrastructural facilityRaw materials

PROCESS OF TOOL DEPARTMENT:1. Planning2. Process Planning3. Material Planning4. Tool Planning5. Scheduling of job6. Finish operations7. Check the component8. If not accepted raise NCR9. Receive NCR if any from T&T10. Check if NCR is valid, if not inform the person raised NCR11. Check if rework is possible, if not reject & inform the user12. If possible raise rework order & go to step313. Else reject the item.

CUSTOMER SERVICE GROUP

OBJECTIVE:The objective of this department is to aim at “PROMT SERVICE” to the customer to their machine problems, supplied by M/S Ace Designers.

SCOPE: Servicing of field complaints. Spares support / selling. Training of customers & MMT engineers

CHIEF OF CUSTOMER SERVICE GROUP

EXECUTIVE - 6 COMMISSIONING ASSISTANT - 2

VENDOR DEPARTMENT

OBJECTIVE

To plan and procure various items required for the activities of the organization with correct specifications and quality at the right time.

To satisfy both external and internal customers by procuring quality and reliable products from approved suppliers and vendors.

To continuously upgrade the quality of inputs by keeping in-view the changing environment and technological advancements.

SCOPE

It includes all purchased items (both inland and imported), vendor processed items andInternally manufactured components and consumables which become a part of the product and critical services.

RESPONSIBILITY

Chief of supply chain shall be primarily responsible for operation of the system. Vendor executive and staff shall be responsible for day activities.

DEPARTMENTAL CHART

CHIEF OF SUPPLY CHAIN

TECHNICAL ASSISTANT VENDOR DEVELOP MECHANICAL

EXECUTIVE VENDOR DEVELOPMENT MEHANICAL (6)

COMMERCIAL EXECUTIVE

JOB DESCRIPTION OF EXECUTIVE

1. Procurement of vendor designated items as per planned order and or purchase requisitions.

2. Development of existing vendors/developing vendors for machining, mechanical sub-assembly etc as per requirements.

3. Collection of vendor data form for registration and approval of vendor.

4. Finalization of quotations, with approval by chief of supply chain.5. Maintenance of valid documents/drawing at vendor end.6. Effect process and cost improvement.7. Office maintenance and documentation.8. Effective implementation and sustenance of ISO 9001: 2008 QA

system and ensure sustenance of SAP system related function.9. Implementation and sustenance of ISO 14001: 2004 EMS

standards in vendor function.10. Any other activity required from time to time.

JOB DESCRIPTION OF COMMERCIAL ASSISTANT:

1. Preparation of stock transfer purchase order / service entry sheet and preparation of records for statutory requirements.

2. To carry out all documentation activities relating to ISO 9001:2008 and ensure sustenance of SAP system in related function.

3. Coordinating with other personnel of the materials function for day to day operation activities.

4. Logistics control.

PROCESS MODULE FOR OUT SOURCING ITEMS

VENDOR FUNCTION

PROCESS INPUTS PROCESS OUTPUTSPurchase Requisitions Outsourced manufactured accepted

componentsDrawings P.O / Trials order P.RBOM Inspection reportsApproved vendor list RFQ’SPlanned orders component listQuality planNCR for assemblyQuotation

PROCESS OF VENDOR DEPARTMENT

1. Receive PR’s, planned order, drawings /BOM.2. Check if the requirement is for new component.3. For repeated components allocate the vendor and raise PO execute the order.4. For new items send RFQ’s and get quotations.5. Enter and compare quotations.6. Finalize the quotation.

RESOURCES REQUIREDERP software package

Trained manpower /HR

Raw materials / items to be outsourced

Office equipment and stationary

Approved vendors / suppliers

Support from relevant functions like ERP, QA ,user functions

PROCESS FOR VENDOR RATING

1. Do vendor monitoring only for an approved vendor.2. Check if the vendor is an active vendor.3. Conduct vendor rating based on ERP data like P.O details like delivery, quality

ordered and quality supplied, quality accepted etc.4. Make grouping /grades of their ratings.5. Compute vendor ratings through ERP.6. Compare their ratings with their earlier 6 months rating and make a report and

inform them.7. Check the rating of the vendor. If it is less than 50% for any vendor, reject the

vendor and delete the vendor from approved vendor list.

Vendor rating mainly based on: Delivery Quality Price Service

ASSEMBLY DEPARTMENT

OBJECTIVE

To carry out Assembly, Inspection and testing of mechanical sub assemblies and final products to meet the specified requirements.

