Radically different !

INDUSTRY 4.0 PROJECTS

AND CCTV STATUS

Presented by : IT Department
Date -: 06.08.2019

BADVE ENGG. LTD. UNIT - IX TPM – The Way of Life 1 of 27

Radically different !
PROJECT DETAILS
1. Access Management System

2. Digital Audit System

3. Robot Output System

4. Biometric Attendance System for Staffs

5. Meeting Manager

6. New CCTV Cameras Installation

7. PDI System in SAP

8. Online Production Confirmation through IT Gun

BADVE ENGG. LTD. UNIT - IX TPM – The Way of Life 2 of 27
Radically different !

PROJECT 1. ACCESS MANAGEMENT SYSTEM

BADVE ENGG. LTD. UNIT - IX TPM – The Way of Life 3 of 27

 ACCESS MANAGEMENT SYSTEM OBJECTIVES
Radically different !

 To monitor contractor performance

 To Eliminate the difference between actual & system manpower

 To Monitor man days data for monthly payment

 Online billing of contractual workers

BADVE ENGG. LTD. UNIT - IX TPM – The Way of Life 4 of 27

 AMS ACTUAL VS SYSTEM MANHEADS REPORT
Radically different !

1109 July 19 (26.06.19_25.07.19)

Actual 25481
Tripod 26838
Tab 26567
Act vs Tripod Diff % -5.33%
Tripod vs Tab Diff% 1.01%
Act vs Tab diff % -4.26%

1114 July 19 (26.06.19_25.07.19)

Actual 9667
Tripod 10435
Tab 10308
Act vs Tripod Diff % -7.94%
Tripod vs Tab Diff% 1.22%
Act vs Tab diff % -6.63%

Reasons -: Negative Diff value due to manpower returned from lines after punching.

BADVE ENGG. LTD. UNIT - IX TPM – The Way of Life 5 of 27

 AMS TRENDS
Radically different !

20
Actual vs Tripod Diff. %
9.73
10
3
0
0
May June July

10
Tripod vs Tab Diff. %
4.4
2.4
1.02
0
May June July

20
12.5 Actual vs Tab Diff. %
10
3.2
0
0
May June July

BADVE ENGG. LTD. UNIT - IX TPM – The Way of Life 6 of 27

 AMS ACTUAL VS SYSTEM MANDAYS REPORT
Radically different !

1109 July 19 (26.06.19_25.07.19)

Actual 36113
System 35238
Diff 875
Diff % 2.42%

1114 July 19 (26.06.19_25.07.19)

Actual 14464
System 14402
Diff 62
Diff % 0%

1109/1114 July 19 (26.06.19_25.07.19)

Total Diff 937
Diff % 1.85%
Reasons -:
• Quality Man day's working in Bajaj & Ashok :- 285
• Accident Man day's :- 214
• Late Coming & Early out:- 402
• Daily Out in 30 Minutes :-36
BADVE ENGG. LTD. UNIT - IX TPM – The Way of Life 7 of 27
 ACCESS MANAGEMENT SYSTEM MONTH WISE MANDAYS GRAPH
Radically different !

25
Actual Vs System Mandays Diff. %

20

15

12.80

10

5.6
5

1.85
0
May June July

BADVE ENGG. LTD. UNIT - IX TPM – The Way of Life 8 of 27

 PROJECT ANALYSIS
Radically different !

Project Contractor labor System

Online Billing of Contractors

Benefits Real time Repeatability of Contractors

Elimination of Mandays Difference

One day Calculation

Cost Savings Actual Cost :- 588220

System Cost :- 566800
Savings :- 21420

Investment Hardware Cost :- Software Cost :-

Responsibility Sumit

Target Date 14.08.2019

BADVE ENGG. LTD. UNIT - IX TPM – The Way of Life 9 of 27

Radically different !
Digital Audit System

Objective :- Online filling of Check sheets & NC analysis for Quality dept.

Vendor :- NRVDESIGNX PVT LTD

Software name :- Tech files

Current status :- Demo version installed in Rahul Chauhan (Quality)PC.

Feedback from Quality department received Today. Will update

points in system.

Target date :- 03.07.2019

BADVE ENGG. LTD. UNIT - IX TPM – The Way of Life 10 of 27

 Audit App Check sheet Screenshot
Radically different !

