A REPORT

ON

PRODUCTION MANAGEMENT AND TIME ANALYSIS

BY

NAME OF THE STUDENT REGISTRATION NO.

AMOL GUPTA 1700372C205

PREPARED IN THE PARTIAL FULFILLMENT OF THE

PRACTICE SCHOOL II COURSE

AT

DEEPAK INTERNATIONAL LTD.

SANSARPUR TERRACE

A PRACTICE SCHOOL II STATION OF

BML MUNJAL UNIVERSITY

MAY 2019

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 Table of Contents

Page

Acknowledgment………………………………………………………………………………………………………. 4

Objective…………………………………………………………………………………………………….................. 5

Problem Statement……………………………………………………………………………………………………. 5

Company Profile…………………………………………………………………………………………………………. 6

Project methodology…………………………………………………………………………………………………… 9

Assembly Line………………………………………………………………………………………………………………… 11

Stages of Assembly line……………………………………………………………………………………………………………. 11

Burning………………………………………………………………………………………………………………………………………………………. 11

Short Circuit Test………………………………………………………………………………………………………………………………………... 12

ICW……………………………………………………………………………………………………………………………………………………………. 13

Heat Sealing Machine………………………………………………………………………………………………………………………………… 14

Cap Burning………………………………………………………………………………………………………………………………………………... 14

Capping…………………………………………………………………………................................................................................ 15

Method………………………………………………………………………………………………………………. 16

Time graph……………………………………………………………………………………………………………………………………… 18
Problem……………………………………………………………………………………………………………… 18

Analysis………………………………………………………………………………………………………………. 19

Solution…………………………………………………………………………………………………………………………………… 20

Conclusion………………………………………………………………………………………………………………………………. 22

Reference……………………………………………………………………………………………………………………. 22

Appendices…………………………………………………………………………………………………………………. 23

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 Dr. Amiya Dash

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 ACKNOWLEDGMENT

I would like to acknowledge everyone who played a role in my academic

accomplishments. First of all, my parents, who supported me with love and

understanding. Without you, I could never have reached this current level of
success.

Secondly, Mr. Sushil Kumar Gupta, who has provided patient advice and

guidance throughout the training process. Thank you all for your unwavering
support.

Special thanks to DEAN Dr. M.B. Srinivas and Dr. Maheshwar Dwivedy along
with my Faculty Mentor Dr. Amiya Dash.

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Objective

My project (Production management and time analysis) focuses on the manufacturing rate
of a battery from assembly line to packaging line. Through this by now I have learned how a
household tubular battery works and what all are the components required in the
manufacturing of a battery and what all are the factors and safety features kept in notice so
that the efficiency of the plant is maximum. Moreover, I have spent a whole week in the
R&D and quality lab of the industry where I learned how inspection of a product is done,
what are the criteria and bottom line guidelines a product must follow to be called as an
okay product and ready to be used in an assembly line.

Problem Statement

Problem that I am working on is the Production Management. The “manipulated” and

“responding” variables of the cause and effect statement is as follows would be observing
and creating a Time/Data Analysis Table through which I will get the Time analysis of a
particular product per station through which I can summarize the PPAP (PRODUCTION PART
APPROVAL PROCESS) and help in increasing the production rate of the factory. Assumptions
I am talking about my project are as follows 1. there is no rejection observed on the
assembly line as well as on the manufacturing line. 2. Only one operator is working per
station Sub problems that i will not address is the quality control of the product as my
project is totally based on the rate of manufacturing per unit time. So in conclusion, m
project focuses on the production and manufacturing rate and how could I help by
increasing it by any means without harming or increasing any explicit spending budget of
the company.

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Company Profile

(DEEPAK INTERNATIONAL LTD.)

This group is a leading manufacturer & exporter of Lead acid battery based in Sansarpur Terrace,
Kangra district, Himachal Pradesh, India. Our product portfolio entails a wide range of SLI Batteries
(Motorcycle, Cars and commercial vehicles), Deep cycle batteries (Home Inverter/Office UPS) and
Solar batteries (Tubular batteries).

