In Plant Supply Chain Management
In Plant Supply Chain Management2014
PROJECT REPORTONSIX WEEK INDUSTRIAL TRAININGAT
(June,12 to July,30) SUBMITED IN PARTIAL FULFILLMENT OF THE
REQUIREMNET FORMBA (Specialization Operations )AtLPU Phagwara
PunjabSUBMITTED BYName: Rahul SinghReg no. 11004563 DEPARTMENT OF
MANAGEMENT LOVELY PROFESSIONAL UNIVERSITY PHAGWARA PUNJAB,
INDIA
ACKNOWLEDGEMENT
The authors are highly grateful to Mr. AMITESH KAPOOR, training
mentor department of business Lovely professional university,
Phagwara, Punjab for providing this opportunity to carry out the
six Week industrial training at SONALIKA INTERNATIONAL TRACTORS
LTD. The authors would like to express a deep sense of gratitude
and thanks profusely to Mr. Ajay Rawat without the wise Counsel and
able guidance, it would have been impossible to complete the report
in this manner. The help Rendered by himself for experimentation is
greatly acknowledged .The express gratitude to other faculty
Members of School Of Business Department, of lovely professional
university, Phagwara, Punjab Their intellectual Support throughout
the course of this work.
Name of Student & Signature
CONTENTS :
INTRODUCTION :Sonalika International was incorporated in 1969
with an aim to serve the Indian farmer community with its quality
products. Since then, keeping itself abreast with time and market
needs, Sonalika has been producing modern tractors as per farmers
requirements. The company is one of the top three market leaders in
Indian tractor industry, as per market share (volumes). In 1995 the
company decided to broaden its horizons and enter the global
markets. Today it is present in about 72 countries (Companys
product exported to Algeria, Angola, Armenia, Australia,
Bangladesh, Cameroon, Ethiopia, Ghana, Ivory Coast, Malawi,
Malaysia, Mauritius, Mozambique, Nepal, Oman, Republic of Benin,
Senegal, South Africa, Srilanka, Sudan, Canada, Zambia, Syria,
Togo, Tunisia, Ukraine, Zimbabwe. etc). With a wide dealer network
of 1100 dealers worldwide and 0.5 million tractors sold till date.
Besides tractors, the company is also producing farm machinery
attachments, multi-utility vehicles, engines, diesel gensets, auto
components, as well as pick and carry cranes. Translating farmers
interest into superior product features through its world class
manufacturing facility, the company manages two popular brands
Sonalika and Solis, in 20HP to 90HP segment. Presently the company
operates from India, with manufacturing unit in Hoshiarpur (Punjab)
and corporate office in New Delhi,also has footprints in Europe,
Africa and Asia. The manufacturing unit in Hoshiarpur has different
cells for various stages of tractor manufacturing. The first phase
being, raw material procurement, that is done by our efficient
quality control team. The procurement is done exclusively from our
certified vendors worldwide. The company follows stringent quality
check norms as set by global pioneers in order to ensure a world
class facility and safety. The company produces worlds finest
engines and tractor transmission system in-house. Leak tests at sub
assembly stage and as fully assembled engine is conducted to ensure
a 100% leak proof engine.The 300 odd components in the transmission
system are manufactured to precise tolerance for efficient
transmission of power. Sonalika has its own high precision CNC
(Computer Numeric Control)machines that ensure high quality of
components manufactured and CMM machines to check adherence to
quality standards. The movement of tractor parts is carried out
through an overhead conveyor to ensure streamlined operations. Each
station is ergonomically designed with built-in features to ensure
adherence to quality standards. The plant has its own testing area
where pre-operation and post-operation quality checks are carried
out to ensure quality. Each unit of tractor that is produced goes
through a series of quality checks at different stages, at our ARAI
certified engine testing centres. The company also has a training
centre where it conducts dealer training programs at various time
intervals. To ensure customer friendliness, the company has its own
customer service centre which takes regular feedback from farmers,
and tries to sort out their product related issues.Our Mission: One
goal- Maximizing productivity of farmlands across the globe. One
team- People working together as a lean global automotive
enterprise as measured by customer, employee, dealer, supplier,
partner and community satisfaction. One plan- Accelerate
development of new products our customers want and value. An
exciting viable brand delivering profitable growth for
all.OurVision:To become the first choice of farming community
across the world.
