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Sameer Sip Project1.01 PDF
Sameer Sip Project1.01 PDF
I, hereby declare that the project entitled “TO STUDY THE PRODUCTION PROCESS OF DRILL BITS &
TO DETERMINE ITS MATERIAL COST WITH THE HELP OF ACUTAL MATERIAL
CONSUMPTION” written and submitted by me to Savitribai Phule Pune University, Pune as partial fulfillment
of the requirement for the award of degree of MBA under the guidance of Prof. Mr. Rahul Deore, is my original
work and the conclusion drawn therein are based on the material collected by myself.
I also declare that this work has not been submitted anywhere else for award of any other degree.
Sameer Barve
Place:
Date:
Signature of student:
1
ACKNOWLEDGEMENT
I wish to express my heartfelt gratitude to Mr. Pradip Joshi, Operation’s manager, Advance
manufacturing, chiplun., For his keen interest, invaluable pains taking and excellent
guidance, patience, endurance, encouragement and thoughtful advice for the project work.
He has been instrumental in making me understand the various procedures and policies of
Advance Manufacturing. His kind support and guidance throughout the course of this project
has helped me to complete my work effectively and efficiently.
I am grateful to Dr. Rakesh Dholakiya, Director, DYPIMR, Pune for providing us with an
opportunity to go beyond the classroom and have a glimpse of the corporate world.
My sincere thanks to my project guide Prof. Rahul Deore for guiding me right from the
inception till the successful completion of the project. I sincerely acknowledge him for
extending his valuable guidance, support for literature, critical reviews of the project. I thank
him for much needed timely advice and suggestions that he has provided.
I thank my family members for their moral support and help with they provided me during th
course of project work. I am also thankful to my friends who gave me continuous inspiration
to complete this project successfully.
Sameer Barve.
2
TABLE OF CONTENTS
EXECUTIVE SUMMARY
1 Introduction 5
2 Objectives , scope 6 -7
Research Methodology
5 21-25
Bibliography
8 47
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EXECUTIVE SUMMARY
The project starts with a brief introduction specifying the need for the study and reasons for
choosing the topic. I have done research on the topic “To study the production process of drill
bits and to determine its material cost with the help of actual material consumption”. The
main objective of the study is to study the production process and to study actual material
consumption in each stage. Project involved primary data which was collected by observation
and secondary data which is collected by viewing company’s data and other reports.
Project report then contains the whole production process carried in Advance manufacturing
as well as the total consumption of HSS straight shank stub drills, Rolled forged drills-Jobber
series, HSS straight shank long drills, Masonry drills-standard. A proper charts depicting the
cost for materials consumption. Project report then contains the interpretations which shows
the difference in the cost in different drill bits followed by the analysis data. Improvement in
the material consumption is suggested by reusing some materials and a brief description is
given on ways of improving Inventory. From the analysis of overall study findings and
suggestions have been provided.
4
INTRODUCTION
In nutshell, drill bits are specialized cutting tools that are used to create cylindrical holes in
various materials. Drilling holes in woods is the most common use for drills bits, but various
other materials may be drilled such as metal, plastic, composite, masonry and more.
Advance manufacturing is place in Chiplun MIDC. They produce drill bits. In this project I
am studying the production process in advance manufacturing as well as actual material
consumption in the company.
Drill bits fit inside what is known as chuck on a drill. When the drills is powered on, the
chuck spins around, creating torque and the axial speed needed to cut the hole.
Various companies in India manufacture drill bits. In this industry in India top manufacturer
company is Neeson tools international.
Advance manufacturing is provide their drill bits to the J.K Files India Chiplun.
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OBJECTIVES
6
SCOPE
To implement start to use industry so latest technology to control more consumption
of material like Data Analysis, Data Analysis etc. but it need well trained employee.
7
COMPANY PROFILE
Advance manufacturing was established in the year April 2019. Advance manufacturing is
placed at Chiplun Mumbai Goa highway & easily reachable via Mumbai by Rail & bus from
Pune by bus or private vehicle. Advance manufacturing produce(files) drill bits. Advance
manufacturing gets raw material from J K Files India Ltd Chiplun. & they give their product
after packing to J K Files India Ltd Chiplun. In advance manufacturing 60 workers &
employees are working in three shifts. Advance manufacturing produce drill bits (files) in
many size.
