Sr No.

Observation
1 The Multiple Material Code show on the printed tag
2 The System might get hang

3 Quantity and MHE / Carrier No. are incorrect

4 Two different material code has same carrier code

The Location is paired with MHE / Carrier in a system even if the store location is empty.
5
6 Printed Ink might get Erase on the tag.
7 Premature Batch was pass

Difference between the actual and system inventory record.(location mismatch, location
8 not empty, worker are inter locking the inventory)

Due to lack of gun scanner with the secondary manpower.

Two workers supply the materials for the tyre building simultaneously, and they share a
scanner. It was seen because of the single gun. The other member was told to scan the two
carriages (handing the scanning work to another team member) and then leave. Since
then, additional team members have come to scan the code and have departed to scan the
nearby machine code. He repeated due to some error. Now that he does not remembered,
which carriage to scan. We were there to address the right one, and he scanned the other.
In this scenario, the probability of repeating the same error (defective type manufacturing)
9 is significant.

Incharge are so pressuring the secondary personnel to bring the material fast because of
10 that they are fergetting to change the machine code and free the inventory location.

Secondary movement personnel were ask to bring the material without generating the
request (the material code will not show in the scanner gun) in the system. Because of that
material and location will remain linked. System will not store any other inventory at that
11 location.

All the tag printed between 09-05-24 11:00PM to 10-05-24 7:00AM hyas not complie with
12 the system. The MHE was not linked the the location in belt storage area.

Overaging Problem observed - Belt of Article code 1331 (winded in MHE No. 31) has just
produce at the machine, and we have also 1 MHE (MHE No. - 020) of 1331 Article code in
the storage area. The secondary personnel has direct taken the recently prodeced material
13 winded in 31 MHE.
Suggested solution

Increase the limit to it's maximum limit or set based on the maximum material can
be fill in 1 MHE
System should not allow 2 material to fill in same MHE (INTERLOCKING)

Should generate the error and it should not allow to start the production.

Train the Second manpower. Allocate 2 manpower to sustain this practice. Consider
the storage area as a WIP store, an independent dept which is bridging the tyre
building and stock). An ideal practice should be stock has to give all the MHE to the
WIP store personnel - Responsibilty of WIP personnel will be (i) to store the MHE
and link it to the location, so the inventory will be updated in the system with
location. (ii) to release the material based on the request generated by the tyre
building, it material movement personnel does not have to directly interact with the
stock dept operators.

1. Provide scanner and train them how to use. 2. Stick the machine barcode near
or at the unloading area.

There is not accountability. Responsibility has to be define first and train them
accordingly. Add a verification system like the personnel who is printing tag has to go
and check 2 time in a shift, weather the secondary manpower is compling with the
system or not. If not report it to shift incharge.

We need to consider the WIP store ad and independent department. (i) The
material movement personnel does not directly interact with the machine operator.
(ii) Make it mandatory in the system to store the inventory and link with the location.
Reported to
Sameer Dabhi
Sameer Dabhi

Sameer Dabhi
Sameer Dabhi

Sameer Dabhi
Sameer Dabhi
Sameer Dabhi

they has responsibilty to maintain the accuracy of

the record. They will look after the storing and
releasing the inventory, interlinking the material and
location Which will help us to make the process
fluent, deal with the problems of overaging. If proper
implementation is done than the planning leadtime
Sameer Dabhi will drastically reduce.

Sameer Dabhi

Sameer Dabhi

Sameer Dabhi

Sameer Dabhi

Sameer Dabhi
Sameer Dabhi