CoreValues:Optimized use of resources to create a product that
can serve world farming community in the best possible way. We aim
to provide quality and value for money to the customers investing
in our products. We start from ourselves, by creating a healthy
working environment for our employees, providing them with all
possible resources and support that helps them in developing a
world class product and services. We believe a healthy positive
self can create a healthy world around us. By growing and
improvising ourselves every day we wish to create a world class
product that serves our global customers the best possible way.
COMPANY TOP MANAGEMENT :
Mr. L.D. Mittal Chairman
Mr. L.D. Mittal is the Chairman of The Sonalika Group Companies.
He is a thorough professional with an illustrious experience of
more than 40 years in a Public Sector Enterprise of repute in
India. Apart from this, he is the Chairman / Director of twenty two
other companies in India.
He has been the Chairman of Tractor Manufacturer's Association
of India. Hehas been awarded many accolades including Pride of the
Nation award,Udhyaog Ratna award, Ernst & Young Entrepreneur of
the Year award etc. He has been a member of National Council of
Confederation of Indian Industry.He was appointed as the Honorary
Consul General of Republic of Macedonia in India as well.
Mr. A.S. Mittal Vice Chairman
Mr. A.S. Mittal is the Vice Chairman of The Sonalika Group
Companies. He is a self made industrialist with a proven record of
extra-ordinary innovation and business acumen. Apart from this, he
is Vice Chairman / Managing Director & Director of twenty two
companies in India.
Mr. Deepak MittalManagingDirector
Mr. Deepak Mittal is the Managing Director of International
tractors Ltd. He is an ardent economist and is known for a strong
customer orientation in all businesses. He is MD of more than 20
Companies. Mr. Mittal is active in various CSR activities including
a project on environment protection etc.
SONALIKA GROUP MILESTONE : 2010
Sonalika Tractors are now EURO III A Norms Compliant Started
Export of Tractors to Argentina & Serbia Executed the export
order to Cameroon worth 40 Million US$.
2009
Grand Launch of technical advanced worldtrac series of tractors.
The series comprises of tractors with advanced features. Developed
in-house unique DIESEL SAVER UNIT FOR SONALIKA Tractors. Became
only Company in India To Produce 90 Hp Tractors.
2008
Launch of RX Series of Tractors. Aesthetically appealing designs
and shape accepted across the world. Export of Tractors Started to
USA.
2007
Joint Venture between International Tractors Ltd. and Magma
Shrachi Finance.
2006
Successfully Developed Four Wheel Drive front axles and
Transmission of tractor for Yanmar.
2005
Achieved turnover of USD 235 Million. Joint venture with Yanmar
of Japan for manufacturing of Tractors in India.
2001
Started in house manufacturing of engine for tractor
application
2000
Entered into Joint venture with Renault-France and
Class-Germany. Which helped the group to upgrade its technology and
systems. 1996 Roll out of first tractor from ITL. 1965
Diversification into manufacture of tractor over whelming response
from the market. 1969 Modest beginning into farm equipment and
machine manufacture and earning name and fame over all these
year.
GROUP COMPANIES :
Incorporated in 1969 to accomplish newer heights of success,
Sonalika Group has come a long way. Over the years, it has
diversified into many new businesses in order to meet the better
needs of the market and customers. Today the group is among the top
three tractor manufacturers of India and provides a complete
product line including tractors, multi-utility vehicles, engines,
farm machinery attachments, diesel gensets, auto components and
pick & carry cranes.