Product Specification:-
Easy to transport
Available in many sizes
Easy to manufacture.
Non corrosive
To drill in walls.
To drill in Woods
In civil constructions
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FUNCTION WISE GOALS
Maximizing profit
High internal and external customer satisfaction.
Organization
Quality product
Production
On time delivery
Low wastage
Maximize performance
People Management Maximizing job satisfaction
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PRODUCT PROFILE
Rolled
HSS
forged Advance Manufacturing Straight
Drills-
Shank
Jobber
long drills.
series.
10
Raw Materials used
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PRODUCT DETAILS
Standard straight shank ground flute drill, recommended for use with hand drilling
machines in drilling thin sections, sheet metal, car and bus bodies and for similar
applications. Also, they are used for automatic and capstan lathes. They are
Ground flute up to 13mm and Milled flute above 13mm. They are designed as per
the IS5100/DIN 1897/BS328 standards.
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2 Rolled forged drills- jobber series.
Rolled forged drills bits are twisted when forged in the manufacturing process. This cause the
molecular structure of steel to follow the flute giving good durability. Diameter range is
about 2.70mm to 13.00mm. Suitable for drilling on Mild steel, Plastic, stainless steel with
point of enhancement (130 degree) and wood drilling operations.
13
3. HSS shank long drills
Straight shank drill with increased flute length for drilling deep and inaccessible holes
or for use in conjunction with drill bushings They are designed as per the IS5102/
DIN 340/BS 328 standards.
14
4. Masonry drills.
Masonry drill bits are designed for drilling into tough materials such as stone, block or
concrete. The feature of masonry drills is long life.
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LITRATURE REVIEW
Review of literature forms an integral as well as an essential part of modern research studies.
No research study is considered complete unless an extensive literature review is made by the
researcher. The basic purpose of undertaking this exercise is to find the research gap between,
studies conducted so far or literature available, and also to finalize precisely the topic of
research and to get insight the research topic selected for study. In this exercise becomes a
sort of exploratory research.
Abstract— Drilling is one of the widely used machining processes for various purposes. Now
a days it is frequently used in
automotive, aircraft and aerospace and dies or mold industries, home appliances, medical and
electrical equipment
industries. Thus, it needs to be cost effective along with the assurance of the quality
specifications within the experimental
limit. In today’s rapidly changing circumstances in manufacturing industries, applications of
optimization techniques in
metal cutting processes is essential for a manufacturing unit to respond efficiently to severe
competitiveness and the
increasing demand of quality product in the market. Optimization methods in metal cutting
processes, considered being a
very important tool for continual improvement of output quality in products & processes [13].
This paper reviews the various
literatures on the optimization of drilling process by studying the influence of various drilling
parameters (spindle speed,
feed rate, drill diameter, drill point angle, etc.) on the performance parameters (surface
roughness, material removal rate,
thrust force, etc) during drilling process.
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Research paper 2 :-
IMPORTANCE:-
Importance of drill bits is to making our work very easy without paying worker for small
work such as for hanging frame on the wall or for the drilling a hole into the wall for hanging
something else. Drill bits also used for the drilling in wood and many other things. Drill bits
are of various types and design and geometry, for a particular field application or drilling
practices. Due to different types the drill bit must be changed after a period of time during
which drilling operations must stop .Drill bits are of various size, ranging from 3.5 inches to
30 inches.
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What is productivity?
Production process:-
Production and Operations management (POM) is about the transformation of production and
operational inputs into “outputs” that, when distributed, meet the need of customers.
Transformation
INPUTS process OUTPUTS
The process in above diagram is offer referred to as the “Conversion Process”. There are
several different methods of handling the conversion or production process i.e. Job, Flow &
Group .