BADVE ENGG. LTD. UNIT - IX TPM – The Way of Life 11 of 27

 PROJECT ANALYSIS
Radically different !

Project Digital Audit System

Paper Less Audit

NC details with Defined action & Target date
Benefits
Assigned responsibility on real time basis
Online Communication to HOD's & Plant head

Avg. paper cost per month :-2500

Cost Savings
Time saving

Quality department with 10 check sheets & 50 Users :- Rs 80,000

Investment AMC for cloud & support :- Rs 40,000
Department wise Cost :- Rs 80,000 per department
DK Singh Sir
Responsibility
Sumit

Target Date 06.08.2019

BADVE ENGG. LTD. UNIT - IX TPM – The Way of Life 12 of 27

 Robot Output System
Radically different !

Objective :- To monitored Robot Utilization data, Production data & Machine

Breakdown details.

Vendor :- MOTOMAN

Software/Product name :- Motoman Software

Current status :- Demo software will be installed in System for 100 days.
Capex & Kaizen will be created for System.

Target date :- Will be decided after discussion with Prem Srivastav Sir

BADVE ENGG. LTD. UNIT - IX TPM – The Way of Life 13 of 27

 PROJECT ANALYSIS
Radically different !

Project Robot Output Analysis system

Online Production data

Benefits Robot utilization & parameters

Downtime details & Data analysis

Cost Savings

System (i7,8GB RAM) :- Rs 65,000

Investment
Software from Motoman for 100 days trial.

Sumit
Responsibility
Vishant Rathi

Target Date 20.08.2019

BADVE ENGG. LTD. UNIT - IX TPM – The Way of Life 14 of 27

 Biometric Attendance System for Staffs & Workers
Radically different !

Objective :- Biometric system to be installed in Pantnagar for Employee Attendance.

Vendor :- M-TECH MULTI SERVICES (Aurangabad)

Software/Product name :- N Series Face Device

Current status :- Model and software compatibility finalized with Vendor and
Corporate team. Rate Confirmation also received Today from
Corporate. PO will be process at our end.

Target date :- 20.08.2019

BADVE ENGG. LTD. UNIT - IX TPM – The Way of Life 15 of 27

 PROJECT ANALYSIS
Radically different !

Project Contractor labor System

Face recognition technology

Benefits No false attendance

Online reports and support

Cost Savings

4 Machines :- Rs 40400 (2 for In Entry, 2 for Out Entry)

Investment
Misc :- Rs 2000

Responsibility Sumit

Target Date 18.08.2019

BADVE ENGG. LTD. UNIT - IX TPM – The Way of Life 16 of 27

 MEETING MANAGER SYSTEM
Radically different !

Objective :- Online gate pass for every visitors with photograph to enter in
in Plant premises.

Software/Product name :- Meeting Manager

Current status :- System running.

(System with software installed in main gate area.

Training provided to Guard team & HOD’s.

BADVE ENGG. LTD. UNIT - IX TPM – The Way of Life 17 of 27

 PROJECT ANALYSIS
Radically different !

Project MEETING MANAGER SYSTEM

Entry Gate pass issued to every visitors

Benefits HOD's define their meetings as per their schedule.

Data Base of meeting

Cost Savings

Hardware Cost (3 Core wires, Switch boxes, C clamp) :- Rs 3547

Investment
UPS :- Rs 4000

Responsibility Sumit

BADVE ENGG. LTD. UNIT - IX TPM – The Way of Life 18 of 27

Radically different !

CCTV STATUS

BADVE ENGG. LTD. UNIT - IX TPM – The Way of Life 19 of 27

 CCTV OBJECTIVES
Radically different !

 To do a constant and consistent surveillance on places those need it the most.

 To monitor and control a particular company's production.

BADVE ENGG. LTD. UNIT - IX TPM – The Way of Life 20 of 27

 INSTALLED CAMERA COVERAGE LIST
Radically different !