International Tractors Limited :
Incorporated in 1995, International Tractors Limited has become
a renowned name in the tractor manufacturing industry. It is one of
the top three tractor companies in India in terms of volumes and
leader in tractor production from a single manufacturing unit. With
a domestic market share of more than 11% (at present), it has a
brand to reckon in India. Till date the company has its presence in
more than 75 countries all over the world with a wide network of
1800 satisfied distributors and dealers worldwide. The company
manufactures a wide range of tractors and farm equipment from 20 HP
to 120 HP, under two different brands named Sonalika and Solis. The
company provides complete agricultural solutions to the farming
community across the globe.
International Cars & Motors Limited :
International Cars & Motors Limited (ICML) is known for
manufacturing multi-utility vehicles (MUV) well suited to meet the
needs of Indian as well as global customers. Established in the
year 2004, the company is one of the leading producers of MUV in
India. Producer of MUV under the brand name Rhino, the company has
the capacity to manufacture 2000 vehicles in a month. It has a
tie-up with MG Rover (UK) for technical details of vehicle
engines.Recognized by Government of India, the R&D center is
equipped with advanced design and testing facility spread over 2000
sq. meters a
Sonalika Agro Industries Corporation :
Established in the year 1969, the company is the maiden venture
of the group and one of the foremost farm & equipment
manufacturing companies in India. The group serves to support the
Indian farmers with mechanization technology to facilitate
persistence of green revolution. Close relationship to Indian
agricultural development has given the company extensive expertise
in designing and manufacturing farm equipment in response to local
conditions.Sonalika Agro is a pioneer in manufacturing advanced
agricultural implements suiting the needs of global farmers. The
farm equipment and services provide a comprehensive support system
to help farmers prosper.
CSR :
Over the decades of success, growth and expansion that we have
seen, there is one important aspect of our business that we began
to consciously think about how we can reshape ourselves as
responsible corporate citizens of this changing world and the
answer is Corporate Social Responsibility. As a socially
responsible citizen, the group has contributed not only to the
economic wellbeing of the communities it interacts with, but has
also enhanced their social wellbeing and development.
Aanand Ashram :
Sonalika understands its social responsibilities very well and
is indeed committed towards the upliftment of needy children.
'Sonalika Charitable Trust' the social wing of the group has taken
up a unique initiative Aanand Ashram. The initiative focuses
intensely on a strategy known as LIFE (Living in Family
Environment) to provide permanent residential care to orphaned and
abandoned children. LIFE emphasizes mainly on promotion of family
bonding amongst deprived children, their mental and physical health
and enhancing social integration to enable them experience 'Joy of
Living'. Sonalika puts in its best efforts to provide affectionate
family atmosphere, make these children live happily and become a
part of the society. We also welcome the volunteers who understand
their social responsibilities and can make a significant difference
to the lives of these children.
Project Clean & Green :
Sonalika Group not only produces world class tractors and farm
equipment, it is also committed to promote best environment
protection practices as part of its Corporate Social Responsibility
(CSR) activity. In 2004, the Group took lead in inviting leading
industrialists of Hoshiarpur and formed the Clean & Green
Association (CGA). Throughout the year, CGA organizes cleanliness
and plantation drives in different parts of Hoshiarpur city. The
main purpose of organizing these drives is to create awareness
among residents about the benefits of a clean and green
environment. says Mr. A.S. Mittal, Vice Chairman, Sonalika
Group.
Employee Welfare:
Employee welfare is essential for the growth and prosperity of
business. Our people are our assets and play a crucial role in the
success of the organization. For overall involvement, motivation
and recreation of employees we have opened Sonalika Officers Club,
a private club providing top class fitness, sports combined with
unrevealed service and efficiency. It was established in 2007 with
an initiative of the Management of our company to promote fitness,
relax and enjoyment after the hectic working schedule of the
employees. Workstation is also considered as a second dwelling for
our employees; hence we also celebrate various religious and
national festivals with our employees and their families every
year.TRENDS IN SONALIKA TRACTORS :
SWOT ANALYSIS OF ITL :
STRENGTH :- Human Resource. Research & Development. Physical
Resources:- SAP,its own IT dept. Availability of Finance. Good
Investors Relationship.