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PROCESSES
There are many different ways of producing a product. Management must choose the best
process, or series of processes. They will consider:-
Available capacity
Available skills
Type of production
Layout of plant & equipment
Safety
Production costs
Maintenance requirements
The production process in Advance manufacturing, which is given in stage wise is as follows:
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MATERIAL MANAGEMENT
Material management thus can be define as that function of business that responsible for the
coordination of planning, sourcing, purchasing, moving, storing and controlling materials in an
optimum manner so as to provide service to customer, at pre-decided level at minimum cost.
From the management point of view, the key objectives of Advance manufacturing are:-
To buy the lowest price, consistent with desired quality and services.
To maintain specific material quality level and a consistency of quality which permits
efficient effective operation.
To develop reliable alternate source of supply to promote a competitive atmosphere in
performance and pricing.
To minimize the overall cost of acquisition by improving the efficiency of operations and
procedures.
20
RESEARCH METHODOLOGY
RESEARCH
Research is to see what everyday else has seen and to think what
nobody else has thought. Research means movement from known to unknown. It is
investigation of significant information on a specific subjects. It is actually a voyage
of discovery. Research is thus an original contribution to the existing study,
observation, comparison and experiment. In short the search for the knowledge
through objectives and systematic method of finding solution to a problem is research.
21
Research design
The research design refers to the overall strategy that you choose to integrate
the different components of study in a coherent and logical way, thereby, ensuring
you will effectively address the research problem; it constitutes the blueprint for
collection, measurement, and analysis of data. It acts as blueprint for the whole
conduct.
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Types Of Research Design:-
Research Design
23
Data
1. Primary data:-
The original sources from which the data is collected for the first time are termed as
primary sources and such data is called primary data. Such data is original in
character and is generated by a survey conducted by individuals or organizations for
enquiry or study purpose.
2. Secondary data:-
The sources containing data which have already been collected and complied
for another purpose are called secondary sources. The secondary sources contain
readily available compendia and already complied statistical statements and reports
whose data can be used by others.
“A secondary sources is publication, reporting the data which have been gathered by
other authorities and for which others are responsible.”
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RESERCH METHODOLOGY USED IN THIS PROJECT
Descriptive Research
The descriptive research involves a systematic study and fact findings for different
situations. In this project consumption of materials are studied in detail and also charts
are prepared for the same.
Primary data
Primary data is that data which is collected a fresh and for the first time. In this
project, the primary data collected is the flow of materials under each stage to know
their consumption. The variations in the process for different types of components are
also captured. The methods used for collecting primary data include:-
Secondary Data
Secondary data is that data which is already collected by someone for some their
purpose. For this project, the secondary data collected is the different concepts and
definitions used in the organization.
The method used for collecting secondary data include:-
-Books
-Company records
-Internet
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DATA ANALYSIS
1. Parting:-
The first stage of production of drill bits is parting of M2 High speed steel by using parting
machine. In this stage according to need of length of the order steel rods are cut in various
length.
Fig:- Parting
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2. Heat Treatment:-
Next stage of drill bits production is heat treatment. In this process firstly pre-heat treatment
is done 860 Degree C. Then high heat treatment is give at 1210 Degree C. Then drill rods
temperature is reduced by penching i.e. kept this heated rods in salt and then temperature is
comes to 540 Degree C.
3. Washing:-
The next stage is washing. In this stage cut steel rods are wash.
4. Tempering:-
After washing tempering is done. In this stage initial tempering is done on the steel rods. This
process is done for 2 hrs. for 3 times.
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6. Fluting:-
Next stage after the rough center leth Fluting is done in to the fluting machine.
7. Finish Grinding:-
After fluting is done then finish grinding is the next stage in drill bits production process.
This stage is done for the get finishing to the drill bits.
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8. Clearance Grinding:-
Once finish grinding is done next stage is clearance grinding. In this stage clearance grinding
is done in grinding machine. Then quality is checked by workers and quality department.
Then drill bits go to point grinding machine.
29
9. Quality Checking:-
In this stage quality is checked by the quality department. In this stage diameter, length,
strength is checked.
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10. Marking:-
In this stage drill bits are marked as per their length and their type.