SCOPE It is applicable to:

1. CNC Machines 2. SPM’s3. Auto lathes

RESPONSIBILTY

Respective chief of machine Assembly divisions shall be primarily responsible for mechanical assembly function with the assistance of other executives and operations.

DEPARTMENTAL CHART

SENIOR EXECUTIVE

CHIEF OF ASSEMBLY (CNC & SPM)

CHIEF OF ASSEMBLY (XL / FLOW CHART)

TRAINEE ENGINEER-1EXECUTIVE-6 EXECUTIVE - 8 TRAINEE ENGINEER- 1

OPERATIVES-24OPERATIVE-25

APPRENTICE-4 APPRENTICE-7

JOB DESCRIPTION OF SENIOR EXECUTIVE

1. Responsible for managing CNC/SPM team2. Monitor status sheets of sub –assemblies of machines 3. Ensure planned output of CNC, SPM machines4. Ensure supply of components on time as per master plan5. Development, preparation and updating of check sheets, process

sheets and assembly procedure sheets6. Responsible for machine assembly and standard trials7. Assisting in-coming inspection, acceptance and maintain their status8. Improve the quality of the product9. Facilitate ISO 9001:2008 implement and sustenance10. Facilitate ISO 14001:2004 implement and sustenance11. Manpower planning for assembly activities 12. Effective implementation of SAP system in related function13. 5-s implementation for good housekeeping.14. To perform any other activity as delegated by chief of assembly.

JOB DESCRIPTION OF EXECUTIVE

1. Responsible for complete assembly and testing of machines assigned.2. Preparation of process sheets and checks sheets where ever

necessary and conduct stage inspection.3. Supply of qualified items for assembly.4. Monitoring /maintaining of assembly schedule chart.5. Raising NCR’s and their reviews.6. Training of the sub-ordinate staffs in assembly and testing activity and

appraisal of sub-ordinate staff.7. Initiate and follow through quality improvement process8. Coordinating with electrical function.9. Coordinating for production of subassemblies.10. Shop data maintenance.11. Involve in quality improvement process.

JOB DESCRIPTION OF TRAINEE ENGINEERS

1. To assist executives in day to day functions of assembly activities.2. Assembly and testing of machines in the absence of executives.3. To familiarize with process module of assembly function.4. Five years implementation for good housekeeping.

JOB DESCRIPTION OF OPERATIVES

1. Responsible for complete assembly viz, Axes assembly / sheet metal guarding assembly as per work assigned by respective executive.

2. Assisting assembly executives in machines inspection and testing.3. Assisting in inspection of items /recording or noticing of NC during the

process of assembly.

JOB DESCRIPTION OF APPRENTICE

1. To assist operatives in day to day activities2. Any other activity assigned from time to time.

PROCESS OF ASSEMBLY DEPARTMENT

1. Planning.2. Check type of assembly to be made and act accordingly.3. Arrange for the materials.4. Start assembly: update status monitoring chart.5. Sub assembly planning.6. Making sub assembly.7. Assemble as per routing sequence.8. Carry out mechanical checks.9. Enter machines history records for a standard machine. 10. If it is a tooled up machine handover to tooling and trials function.11. If it is a standard machine demonstrate to the customer (if required).12. Take required CAPA.13. Handover the machine for packing.14. Handover the relevant documents to ERP/CSG.

COMPONENTS MANUFACTURING DEPARTMENT

It is a manufacturing unit, which manufactures components as per design. Its end users are assembly people. It manufactures components both for CNC Machines as well as for SPM’s.

DEPARTMENT CHART

Chief of CMD

Manager CMD

Executive CMD QA-3 Executive CMD (1) Supporting Activity

Executive shift-in-charges-2

Executive Methods Engineering

Executive CNC operations-6

Operatives-18 Store staff-1

Inspectors - 1

CMD, SDM Controller-1

FUNCTIONS:

1. Evaluation / creation and maintenance of the routing sequences and estimating setup/ machining time for the components manufactured in CMD in SAP system.

2. Coordinate with CMD planner in reviewing of planned orders.3. Review of production order status along with shift in charges4. Establishing the various components of CMD in Kellenberger CNC

Grinding machine and is responsible for its utilization, and OEE.5. Implementation and sustenance of ISO 9001: 2008 QA system in

component manufacturing division and related documentation.6. Implementation and sustenance of ISO 14001 activity in CMD.7. Take care of HR and T related activities of CMD and to aim at

improving efficiency/motivational levels of the employees of CMD.8. Ensuring the delivery compliance of components with the help of shift

in charges.