WEAKNESS :- Import of tractors Implements. Unsuccessful Rhino
Car. Lack of Advertisement Regarding their product.
OPPORTUNITIES:- Unexplored Market for Export.
THREATS:- Competitors:- Mahindra & Mahindra. John Deere. New
Holland. Sawarj
ORGANIZATION STRUCTURE FOLLOWED BY ITL : Chairman
Vice - Chairman
Managing Director
Chief Operating Officer
Joint Chief Operating Officer
HOD of Every Dept
Managerial Staff Executives
Support Staff
Workers
PRODUCTS OF ITL :Sonalika Internationals Tractors produces
products both at international level as well as domestic level.
INTERNATIONAL MODELS :- DI SeriesRX SeriesSolis EECSeriesSOLIS
SeriesWORLDTRACSeries
DI-60DI-60RXSOLIS -20SOLIS-35RXWORLDTRAC75RX 4X4
DI-75DI-75RXSOLIS -50SOLIS-45RXWORLDTRAC75RX 4X4
DI-730IIDI-45RXSOLIS -70SOLIS-50RX
DI-745IIIDI-50RXSOLIS -75SOLIS-70RX
DI-750IIDI-60RXturboSOLIS-90SOLIS-90RX
Gardentrac DI-60SOLIS -60RXturbo
DOMESTIC MODELS :- DI SERIESWORLDTRAC SERIESRX SERIES
DI-730IIWORLDTRAC 75RX 2W/4WDI-45RX
DI-734S1WORLDTRAC 90RX 2W/4WDI-47RX
DI-734S3DI-35RX
DI-735S3DI-60RX MM
DI-740IIIS3DI-750IIRX
DI-45IIIGardentrac DI-20
DI-750IIIDI-745IIIRX PP
SLIENT FEATURES OF DIFFERENT MODELS :
SUPPLY CHAIN MANAGEMENT(SCM) :
Supply chain management is the management of the flow of goods.
It includes the movement and storage ofraw materials,
work-in-process inventory, and finished goods from point of origin
to point of consumption. Interconnected or interlinked networks,
channels and nodebusinessesare involved in the provision
ofproductsandservicesrequired by end customers in asupply
chain.Supply chain management has been defined as the "design,
planning, execution, control, and monitoring of supply chain
activities with the objective of creating net value, building a
competitive infrastructure, leveraging worldwide logistics,
synchronizing supply with demand and measuring performance
globally.SCM draws heavily from the areas ofoperations
management,logistics,procurement, andinformation technology, and
strives for an integrated approach.Supply chain management is a
cross-functional approach that includes managing the movement of
raw materials into an organization, certain aspects of the internal
processing of materials into finished goods, and the movement of
finished goods out of the organization and toward the end consumer.
As organizations strive to focus on core competencies and becoming
more flexible, they reduce their ownership of raw materials sources
and distribution channels. These functions are increasingly being
outsourced to other firms that can perform the activities better or
more cost effectively. The effect is to increase the number of
organizations involved in satisfying customer demand, while
reducing managerial control of daily logistics operations. Less
control and more supply chain partners led to the creation of the
concept of supply chain management. The purpose of supply chain
management is to improve trust and collaboration among supply chain
partners, thus improving inventory visibility and the velocity of
inventory movement.Main function of supply chain management are as
follows: 1) Inventory management. 2) Distribution management .3)
Channel management. 4) Payment management .5) Financial management.