DVR Area
Plant IP Of DVR Camera No Camera Location Cameras Status
Location Coverage
Camera 1 Silencer Final Assly 10-15 mtr Working
Camera 2 Shot Blasting 10-15 mtr Working
Camera 3 Leakage testing Area 10-15 mtr Working
Camera 4 Silencer CT 100 10-15 mtr Working
Camera 5 Shot Blasting inside 10-15 mtr Working
1109 10.0.9.180 Production 1
Camera 6 Paint Shop area 10-15 mtr Working
Camera 7 Powder Coating 10-15 mtr Working
Camera 8 Silencer K1 10-15 mtr Working
Camera 9 N/A Empty Port
Camera 10 Scrap Yard 10-15 mtr Working
Camera 1 Center Stand line 10-15 mtr Working
Camera 2 Silencer CT 100 Assly 10-15 mtr Working
Camera 3 Old Press shop 1 10-15 mtr Working
Camera 4 Side Stand Line 10-15 mtr Working
Camera 5 Ashok Leyland Line 10-15 mtr Working
1109 10.0.9.181 Production 2 Camera 6 Main Step Line 10-15 mtr Working
Camera 7 Main Step Line 10-15 mtr Working
Camera 8 Brake Lever & Fairing line 10-15 mtr Working
Camera 9 Brake Lever 10-15 mtr Working
Camera 10 Ashok Leyland Line 10-15 mtr Working
Camera 11 Old Press shop 2 10-15 mtr Working

BADVE ENGG. LTD. UNIT - IX TPM – The Way of Life 21 of 27

 INSTALLED CAMERA COVERAGE LIST
Radically different !

DVR Area
Plant IP Of DVR Camera No Camera Location Cameras Status
Location Coverage
Camera 1 Dock Area 10-15 mtr Working
Camera 2 N/A Working
Camera 3 Canteen Towards Unit 14 10-15 mtr Working
Camera 4 N/A Empty Port
Camera 5 Scrap Yard 10-15 mtr Working
1109 10.0.9.182 New Press shop Camera 6 Scrap Yard 10-15 mtr Working
Camera 7 Gate 3 10-15 mtr Working
Camera 8 Material Unloadind area 10-15 mtr Working
Camera 9 New Press shop 10-15 mtr Working
Camera 10 Trolley Maintenance 10-15 mtr Working
Camera 11 Canteen 1 10-15 mtr Working
Camera 12 Canteen 2 10-15 mtr Working
Camera 1 Final Assly 10-15 mtr Working
Camera 2 Material Gate 10-15 mtr Working
Camera 3 Entrance Of unit 9 10-15 mtr Working
Camera 4 Silencer final Assly 10-15 mtr Working
Camera 5 Dispatch Area 10-15 mtr Working
Maintenance
1109 10.0.9.183 Camera 6 Packaging Zone 10-15 mtr Working
Office
Camera 7 Unit 9 Store 1 10-15 mtr Working
Camera 8 Unit 9 Store 2 10-15 mtr Working
Camera 9 Powder coating loading 10-15 mtr Working
Camera 10 Trolley Maintenance 10-15 mtr Working
Camera 11 Admin Office 10-15 mtr Working

BADVE ENGG. LTD. UNIT - IX TPM – The Way of Life 22 of 27

 INSTALLED CAMERA COVERAGE LIST
Radically different !

IP Of Area
Plant DVR Location Camera No Camera Location Cameras Status
DVR Coverage
Camera 1 Store 14 Entrance 10-15 mtr Working
Camera 2 Car Parking Area 10-15 mtr Working
Camera 3 Stripping Area 10-15 mtr Working
1114 10.0.9.184 Store Unit-14 Camera 4 Notching area 10-15 mtr Working
Camera 5 Notching area 10-15 mtr Working
Camera 6 Dock Area of Unit 14 10-15 mtr Working
Camera 7 Store 14 Fist floor 10-15 mtr Working
Camera 1 SPD packaging area 10-15 mtr Working
Camera 2 Paintshop Lab 10-15 mtr Working
Camera 3 Emp Gate 10-15 mtr Working
Camera 4 PTZ Unit 14 360° Working
Camera 5 Dispatch Unit 14 10-15 mtr Working
1114 10.0.9.185 Dispatch Unit 14
Camera 6 Conveyer loading area 10-15 mtr Working
Camera 7 FG area Unit 14 10-15 mtr Working
Camera 8 ACED FG area 10-15 mtr Working
Camera 9 Conveyer loading area 10-15 mtr Working
Camera 10 Ashok Leyland Assly. 10-15 mtr Working
Camera 1 Tripod 1 15-20 mtr Working
1114 10.0.9.187 Tripod Area Camera 2 Tripod 2 15-20 mtr Working
Camera 3 Tripod 3 15-20 mtr Working

BADVE ENGG. LTD. UNIT - IX TPM – The Way of Life 23 of 27

 INSTALLED CAMERA WORKING STATUS
Radically different !