JOB DESCRIPTION OF EXECUTIVE CMD – QA

1. Inspection of all vendors supplied components, movements of accepted components to next process, certifying acceptance and report it to the SAP system.

2. Inspection of Raw material forgings and castings as per quality plan.3. Audit inspection of in house manufactured component and recording

the results in SAP.

JOB DESCRIPTION OF SUPPORTING ACTIVITY

1. Responsible for data maintenance and analysis through TPM-Trak.2. Ensuring the maintenance and traceability of components in storage

location.3. Ensure the delivery of items from CMD to Central Stores.4. Manual Technical completion of production orders in case of any

rejections.

JOB DESCRIPTION OF EXECUTIVE SHIFT IN CHARGES

1. Planning of components manufacturing activities as per schedule. Scheduling, loading of machines and material movement as per routing sequence.

2. Coordinating with concerned Vendor Executive for Vendor activities from CMD.

3. Coordinating with concerned executives, operatives and stores personnel of CMD day to day activities.

4. Coordinating with related functions viz, Design and Development, Assembly, Tool Room, Plant Engineering and stores of day to day activities.

5. Identification and traceability of WIP components wrt production order and coordinate with MRP controller for any deviations.

6. Overview Routine maintenance and up keep of plant machines and equipments.

7. Continuous improvement in process, component quality, new tooling methods and effective utilization of productive machines.

JOB DESCRIPTION OF EXECUTIVE METHOD ENGINEERING

1. Preparation of process sheet and process drawing for critical components and maintain necessary documentation.

2. Study the existing process and improve.3. Design, manufacture and prove new fixtures for operations on CNC

and Conventional Machines.4. Preparation of process costing for the components manufactured in

CMD.

PROCESS MODULE FOR COMPONENT MANUFACTURING DIVISION

PROCESS INPUTS PROCESS OUTPUTSBOM Drawings Finished componentsERP Data Check sheets / inspection

sheetsQWI’s Dispatch list Production order Rejection analysisNCR’s from user function CAPA

RESOURCES REQUIREDERP Software PackageSkilled Manpower MachineryRaw MaterialsCalibrated Instruments and Guages Office and Stationery MaterialsGeneral Infra Structural Facilities

OBJECTIVE:

To plan, manufacture and supply components as per specified quality requirements by making use of appropriate resources.

SCOPE:Components of Standard CNC Machines. Components of Special Purposed Machines (SPM’s). Any other special requirements decided from time to time.

LEAN MANUFACTURING: Following are the areas in which Lean Concepts are implemented:

1. High volume machine components are processed in batches of 15 days requirements.

2. Delivery effectiveness is being monitored using MIN safety levels of inventory.

3. New facilities are added keeping in mind lean concepts MAZAK with multi Pallet system Single piece flow Zero set up time Unmanned operation

4. JIT concept is being implemented in procurement of standard components processed in group is like AUTO CNC & AMASL.

INFORMATION SUPPORT GROUP

DEPARTMENTAL CHART:

Functions of ISG:

1. Taking note of current requirement.2. Securing data.3. Analysis of new trends.4. Backup of data5. CRM, ERP.6. Software update, installation of patches.7. Maintenance of servers.

EXECUTIVE-2 EXECUTIVE-3EXECUTIVE-1 EXECUTIVE-4

CHIEF OF ISG

JOB DESCRIPTION OF EXECUTIVE -1:

1. Ensure functioning of LAN hardware.2. Ensure that downtime of any computer is kept minimum.3. Audit backup log to ensure that all essential data is backed up

regularly.4. Maintain already created software program.5. Implementation and sustenance of ISO 9000 and 14000 activities.6. Implementation of SAP system.

JOB DESCRIPTION OF EXECUTIVE -2

1. Fresh user to new CRM users.2. Reports related to CRM user login to CRM software.3. Web designing and creating new users, and fixing security levels.4. Sales and support processes decided by CRM.5. Providing help to CRM user related to usage of software.

JOB DESCRIPTION OF EXECUTIVE -3

1. Incorporate new IT technologies.2. Train users as per desired objectives.3. Develop add-on modules to SAP as per requirement.