6) Supplier management .7) Transportation management .8) Customer
service management.Now every company have their own supply chain
management and there is no hard and fast standard to follow a
particular supply chain management. Every company follow its own
supply chain depending to their convience , cost , time , manpower,
global presence, investors relationships, suppliers relationships
etc.But in Sonalika tractors, I got a store and production planning
and control (ppc) departments where I have to work for 6 weeks
first in main store and then in ppc department. In store department
they provide me a task to physical observe all the materials
present in the store whether the material is at right place or not
and how to improve the efficiency of the store i.e in a limited
space how we can adjust more material and what kind of automation
we used for loading and unloading the material. Now how the inplant
supply chain of main store department works in the Sonalika
tractors are shown by flow chart in the next page. In this flow
chart I tried to shown the whole process , how the material comes
and how it goes to different stages.There are fourteen stages must
be fulfilled while converting the raw material into finished
product. In the first stage there is a purchase order checking
(p.o) of all the logistics vehicles before enter into the gate. In
this purchase executives of the logistics check the vehicles
whether they carry the right material or not which they ordered to
their respective vendor. If the material is not ok then it will
reject at that time only and raw material went back to the
respective vendor. The 2nd stage is the gate entry of those
logistics vehicles which is accepted by the purchase executives.
The 3rd stage is the vehicles reporting receipt . In this the
driver of the vehicles reporting the reception counter and giving
report of vehicles i.e., which type of material they carry
And then receptionist calling to the store department and asks
the store manager vehicle no. carrying a particular component, is
it unloading right now or u need some time. The 4th stage is the
document verification by the store executives, whether they have
full document of material which they have right now or not
,documents like vat bill, etc. If there is missing of any document
then vehicles should not be unloaded and ask the driver of the
vehicles go and get the affidavits of missing document. The 5th
stage is the inward register entry of the raw material which is
accepted by the store executives. The 6th stage is the tag making.
In that store manger give orders to the store executives to made a
tag for the particular component i.e they a serial number which is
act as code to a particular components. The 7th stage is the
unloading of vehicles . Vehicles should be unloaded manually or by
using overhead cranes depending upon the type of material. The 8th
stage is the physical verification of the unloaded material by
quality executives. They audit the material by taking samples or by
inspection of all the component depending upon the type of
components and the tolerance limit of the company is only 1%. The
9th stage is the tagging of all the components that is unloaded.
The 10th stage is the movement of the material to different areas
of the stores .The material should move to the different part of
the stores by using trolleys, overhead cranes or labour. The 11th
stage is the making of material receipt inspection report by using
a special software called ( SAP) .It is a companys own software all
the work with in the company should be done by only the use of this
software. In this stage the rejected material goes to the rejection
store and then to the vendor and ok material goes to the operating
store from where the BOM i.e bill of material generated. The 12th
stage is BOM run. In this stage BOM should be generated for the
production line i.e all the components required for the
manufacturing should be placed at right position on the line from
the operating store. The 13th stage is a production against BOM. In
the 14th stage there is a movement of finished goods to the
dispatch department.OBEJECTIVE OF THE PROJECT:Sonalika
international tractors ltd has its own H.R, QUALITY CONTROL, PPC,
R&D, STORE, DISPATCH, PURCHASE AND LOGISTICS departments. The
H.R department gives me chance to handle the store department. It
is one of the main department of the Sonalika tractors and the
whole production of tractors depends upon that only. If it works
well, this definitely increases the production of the whole
plant.The main purpose of my project is to increase the efficiency
of the store i.e How we store more and more material in a limited
space. What kind of automation required in the store to reduce the
time and labour cost. What kind of machines we used for loading and
unloading of material. How we easily access the material for BOM
generation. The current problem in the main store is space. They
have limited space to store the material, due this logistics
vehicles should stand outside the company two days sometimes more
than two days. It also increases the cost to the company. So, when
I visit to the store and I got a training mentor MR.AJAY RAWAT the
deputy manager of the store, I asked him I am a trainees in your
company and they shifted me to your department. He told me ok and
gave me task to see first how the process in the store is going on,
how the material is loading and unloading and how we store more and
more material in that limited space. He told me you have to find
solutions against that problem. This is the main aim of my
project.