Our state-of-the-art battery manufacturing facility is located at Plot No. 115-119, Industrial Area,
Phase III, Sansarpur Terrace, 176 501, District- Kangra, Himachal Pradesh, India. The plant is fully
automated and its sophisticated machinery is imported from world Leader OPTAMAC, USA and
other reputed battery machines producers located in Germany, Denmark, Taiwan and China. We are
a member of the renowned business group named Deepak International Ltd, An ISO 9001: 2015
organization engaged in manufacturing and exporting of engineering products in India & overseas
for the last 60 years.

Deepak Group’s history dates back to 1950 when the company instituted a factory to
produce complete bicycle & spare parts for the Indian market.

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image 1

Our strong presence in the industry, and our commitment to produce quality products,
coupled with our experience and technical know-how has helped us built a wide-reaching
eminence as a global manufacturing & exporting partner for automotive battery & power
storage solutions.

With a nationwide sales & service network in place, we are not only known for quality
batteries, but also for aftermarket knowledge, customer sales support and marketing
expertise. Our product expansion and continued growth in various markets is absolutely due
to the support of our business associates in India and overseas market.

We, at Deepak Group, will continue endeavour to produce and market quality automotive
and power storage solution to fulfil the need of scores of happy consumers, channel
partners and overseas business associates.

Image 2

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Project Methodology

Assembly line (Case Study)

The task given to me was about what are the measures and crucial steps as an employee of
the company, I must take to increase the production as well as to decrease the time
consumed in an assembly line per station such that the company is able to produce as many
goods as per the client’s demand and as well as for the extra lot in case of any sudden order
to prevent any hassle or discrepancy in the unit. So work on the project, the first person I
interviewed was Mr. Das, he is the Quality manager of the factory and he gave me a brief
summary about the company and how all the things work around. After that, I interviewed
Mr. Ankur, he is the production manager of the company so he also gave me a brief
overview of the manufacturing unit of the plant along with each and every detail of the
products manufactured by DEEPAK INTERNATIONAL LTD. After that along with a supervisor I
went for the company tour and visited each and every section of the company from
manufacturing to assembly then to quality and in the end to the packaging. Through this is
got a visual overview along with the terms and names given to each section of the company
in their native layman language. In the starting I observed the manufacturing rate and
assembly rate of time with the help of a stopwatch and recorded each and every time per
station taken by an operator to pass the battery to the next station after completing his/her
work.

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Image 3

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Stages of an Assembly line

1. BURNING
This is the first stage of manufacturing and assembly of a tubular battery, well the
stages that are discussed below are same for all kind of batteries including solar
batteries irrespective of their size and ampere capacity.

In this process, 2 workers side by side on a single station assembles 2 lead oxide and
1 lead plate parallel to each other in a custom made box (depends on the model) and
1 operator (burner) burns the pure lead connectors and melt them such that all
three of the plates gets connected to each other forming a ladder base structure.
There are four “BURNING” stations in the assembly line, burning 4 cells each (12 lead
plates each).
A battery consists of 6 cells each comprising of 2 negative lead oxide plates and 1
pure lead plates. Each cell caries a voltage of 2V, adding up makes the battery of 12V

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 2. Short Circuit Testing
This is the second station of the assembly line in which after placing 6 cells in the
container, any contact between the cells is checked through a “Short Circuit Testing”
machine.

This is a semi-automated machine in which with the help of sensors, a battery is

stopped right beneath 6 probes and these probes are vertically moved downwards
to check the given gap between the cells. If there is no fault found in the cells
placement, then the battery is sent to the next station.

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 3. ICW (Inter cell welding machine)
This is the 3rd station of the assembly line, as the name suggests in this station a
semi-automated resistance welding machine (spot welding) is used to weld the cells
inside the battery.

FEATURES -

MAX. And MIN. Welding Limit: 0-9.99kj, Welding Heat: 0-99.9%, Welding Currency: 0-12.9ka
Welding Time: 0-99 period, Production Capacity: 80 batteries /hour
Electric power: AC380V, 50Hz, 80KW

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 4. Heat Sealing Machine
After welding the lead joints with the help of Inter cell welding machine, the battery
is pushed over to the heat sealing machine to seal the battery with a plastic lid.