JOB DESCRIPTION OF EXECUTIVE -4

1. Ensure functioning of LAN.2. Any other responsibility assigned by the superior from time to time.

OBJECTIVES:

The objective of this department is to streamline the functioning of computer activity related to information systems. This shall serve as reference to all personnel of ISG and connected personnel /group.

SCOPE:

The procedure is applicable to the following activities of ISG:

1. Breakdown maintenance2. Commissioning of new IT resources.3. Support and services by ISG.4. Disaster recovery and backup.

PROCESS MODULE FOR BREAKDOWN AND MAINTENANCE

Process inputs

Process output

Breakdown call from user Fully validated information system

Trouble shooting checklists Service reports

Approved vendor lists Training document

Manual for hardware and resources

RESOURCES REQUIREDERP software package

Trained manpowerOffice equipment

Supplier product catalogueInfrastructure like IT spaces

Storage racks and facilityIT equipment to be repaired

PURCHASE DEPARTMENT

JOB DESCRIPTION OF EXECUTIVE

1. Preparation of annual requirement in consultation with Chief of materials for long lead & other bought out materials.

2. Negotiation with supplier, Releasing of Purchase order.3. Analysing the quotation & finalization of purchase order in

consultation with higher authorities in case of annual requirement and new items, new supplier.

4. Maintaining the relevant documents of transaction relating to procurements.

5. Following up with supplier for timely delivery & with accounts for payment wherever necessary.

6. Cost control on procurement, identifying the new supplier & alternative manufacturers.

7. Collection of items whenever necessary.8. Arranging to return the rejected items and informing the accounts for

raising the debit notes.9. Effective participating in inventory control management activities.10. 5’S activities.11. Effective implementation & sustenance of ISO 9001:2008 QA system

standards.

CHIEF OF SUPPLY CHAIN

CHIEF OF PURCHASE

EXECUTIVE (2)

12. Effective implementation & sustenance of ISO 14001:2004 EMS system standards.

13. Effective implementation & sustenance of SAP system.

PURCHASE FUNCTION

PROCESS INPUT PROCESS OUTPUTIDS, Information sheet EnquiriesPurchase requisition (PR) from user functions

PO’s

Approved Supplier ListSupplier dataQuotation from supplier

RESOURCES REQUIREDERP software package

Trained manpower resourceSupplier and product catalogues

Necessary IT resources for ERP like PC, printers,etc.

PROCESS OF PURCHASING

1. Receiving drawings, BOM from design department.2. Check if it is a new component.3. If possible to accommodate with present supplier then proceed as per

defined process.4. If not then send RFQ to supplier and get quotes scrutinized negotiate

and finalise after comparing quotes.5. Enter into record and receive purchase requisition.6. Convert PR’s to PO.7. Release PO8. Check if material is to be imported 9. If yes, then follow and get LC details & inform supplier.10. Get delivery details from supplier and inform finance and excise.11. If not imported get material & make goods receipt.12. Check if inspection is required, if so organise through QA, if material is

accepted take into stores stock.13. If not QA to raise NCR on purchase.14. Receive NCR & send items to supplier for rework or replacement.

SHEET METAL DEPARTMENT

DEPARTMENTAL CHART:

EXECUTVE IV SHIFT PROD

EXECUTIVE V SHIFT PROD EXECUTEIVE III

PLANNING

CHIEF OF SUPPLY CHAIN

CHIEF OF SMD

Executive Production - 1

EXECUTIVE II ENGG & PROCESS

CAPACITY PLANNER

QUALITY INSPECTION

PROCESS DEVELOPMENT

FITTERS -11

WELDERS-22

APPRENTICE -2/ HELPERS-2

JOB DESCRIPTION OF CHIEF OF SMD:

1. Plan and ensure manpower, machineries and infrastructure with reference to IDS and planning.

2. Plan and ensure sheet metal components as per IDS and planning.3. Plan and implementation of improvement activities and company initiatives in

the department.4. Implementation and sustenance of ISO 9001: 2008 QA system and its

improvement.5. Implementation and sustenance of ISO 14001:2004 EMS system.6. Implementation and sustenance of SAP system7. Plan for human resources and training related activities in the department.8. Measurement and score card analysis.