FINDINGS / OBSERVATIONS :The following points which I observe
during my project are as under : The parts or components like
tyres, fender , bonut assembly, etc. should not be placed according
to the category bais i.e there is no categorical representation of
the material. If the material is put in a category bais then it is
difficult to access the parts from a particular place .This can be
prove by the given below figure of the store.
There is no specific identification number on the racks. The
spare parts are placed randomly into the racks. Due to this the
person who is particular known to that place only he can access the
parts from the racks. If he is absent or currently not present to
their position. Then it is very much difficult for the unknown
person to access the material from the racks. Due to this the lead
time for BOM generation increases and this will directly effects
the production. The space in the store is not fully utilized i.e
the parts in the store is put only at the ground level. There is as
such no arrangement in the store to placed parts upto the roof
level. If they doing so they can store more material in a limited
space. The given below figure gives the prove of that statement.
There is a need of automatic leakage testing machine for testing
fuel tank. In the store there is a one separate room which is
specially meant for testing the tank and 5 to 6 person are assigned
for that individual work only. This manually testing of fuel tanks
takes time and include labour cost and takes more space that is the
main issue. Instead of manually testing they can install one
automatic machine in the store that will definitely reduces labour
cost, time and space that is the major issue. There is manual
loading of some parts which takes more time for unloading of parts.
The parts which are manually unloaded can be unloaded by using
material handling equipment. There is one part of tractors i.e
bonut assembly which is manufactured in the sheet metal shop of the
company store itself and packed it into the pallets and then
loading it and transport to the kala amb plant for paint only and
then it again goes back to the company The whole process takes a
lot of time, wastage of money and including transportation cost.
Why should company cannot install a small machine of paint for that
small parts in the sheet metal shop. The one thing I observe which
is not related to my department i.e store but it is very much
important for the industry to take care of that. The issue is
related to the safety of the workers. Even a single worker in the
assembly line cannot wear a safety helmet and gloves. This matter
is very serious to the company but the company take it lightly. The
workers in the assembly line is not the company permanent
employees. They did not get any kind of facilities given by company
like incentives, bonus etc. so salary is the main motivational
factor for the employees for giving their best. The workers in the
company are contractual based. And the contractors simply told them
u have to do this work only and give them a training of just two or
three days. Due this the quality production is decline. Out of 230
tractors that manufactured in a day 50 tractors should be reopen
again.RECOMMENDATIONS / SUGGESTIONS :The following are the
suggestions against the current problems which I gave to the store
manager are as under: They can apply KAIZEN PROCESS PROJECT. what
is kaizen and what are the benefits of kaizen and which tractors
industry apply kaizen project I will explain it as under:MEANING OF
KAIZEN :
Kaizenmeans "improvement" or "self-changing for the best of
all", refers to philosophy or practices that focus upon continuous
improvementof processes in manufacturing, engineering, business
management or any other . When used in the business sense and
applied to the workplace, kaizen refers to activities that
continually improve all functions, and involves all employees from
theCEOto theassembly lineworkers. It also applies to processes,
such as purchasing andlogistics, that cross organizational
boundaries into thesupply chain.By improving standardized
activities and processes, kaizen aims to eliminate waste . Kaizen
was first implemented in severalJapanese businesses.
BENEFITS OF KAIZEN PROCESS :The following are the benefits of
kaizen project in assembly line and store department of the
manufacturing industries. All-round waste reduction is the basic
principle of the Kaizen process, "waste" meaning everything that is
unable to create added value, i.e. space that it not used in the
best possible way, waiting times, unnecessary movement of materials
and processes. The system is directed towards a continuous flow of
the industrial process through optimized handling of components and
tools. Materials are collected and brought to the assembly lines
based on a system used by the supermarkets that puts the right
components for each unit being assembled. This technique simplifies
the tasks of the assembly line workers and gives them time to
correctly fit each piece during the assembly process which
ultimately results in a quality process. It also makes for a
cleaner, safer working environment as well as improving the overall
appearance of the shop floor.