In this the edges of the container are heated to some extent that the plastic edges
start to deform and melt, at this moment the machine puts the lid on the top and
apply pressure on it to join/weld both the plastic pieces together.
Temperature at which the container plastic heated is around 40 C.

5. Cap burning
In this process the lead caps are burned and joined on the top of the finished dry
battery which plays the role of the negative and positive pole of the battery through
which the wires would be connected.

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 6. Capping
In this process, the operator fix plastic caps on the lid through which the diluted acid
will be filled in the battery.

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Method

The task given to me was about what are the measures and crucial steps as an employee of
the company, I must take to increase the production as well as to decrease the time
consumed in an assembly line per station such that the company is able to produce as many
goods as per the client’s demand and as well as for the extra lot in case of any sudden order
to prevent any hassle or discrepancy in the unit. So work on the project, the first person I
interviewed was Mr. Das, he is the Quality manager of the factory and he gave me a brief
summary about the company and how all the things work around. After that, I interviewed
Mr. Ankur, he is the production manager of the company so he also gave me a brief
overview of the manufacturing unit of the plant along with each and every detail of the
products manufactured by DEEPAK INTERNATIONAL LTD. After that along with a supervisor I
went for the company tour and visited each and every section of the company from
manufacturing to assembly then to quality and in the end to the packaging. Through this is
got a visual overview along with the terms and names given to each section of the company
in their native layman language. In the starting I observed the manufacturing rate and
assembly rate of time with the help of a stopwatch and recorded each and every time per
station taken by an operator to pass the battery to the next station after completing his/her
work. So I made a daily excel report comprising of the data of the TIME ANALYSIS I did.

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In this as the readers can see, the time analysis of 3 different models of battery is written
down according to the time each station takes to complete its one process and then move
on to the other one.

Like this we calculate the “BOTTLE NECK” term used to determine the most time consuming
station of the whole assembly line.

Majority of the data calculated and observed is approximately same but there is a pattern in
the following data that the most time consuming station of the assembly line is the “ICW” or
the INTER CELL WELDING MACHINE taking approximately on an average 1min and 10
seconds.

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Time graphs

Here I am presenting you the time graph of the operators respective the time of the day
they were working. Through this we can calculate the time at which the productivity of the
operators was maximum.

The table is about the time took by the operators to assemble 10 batteries before and after
lunch. The cycle times gives the data interpretation of the number of batteries per cycle.

PROBLEM

How can we increase the productivity of the plant by increasing the manufacturing rate and
decreasing the assembly line time rate?

Moreover, identifying the bottle neck of the assembly line and how to decrease it.

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Analysis

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This is the graph plotting the annual production data compared with the idle production
rate.

Solution

With the help of Mr. Rajesh we both came up with multiple reasons and solutions for the occurring
problem. reasons behind the problem –

1. Assembly line 1 was on the ground floor with larger working space and highly ventilated and
bright area whereas Assembly line 2 was on the first floor which was more heated and lowly
ventilated

2. The workers of Assembly line 1 are the workers who work on per piece basis whereas the workers
on assembly line 2 work on a monthly basis with a monthly wage.

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solution

1. Shift the assembly line 2 to the ground floor with better working environment

2. Workers should get their wages according to the per piece battery they assembled. Here is the
data that I used to summarize daily digitally on my tablet to keep in note.

This was the data calculated by me and Supervisor of the assembly line 1 Mr. Rajesh.

Here we compared the data according to the working hours per shift and the production
rate per assembly line of the company.

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CONCLUSION

 By implementation of line balancing in an assembly line the overall equipment effectiveness

of the line will have increased by 14%. Non-value added activities are eliminated. I.e.
 Reworks are eliminated at cast on strap. By implement post trimming automation strategy in
the line will reduce man power and also reduces rejection at leak test due to accurate
cutting at post trimming.
 Productivity improved in line i.e. Shift production increases from 112578 to 121290 batteries
per month from one line (line 6).

 It should be noted that some changes in the assembly line in company increase the
availability, performance and quality and it improves the overall productivity in a line.

REFERENCE

“STATISTICAL PROCESS CONTROL-SECOND EDITION” by John S. Oakland and Roy F. Followel

1994

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 APPENDICES

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