Foundry Projects

Proposed Projects : Yield improvement

Scheduled
Present Planned Details
PART NAME cost
Yield Yield Nov 16 Dec 16 Jan 17 Feb 17 Mar 17 attache
benefit
d

Fork 35% 65%

(single row) (Multiple stack)

Bearing Cap 39% 56% (8

(6 cavity) cavity)

Locking
45% 72%
gage
 Foundry Projects
Proposed Projects : Energy savings
Scheduled
Present Planne cost Details
PART NAME Nov Dec Jan Feb Mar
units/day d benefi attache
16 16 17 17 17 t d

HT elimination on
cam shaft
450 nil
Compressed air –
separate line
620 360
Melting power per
kg
2.9 2.1
 Foundry Projects
Proposed Projects : Manpower reduction
Present Scheduled
PART NAME man Planned cost Details
Dec Jan Feb Mar
days Nov 16 benefi attache
16 17 17 17 t d

HT elimination of
6 / day nil
cam shaft
Fettling elimination
2 / day 0.5/day
on forks
Fettling elimination
10/day 2/day
on cam shaft
 Foundry Projects : COMPLETED
Yield Improvements Part Name : Shift linkage W 201 from 6 Cavity to 9 Cavity

Before Cavities RM Con Co roll Contr Power Maint Packing Total

Last year
9 20.85 8.43 8.43 10.83 17.80 1.89 0.05 68.26
COP Rs.
67.63
6 20.85 9.27 9.27 11.91 19.58 2.08 0.05 73.00

6 Cavities Savings :
AFTER Cost per part : Rs 4.74
Annual Production : 36000 Numbers
Present (Present)
COP Rs.
68.26 Annual Savings : Rs 1.61 Lacs

Status : Implemented, Date : 01.04.16

9 Cavities
 Rejection Reduction - HDS 30 Outlet

Defects : Internal Shrinkage & Blow / gas trapping April May June July August Sep
Produced No prod 892 344 360 592 No prod
Rej 292 94 236 103
% Rej 32.8 27.4 65.6 17.5
Cost of Rej. 0 68467 22041 55336 24151 0

Before
Produced in H1 ( May- Aug ) : 1236 Nos
Rejection in H1 ( May-Aug ) : 386 Nos
% Rej. in H1 ( May-Aug ) : 30.1 %
Rejection cost in H1 : 0.91 Lacs

After
ACTION TAKEN Produced : 952 Nos
Rejection : 339 Nos
1. DOUBLE INGATE 10X15 MM PROVIDED AT OPPOSITE SIDE OF % Rejection : 35.6 %
EXISTING GATE TO MAKE CONNECTION DIRECTLY TO HOT SPOT AREA Rejection cost : 0.79 Lacs
OF CASTING

2. CORE DRILLING DONE IN ALL THREE PRINTS TO RELEASE GAS FROM

CORE
Annual Requirement : 3600 Nos
3.PRINT AREA INCREASED BY 10 MM IN CORE BOX AND PATTERN Savings :
TOOLING TO RELEASE GAS FROM CORE
Q2 ( Jul-Sep) : No saving ( Rej increased )
If rejection controlled with in 5 %
Annual Savings : Rs 2.12 Lacs
Status : Implemented : 11 Aug’16
 IMPROVEMENT PROJECTS SUMMARY
APR’16 – SEP’16
SECTION PROJECT DESCRIPTION BENIFITS COST SAVING IMPLEMENTED FROM YEARLY
SAVING
 REJECTION & COST SAVING SUMMARY
PART NAME IMPROVEMENT DETAIL YEARLY REQ. IMPLEMEN COST
TATION SAVING /
FROM YEAR

TOTAL COST SAVING / YEAR 20.45 LACS / YEAR

 FUTURE PLAN - IMPROVEMENT PROJECTS SUMMARY

SECTION PROJECT DESCRIPTION BENIFITS COST SAVING TARGET REMARK

DATE