TRACTORS INDUSTRY THAT APPLY KAIZEN PROJECT :
Argo Tractors has introduced the Kaizen project. A business
management and manufacturing system already throughly tried and
tested by many others. One that focuses on continuous improvement
of industrial processes, quality, lead time reduction, reducing
waste and the ensuing manufacturing costs.All-round waste reduction
is the basic principle of the Kaizen process, "waste" meaning
everything that is unable to create added value, i.e. space that it
not used in the best possible way, waiting times, unnecessary
movement of materials and processes. The system is directed towards
a continuous flow of the industrial process through optimized
handling of components and tools. Materials are collected and
brought to the assembly lines based on a system used by the
supermarkets that puts the right components for each unit being
assembled.
This technique simplifies the tasks of the assembly line workers
and gives them time to correctly fit each piece during the assembly
process which ultimately results in a quality process. It also
makes for a cleaner, safer working environment as well as improving
the overall appearance of the shop floor.These changes in our
manufacturing process achieved with the Kaizen project have
cascaded throughout all the Argo Tractor factories, from Fabbrico
to San Martino in Rio and Luzzara. Thanks to the project, our
assembly lines are constantly upgraded with the introduction of new
technologies, robotic systems and automatic equipment allowing us
to work with the level of accuracy, reliability and safety required
by the increasingly higher production standards of the new tractor
ranges designed and manufactured by Argo Tractors. The material
should be placed according to category based like tyres should be
placed according to the model of the tractors. And also tyres ,
fender, and other parts so, that at the time of BOM run the parts
should be easily accessible by the workers. By doing this the time
reduces for the movement of material to the production line and
increases the production. And the main problem i.e space should
also be resolved by putting the parts in the pallets up to the
roof. In this we can store more parts in that limited space. We can
use automatic testing machine for the leakage testing of fuel tank.
There are so many machines used for the same purpose but the best
is as under :Helium leak testing for fuel tanks - mass spectrometer
dry testTQC has specialised in the automatic helium leak testing of
components for many years. Fuel tanks have previously been regarded
as a leak testing problem - the volume is unstable and too large
for air decay testing. Water dunk testing is operator dependent and
causes longer term damage to the unpainted tank. Neither method
will detect a fine vapour leak.
Quantifiable leak testing Calibration to ISO 9000 Fast, clean
and dry test High sensitivity Automated pass/fail limits No drying
costs and no tank water damageNow proven by several installations,
TQC is able to supply Fuel Tank Leak Testing using Helium. The
system provides a fast reliable dry test with numerical leak
results. The sensitivity is equivalent to a "dunk tank bubble" once
in several days. Connections to the tank are made automatically,
the system is self-monitoring and the operator may be unskilled.
The system is suitable for leak testing metal or plastic
tanks.Typical specification for a 75 litre fuel tank
is:Throughput48 second cycle (twin station unit)
Test Pressure200mbar (3psi)
Pass / fail limit10-4 mbarl/sec (0.1mm3/sec)
Helium usageapprox 8000 tanks/standard cylinder
Description : The fuel tank is placed in a supporting cradle
which slides into a stainless steel chamber. Operator controls
close a safety shielded chamber door. The sequence is automatically
started by the door closure. The chamber and tank are pumped down
together to a pressure of 180mbar, at which point the tank is
isolated from the chamber. The chamber is further reduced to less
than 0.1 mbar, during which time the tank pressure is monitored to
check for a gross leak. A 10% concentration of helium is dosed into
the tank, allowed to disperse, and the chamber is sampled for
leakage using a mass spectrometer. After the test, the helium is
evacuated, the chamber and tank are vented together to atmosphere,
and the door is opened automatically. Results are then logged for
SPC analysis.By the installation of that machine the cost of extra
labour is reduced and at the same time they can check more tanks
within the same time. And lastly the main problem that is space
which is specially meant for checking the tank can be used to store
another parts. Identification number should be given to each rack
and according to that parts should be store at right place so, that
the parts can be easily accessible by anyone. This can be shown in
the given below figure.