JOB DESCRIPTION OF EXECUTIVE-1. Ensure that all sheet metal components are produced in shop as per plan and

quality norms.2. Plan for preventive maintenance and trouble shooting of SMD machines.3. Plan for the required tooling, accessories, jigs and fixtures. 4. Scheduling of work center as per planning.5. BOM and routing updating in SAP.6. Plan for improvement activities.7. Any other job assigned within the function from time to time like development

of drawings, designs or fixtures etc.

JOB DESCRIPTION OF EXECUTIVE II1. Design of jigs and fixtures.2. Preparation of process drawings and quality work instructions.3. Programming of CNC machines like Laser, Bending and ROBO welding.4. Trails and prove of components in ROBO welding.

JOB DESCRIPTION OF EXECUTIVE III

1. Preparation of production order with reference to planned order.2. Correction of production orders.3. Updating the capacity chart of planning.4. Plan for dispatch report.5. Plan and feedback to schedule for shortage items.6. SDM entry for welding activity.7. Prepare planning of sheet metal component as per SAP.8. Ensure that all sheet metal components are produced in shop as per plan and

quality norms.

JOB DESCRIPTION OF EXECUTIVE IV

1. Ensure all machines are working with reference to tooling, fixtures and regular maintenance activities.

2. Programming for Laser cutting, Bending and ROBO welding machines for sheet metal components.

3. On time movement of items as per scheduling.4. Creation of NCR for in-house rejection and drawing mistakes.5. Plan for preventive maintenance of machines.6. Plan for rework of items.7. Inspection of raw materials and ensure the weight as per SAP.8. Plan for movement of items for inspection and painting.

JOB DESCRIPTION OF CAPACITY PLANNER

1. Schedule the machines as per production order.2. Plan and ensure dispatch of sheet metal components to store.3. SDM for Laser and Bending operations.4. Maintaining records and documents.

JOB DESCRIPTION OF QUALITY PLANNER

1. Inspection of finished components for any operations.2. Inspection of vendor components.

JOB DESCRIPTION OF PROCESS DEVELOPER

1. Manufacture of JIGS and FIXTURES for all operations (if necessary).2. Trails of components in Welding and ROBO Welding.

JOB DESCRIPTION OF FITTERS

1. Check for correctness of all components and see that it conforms to the drawing, if not inform the executive.

2. Execute production activities like cutting, drilling, marking, tapping and bending.3. Follow up for the supply of semi finished items for further operation.4. Maintain necessary records like inspection report for critical components.

JOB DESCRIPTION OF WELDERS

1. Check for dimensions and angles of the semi finished component WRT to drawings.

2. Executive production activities like welding etc and updates in SAP operation confirmation.

3. Ensure for squareness and dimensions within tolerance given in drawing before welding operation.

4. Ensure that components after welding are sent to finishing operations.

CENTRAL STORES

Central stores or storage is the function of receiving, storing and issuing materials. It includes Bought out items, In-house manufacturing items and also swapped items return from assembly department.

OBJECTIVES:

To ensure that the materials at incoming stores are handled, stored and preserved, and made available in time properly to avoid damage and deterioration.

SCOPE:

This shall cover bought-out items, vendor and internally manufactured items required for assembly of products.

RESPONSIBILITY:

Chief of operations shall be primarily responsible for the operations of the stores. Stores executive and staff will be responsible for any day to day activities.JOB DESCRIPTION OF EXECUTIVE STORES:

1. Co-ordination with related functions i.e., purchase, vendor, TSG, tooling and trials, assembly division, A & packing for day to day functions.

2. Receipt storage and Issue control:

Bought-outs, vendor and internally manufactured items required for the assembly.

Acknowledge customer supplied items and pass on information to TSG/CSG.

3. Keeping items ready for dispatch as per packing list.4. Maintenance of location plan.5. Implementation and sustenance of 9001 and 14001 systems.6. Implementation of SAP system.7. Clearance of items as per quality plans.

JOB DESCRIPTION OF STAFF-1 (RECIEPTS)

1. Receiving material as per purchase order.2. Check the materials as per purchase order.3. Report to the system regarding receipts.4. Sending/offering materials for inspection as per quality plan.5. Moving accepted material to designated location.

6. Acknowledgement of customer supplied items and report to TSG/CSG.

STAFF 2, 3 & 4: (ISSUES)

1. Issue of materials as per pick list of SAP/MRN/Packing list/ship list.2. Update records in electronic media.3. Acceptance of the returned items as per stores return note.4. Maintenance of records.

