Presented By:Amber Jain (009)Amit Panjabi (010)Mukul Sharma (027)Nitin Chavan (029)Varun Patel (060)
Planning of NG6 Valve at
About the Organization and ProductsProcess flow of NG6 ValveS&OPCalculation of Annual Demand, Available time & TAKT TimePAC through KanbanConflicts
Agenda
Leading specialist in drive and control technology.
Serves customers through manufacturing facilities and service centers in Ahmedabad and Bangalore, six direct sales offices and 62 sales and service partners spread all across India.
Market Segments:• Automobile Applications• Factory Automation• Renewable energies • Machinery Application and Eng.
Major Customer • Caterpillar
About the Organization
1) Hydraulic Control Valves: Directional Control Valves Flow Control Valves Pressure Control/Pressure Relief
Valves Check/Non-Return Valves
3) Hydraulic Pumps: Axial displacement Pumps
Gear Pumps Vane Pumps Radial Piston Pumps
Products of the company2) Cylinders Product Range: NFPA Hydraulic Cylinders Mill Type Hydraulic Cylinders Large Bore Hydraulic Cylinders
Hydraulic Cylinder Podcasts 4) Hydraulic Manifolds:
5) Hydraulic Power Units Fixed and Variable Displacement
Power Packs Close Couple Motor Pump Groups
Annual Demand in numbers calculated as average of last 3 years sale.
Plan is provided by Sales team.
Yearly production is leveled across the weeks.
Stakeholders Involved:- Sales Planning Production Project Management
Yearly Plan (NG6 Valve)
Weekly Slot is fixed in SAP. This limits the issue of raw material for that week.
Incase of demand fluctuation the plan is changed on request of sales team.
Daily plans are drawn from weekly plans.
Based on the weekly demand number of shifts to be run daily are decided.
If Weekly demand is not met then slot for next week is updated accordingly.
Weekly Plan & Daily Plan
Further explanation is w.r.t. Valve Housing
OEE: 85-90%
Capacity Planning
Particular Value Calculation
Cycle Time 3 min Batch of 6 valves takes 18 min for machiningValves machined Ideally 440 1320/3Customer Demand (Forecasted) 376.71/day 113013/300Production Possible per day 383/day 0.87*440 OEE=87%
Particular (Valve Housing) Value Calculation
Annual Demand 113013Number of Working Days 300 DaysTime Available per Day 1320 Min 3 shifts including break(24*60-2*30-4*15)Customer Takt Time 3.50 Min 1320*300/113013
KANBAN is used for production flow control.
Two Bin system Maintained each of capacity of 240 casting.
Each Bin has 10 Pallets (24 casting per pallet).
Inventory of 960 Castings (480 at store two bin, 480 at machining two bin)
No waiting for machining process because of inventory of 480 castings at store
Inventory Coverage:- 1.3 days
PAC
KANBAN Calculation
10 KANBAN per BIN => 240 Castings per BIN
Number of KANBAN= (( Demand+ Variation)* Lead Time)/Container Qty.
Element Fill-in Element DescriptionOrder lead-time 0.7 Time to place and acknowledge orderTransit lead-time 0.5 Supplier delivery timeInternal lead-time 0 Production or movement from storesContainer qty 24 Number of parts per each container Equivalent to Kanban sizeDaily demand 374Daily demand variation 10Total Leadtime 1.2# Kanban Cards 20
These should all be in same units of time, generally in days
These should all be in same units, generally pieces
Information Flow
240
240
240
Supplier
P W
Store - 480 Shop Floor - 480
MaterialInformation240
Monthly DemandDaily Demand
KANBANProduction Card
Allowable Quality Level (AQL) is 10%.If Rejection > 10% , entire lot is rejected.In case rejection is about 12% , supplier does QC at Rexroth
plant.CAPA is developed by the Supplier & 100% QC is done for
next slot.
Conflicts :
Recommended