The material handling equipment used for the loading and
unloading, storage of the material and material movement are us
under :Material-handling equipmentis equipment that relate to the
movement, storage, control and protection of materials, goods and
products throughout the process of manufacturing, distribution,
consumption and disposal. Material handling equipment is the
mechanical equipment involved in the complete system. Material
handling equipment is generally separated into four main
categories: Storage and handling equipment. Engineered
systems.Industrial trucks.Bulk material handling.Material handling
equipment is used to increase output, control costs, and maximize
productivity.Storage and handling equipment :Storage and handling
equipment is a category within the material-handling equipment .
The equipment that falls under this description is usually
non-automated storage equipment. Products such aspallet
racking,shelving,casters and carts, among others, belong to storage
and handling.
Industrial mezzanine.
pallet rack
By the use of this type of racks we can store parts up to the
roof level. In this way we can store more parts in a limited space
and the efficiency of the store definitely increases.Engineered
systems :Conveyors,Handling Robots,AS/RS, AGV and most other
automated material-handling systems fall into this category.
Engineered systems are often a combination of products integrated
to one system. Many distribution centers will optimize storage and
picking by utilizing engineered systems such as pick modules and
sortation systems. IndustrialKUKARobots for palletizing AS/RSBy the
use of AS/RS and industrial robots, the effort of labour is reduced
and also the labour cost and time. And we can store and access
parts upto the roof level easily and quickly without breaking it by
the use of AS/RS. The workers in the assembly line must wears
safety helmet and gloves during the working shifts. If they do not
do so the company did not got any loss in the shortrun but in the
longrun it will definitely effects the company. The company have to
pay in case of any accidents with the workers. So safety of the
workers is also important.
The assembly line workers should got a training at least two or
three months so, that they know every stage of the assembly and job
rotation to different should be there so, they got knowledge of
every stage to assembly line. By doing this the defect rates
decreases and company can approach for the six sigma .
LIMITATIONS OF THE PROJECT :The following are the limitations of
the project are as under: Due to hot summer it is very difficult to
observe the things in the store department and and there is no
arrangement of any fans or aircooler so, it is very much difficult
to sustain in the store in this hot summer without any facilities
from morning till to the evening to observe the things. During the
starting days of my training ,the H.R people did not decided which
particular department they want to send me and they simply asked me
to go and meet this sir, that sir and so on. They did not take me
seriously and I face a lot of problems to move here and there in
that hot summer and then finally they decided to send me to the
store department. The H.R people did not provide any kind of
information related to the training and they simply asked go the
store and meet with the store manger, he will entrain you . There
is one policy of the company and every department of the company
follow this. The policy is that do not share any kind of company
important information. The store manager also follow this policy
and whenever I have some doubts ,he simply told me I cannot told
you.
REFERENCES :1. www.sonalika.com.2. www.wikipedia.com.3.
www.agrotractors.com.4. www.tqc.co.uk.5. www.thomasnet.com.6. Ajay
Rawat (store Manger).7. Vinod kambli (Assembly line Manger).8.
Gurpreet Singh ( Store Executives).9. Krishna (Store
Executives).School of business, lpuPage 2
PURCHASE ORDER CHECKING ( P.O)
PHYSICAL MATERIAL VERIFICATION VEHICLE UNLOADING TAG MAKING
INWARD REGISTER ENTRY DOCUMENT VERIFICATION VEH. REPORTING RECIPET
GATE ENTRY
TAGGING OF MATERIAL
MATERIAL MOVEMENT
MRIR OF MATERIAL
REJECTION STORE
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