Sr.
No. Total Installed Cameras Total working Cameras Total not working
1 62 62 0

Not working cameras details with target date

Sr. Affected Action to be Target

No. Problem in Cameras cameras Taken Status Date

No Issue
2

BADVE ENGG. LTD. UNIT - IX TPM – The Way of Life 24 of 27

 NEW REQUCCTV CAMERAS INSTALLATION EST LIST
Radically different !

Camera No. of
Sr. N. Camera Location DVR Location Requested By
Type cameras
1 Plant boundary IT (NVR to be installed ) PTZ 1 Mr. LD Kandpal
2 Plant boundary IT Night vision 10 Mr. LD Kandpal
3 LBG, plant 14 inside Dispatch 14 Dome 3 Mr. GS Agarwal
4 Scrap yard(1109) Press shop Dome 2 Mr. Virendra (PPC)
5 Tool Room Production office Dome 2 Mr. RKC
6 Powder coating Production office Dome 3 Mr. GS Agarwal
7 Conveyor loading Production office Dome 1 Mr. GS Agarwal
8 Kit Bin Assembly Maintenance office Dome 2 Mr. GS Agarwal
9 Silencer final asly Maintenance office Dome 2 Mr. Rajesh Maind

Budget :- 6-7 lacs

Status : - Got Quotation from existing vendor

Comparing with another supplier for best pricing

Target date :- 03.08.2019

BADVE ENGG. LTD. UNIT - IX TPM – The Way of Life 25 of 27

 SURVEILLANCE ACTION REPORT SCREENSHOT
Radically different !

BADVE ENGG. LTD. UNIT - IX TPM – The Way of Life 26 of 27

 PROJECT ANALYSIS
Radically different !

Project New CCTV Cameras Installation

Total outer area under surveillance

Benefits Online monitoring

Report Generation & Data base

No manpower required for Plant Premises Security

Cost Savings
No extra system required for surveillance

Investment Panel boxes (20 pieces) :- Rs 90,000

Responsibility Sumit

Target Date 14.08.2019

BADVE ENGG. LTD. UNIT - IX TPM – The Way of Life 27 of 27

 PDI SYSTEM IN SAP
Radically different !

Objective :- Zero Customer Complain.

Software/Product name :- SAP

Current status :- Master Updation in Development Server

Quality Parameters material wise required from Quality Dept.

Matter is discussed with Mr. DK Singh

Target date :- 07.08.2019

BADVE ENGG. LTD. UNIT - IX TPM – The Way of Life 28 of 27

 PROJECT ANALYSIS
Radically different !

Project PDI system in SAP

Benefits

Cost Savings

Investment

Responsibility DK Singh sir

Target Date

BADVE ENGG. LTD. UNIT - IX TPM – The Way of Life 29 of 27

 ONLINE PRODUCTION CONFIRMATION THROUGH IT GUN
Radically different !

Objective :- Online Production Confirmation

Software/Product name :- SAP

Current status :- Under Discussion

Target date :-

BADVE ENGG. LTD. UNIT - IX TPM – The Way of Life 30 of 27

 PROJECT ANALYSIS
Radically different !

Project ONLINE PRODUCTION CONFIRMATION THROUGH IT GUN

Benefits

Cost Savings

Investment

Responsibility

Target Date

BADVE ENGG. LTD. UNIT - IX TPM – The Way of Life 31 of 27

Radically different !

BADVE ENGG. LTD. UNIT - IX TPM – The Way of Life 32 of 27

Radically different !

26 June 19- 26 July 19 1109 1114

Mandays Cost Mandays Cost
Actual Mandays 36113 15167460 14464 6074880
System Mandays 35238 14799960 14402 6048840
Savings (in Rs) 367500 26040
Total savings (in Rs) 393540

BADVE ENGG. LTD. UNIT - IX TPM – The Way of Life 33 of 27