11. Packing;-
This is the last stage of drill bits production in Advance manufacturing. In this process drill
bits are packed according to various types and length. Firstly Drill bits are kept in plastic
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pouches, then they are kept in plastic tubes. And finally this tubes are kept in boxes for
dispatching.
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Final product packing ready to dispatch for J.K Files.
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CONSUMPTIONS OF RAW MATERIALS.
10 Units 30 300
10 cello tape
10 Units 20 200
11 Markers
Packing material 500 Units 10 5,000
12 (plastic tubes)
20 Units 30 600
13 Boxes for packing
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Rolled forged drills-Jobber series.
35
HSS Straight Shank Long Drills
Sr. Quantity
No. Material Required Unit Price(Rs) Amount(Rs)
Description
36
Masonry Drills-standard
37
DATA ANALYSIS
38
Rolled Forged Drills –Jobber Series
39
HSS Straight Shank Long Drills
40
Masonry drills-Standard
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INTERPRETATION
It has been found that Rolled forged drills steel is more in quantity so it increase
value by Rs40,000 a compare to HSS straight shank drills, HSS straight shank long
drills and masonry drills.
HSS straight shank long drills have comparatively length wise long than HSS
straight shank drills, rolled forged drills, masonry drills so it need less DWX32 oil
and decrease the value of DWX32 oil by Rs 1,340.
Packing material i.e. plastic tubes are used for rolled forged drills are high because of
quantity of pieces of drills are increase as compare to HSS straight shank as well as
masonry drills. Rolled forged drills are required Rs3,500 more than HSS straight
shank long drills for plastic tubes for packing.
For Rolled forged drills requires more no. of boxes for packing as compare to HSS
straight shank stub drills as well as HSS straight shank long drill. Rolled forged
packing required Rs150 more than HSS straight Drills and masonry drills and
required Rs300 more than HSS straight shank long Drills.
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IMPROVEMENT IN CONSUMPTION OF MATERIAL.
Reuse:
Reusing some materials can help reduction of materials, so as the cost.
Materials such as Gloves, Nose masks can be used for many weeks instead of using
them for just few days and throwing them.
Inventory:
Sometimes company over-to-order the amount of materials required to fulfill the
order & then some materials, especially in the make-to-order environment. The true
costs of excess inventory levels should be analyzed carefully before the company
orders excess raw materials.
43
This will lower shipping costs, and the amount of obsolete stock that your company
retains.
44
FINDINGS
Skilled Workers:-
The industry faces the shortage of skilled workers. In most of units, it has been
observed that there are less experienced and trained workers and officers in required
number. Thus, with traditional approach and unskilled and untrained workers, the
development of the industry cannot be achieved.
Quality Control:-
The production process is one of the important aspect of this industry. Machines ,
tools, should be of good quality.
Outdated Materials:-
It has been found that some materials which are in bulk gets expired at times which
results in loss.
Lack of Coordination:-
There is a lack of coordination between the workers and the engineers.
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SUGGESTIONS
Esprit de corps:-
It is an important concept in administrative management theory. The proper
coordination between workers and engineers will help the workers in making less
mistakes on production line and thus result in overall productivity.
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CONCLUSION
1.From this project in “ Advance Manufacturing Chiplun“ conclude that industry use
production process for HSS straight shank stub drills , Rolled Forged Drills –Jobber Series,
HSS Straight Shank Long Drills, Masonry drills-Standard.
2 .Material consumption of HSS straight shank stub drills , Rolled Forged Drills –Jobber
Series, HSS Straight Shank Long Drills, Masonry drills-Standard. Mostly m2 high speed
steel type in production process. So need to proper inventory managemanet of m2 high
speed steel.
3. HSS Straight shank stub drill have low oil consumption consumable used so costing
for manufacturing production automatically reduce so, profitability increase
4. Improvement consumption of material we can implement some standard technique
like quality policy & quality related to operation managemanet.
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BIBLIOGRAPHY
3 websites:-
1. Advance Manufacturing website:- www.advancemanufaturing.com
2. www.J.k.files.com
3. Technology Information, Forecasting and assessment council. Website-
www.tifac.org.in
4. https://en.wikipidia.org/wiki/driilbits.
5 www.joernels.elsevier,com
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