HELPERS:

1. Material movement and storage within stores.2. Material movement from stores to assembly.3. Loading and unloading of materials.4. Use of cranes, trolleys.5. Maintenance, cleaning of storage space.

INVENTORY CONTROL TECHIQUES

1. Always Better Control (ABC) Analysis2. Fast moving, Slow moving and Non moving (FSN)3. Max-minimum system4. Economic Order Quantity (EOQ)5. FIFO method

FUNCTIONS OF STORES DEPARTMENT1. Receipts:

In-house manufacturing components – CMD/SMD Bought out items.

Raw materials Finished items

Excess /swapped items return from assembly Tooling and trails –customer items

2. Storage (items moved to location)

Taking receipt report every 1 hr. once –customized report. Move the items to the respective locations. While keeping items in location if any discrepancy (wrong

items) found informed to receipt entry person for reverse the receipt and send back to the respective department.

If new items received keep in an identified place and inform to supervisors for allocating location.

Identify the items Location with item ID on yellow sticker. Update the location in SAP. AM-Block R-Rack L-Level

3. Issues

Pick list issues General/consumable item issues Shortage item issues NCR items replacement

SHELF LIFE ITEMS:

1. Put tag mentioning date of receipt during receipt.2. Move the items to the respective location 3. Issue first cum first basis(FIFO method)4. During issue if shelf life items found receipt date beyond 3 year inform to

supervisor for scrap the item Ex: all petroleum products, belts, rubbers etc

APPLICATION OF 5’S – 3 BIN SYSTEM1. Red color : Hazardous waste like oil soaked cotton waste, chemical/paint waste

oil soaked polythene covers2. Blue color: Recycle items like paper, wood

3. Green color: Eco friendly waste like food waste

TECHNICAL SUPPORT GROUP

DEPARTMENTAL CHART

JOB DESCRIPTION

SENIOR EXECUTIVE:

1. Releasing indicative delivery schedule.2. Releasing quotation and releasing pricing3. Conducting monthly meeting and weekly production meeting4. Submission of MIS report5. Preparation and submission of proposal6. Submit order acceptance7. Implementation and sustenance of ISO 9001, 14001 and SAP activities.

Managing Director

Sr.Executive TSG

Jr.Executive-2 Executive-4 Commercial asst-2

Office Executive

EXECUTIVE/Jr. EXECUTIVE/TRAINEE EXECUTIVE – TECH SERVICES1. Initiate contract review meeting-pre & post order2. Communicate and interface with all the functions of the company3. Initiate in preparation , issue and maintenance of information sheet4. Issue of check lists5. Handling changes in contract

OFFICE EXECUTIVE AND COMMERCIAL ASST

1. Preparation of proposals2. Maintenance of sales order in SAP3. Distribution of incoming mail to the concerned official4. Maintenance of customer supplied items5. Dispatch and maintenance of check lists.

FLOW CHART OF ACTIVITIES IN TSG

MMT CUSTOMER

ENQUIRY

PROPOSAL

NEGOTITIATION

PURCHASE ORDER

ORDER ACCEPTANCE

CUSTOMER INSPECTION

DISPATCH

OBJECTIVE:

To define and describe the procedures followed by the Technical Services function to ensure that the services offered within the function helps to manufacture a quality product and conforms to the specified requirements of the customer.

SCOPE

Applicable to pre-order and post-order activities for the entire product range including contract reviews and order acceptance.

PROCESS MODULE FOR PRE SALES ACTIVITY

PROCESS INPUTS PROCESS OUTPUTSCustomer enquiry by phone/fax/mail/letter Proposal/Quotation/Offer for a machine to

customer /MMTEnquiry from MMTPrevious order/supply detailsCatalogues of different models Order won /lost statementFeatures & specifications of different modelsPrice list of different models & related items

RESOURCES REQUIREDCRM software package

Trained manpowerOffice equipment and stationery

ERP software packageCAD software package

Vision/Mission

Ace Designers Ltd

Vision Mission statement

Our Vision

Large scale producer of world class machine tools

Our Mission We will recognize our responsibilities as corporate citizens to fosterProgress, to promote general welfare of the societyWe will provide an environment to our staff to grow and advance toProsperity and thus promote a sense of belongingWe will exceed customer expectations through reliable product, on time delivery, cost effective solution with an added assurance of prompt service Our Values • Customer delight • Cost effective working • Passionately ensuring quality • Empowering people • Business ethics & transparency