IMPROVEMENT IN SUPPLY CHAIN OF PLANET CARRIER HOUSING

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GROUP MEMBERS Roll No.

ABU ASIF HASAN MP13001

AJIT KUMAR SINHA MP13003

AKASH PRIYRANJAN MP13004

ASHUTOSH K TRIPATHY MP13017

GYANESH DUBEY MP13026

SUMANTRA KUMAR KHAN MP13060

TEAM MEMBERS

IMPORTANT NOTICE

The data and processes mentioned in the report are CONFIDENTIAL. No any information can be used without the written permission from the organization.

• TML Drivelines Limited is a leading manufacturer of automotive transmissions & Axles component for a wide range of medium and heavy commercial vehicles.

• TML Drivelines Limited is a 100% subsidiary of TATA MOTORS Limited.

• The turnover of TMLDL 2013-14 was Rs. 700.14crores. HVAL is having a permanent manpower of 2200 employees.

• TML Drivelines Limited is also the major supplier of the transmissions to the TATA Motors Limited.

• The latest addition to product portfolio of TML Drivelines Limited , for Tata Motors, is the India’s first indigenous 9-Speed Transmissions.

TML DRIVELINES LIMITED

• The 9 speed gear box requires a very critical part called “Planet Carrier Housing”

• The schematic diagram shows the Planet Carrier Housing.

• Avtec Limited is the supplier for finish Planet Carrier Housing to TML Drivelines Limited. The forging raw material is being supplied by Trinity Forge, Pune. Semi finish machining is being done by Walia Industries, Pune, JMT Auto Ltd Jamshedpur and Avtec Hosur.

PLANET CARRIER HOUSING

PCH Ready for Despatch

Drilling & Treading Boring Grinding

Pocket milling

Induction Hardening

Spline Hobbing & Threading

Turning

Forging

PROCESS FLOW OF MANUFACTURING PLANET CARRIER HOUSING

PROBLEM DESCRIPTION

• Loss of sales in G1150 gear boxes due to inconsistent supply of Planet Carrier Housing.

• The efficiency of the current supply chain is very low.

• There is huge uncertainty in the demand vs actual receipt of PCH.

• Last 2 months’(Especially of Sep.) data of demand vs supply reveal that against a requirement of 400 numbers Planet Carrier Housing in a month the total Supply being hovering around 300.

• In addition this the company is expecting to have a higher demands of the product.

TMLDL Store, JSR

Gear Box Assembly Line TMLDL, JSR

Trinity Forge Pune

Walia Industries, Pune

Machine shop TMLDL,JSR

Avtec Ltd,Kharagpur

Forge RM

Pocket Milled PCH

Finish PCH

Turning facility @Avtec Ltd, Hosur

JMT Auto,JSR

Turned,milled PCH

CURRENT SUPPLY CHAIN OF PLANET CARRIER HOUSING

MANUFACTURING CONSTRAINTS

• AVTEC does not have facility for Turning , Drilling, Milling and they are sending this material to Hosur at their other facility.

• The bottle neck operation is Pocket Milling and Boring. in terms of quality.

• The cycle time of operation in Pocket Milling for a single job 94 Minutes which is the maximum, restricting the capacity to 14 /day against a requirement of 40/Day at present.

• This issue is addressed by developing an additional supplier at Pune, M/s Walia Industries.

• The cycle time of Boring operation is the highest at avtec that is 69 minutes restricting the capacity to 21/day. A second machine has been installed for this operation which increases the capacity to 42/day.

• Since there is no other machining constraint, if the boring machine is getting Planet Carrier Housing with Pocket Milling Done every 30 minutes then the customer demand of Planet Carrier Housing can be met.

TMLDL Store, JSR

Gear Box Assembly Line TMLDL, JSR

Trinity Forge Pune

Walia Industries, Pune

Machine shop TMLDL,JSR

Avtec Ltd,Kharagpur

Forge RM

Pocket Milled PCH

Finish PCH

Turning facility @Avtec Ltd, Hosur

JMT Auto,JSR

Turned,milled PCH

FINAL SUPPLY CHAIN

RECOMMENDATION

• JMT Auto can be given the demand for doing all the turning, milling and drilling operation.

• As a result Avtec will receive Turned , Milled and drilled Planet Carrier Housing instead of Raw forging from TMLDL .

• This will lead in reduction of one stage .

• It will reduce the lead time of Avtec

• Pocket milled planet carrier housing (operation done at TMLDL) to Avtec.

CONCLUSION

• The supply chain can be made simpler by eliminating one major machining source . This will improve the availability of material at Avtec for finishing.

• Reduction in no. of stages at Avtec has been reduced by 1 this will help them to maintain inventory and reduce complexity.

• TMLDL needs to follow the ordering sequence.

• Due to presence of higher uncertainty there needs to me better communication and coordination which will bring supply chain efficiency.

There is a raise in the receipt of the components as compared to Sep’14.