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

Process Flow of NG6 Valve

Planning Process(Forecast)

Yearly Plan Leveled across weeks

Yearly Plan

Weekly Plan

Daily Plan

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 :

THANK YOU…