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Summer internship projectCarried out in JSW
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Special Thanks To
Mr. Manoj Kumar Jha (costingmanager)
Mr. Nitin Tekade (HR Head)Mr. Sanjay Swami( ppc incharge)Mr. Rahgunath Dhumal( S.P.T)
Mr. Pravin naulakiya(techn.)
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Introduction
Company name : JSWProject Topic : optimization of
production cycle time for the productG I, GL , PPG I, PPGL.Under the guidance of Mr. Manojkumar Jha.
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Steel industry profile
100 years old6th largest producer of iron ore in
worldCapacity (124 ml tonnes 2012 < 275ml tonnes 2020 ).
Capital investment 100000 cr.Employment for 2 million people.
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Ab out JSW
Founder 1952
1982 - vasind plant1983 - Tarapur plant1994 - Vijaynagar plant
InvestmentProducts
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important break troughs
Indias only fully integrated stainless steelplantIndias only integrated private sector galvanized steel producer Indias only diameter su b merged A rcwelded steel pipes
World standard sponge ironIndias only integrated green-field steelproject.
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COLOR CO A TING PRODUCT ION PROCESS
COLOUR CO ATING
G A LV A NS ING
ROLL ING
P ICKLING
SL ITTING
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P roduction cycle
1Sale order received from marketing dept.analysis of order
2order ganerated in oracle softwareorder sign b y production/QC dept.
3spec release ( technical specification)
4H.R processing
5 G.L. finishing
6dispatch
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Expected time required for each stage
receivingorders , 1 day
order ganerating ,
1 day
spec
release ,1 day
H.Rprocessing ,
2 day
G. L.finishing ,
1 day
dispatch ,1 day
Ex pected time required for each process
receiving ordersorder ganeratingspec releaseH.R processingG. L. finishingdispatch
Total days required for production ( appx.) = 7 days.
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ANALYSIS OF DATA
PROCESS(including all) STANDERD TIME ACTUAL DATESales Order Received ------ 25th April 2011Order Generated In
Oracle Software
1 day 25th April 2011
Spec released. 1 day 26th April 2011Slitting 1 day 20th may 2011Pickling day 21th may 2011
Rolling day 23rd
may 2011Galvanizing day 31st may 2011Colour Coating day 31st may 2011Dispatch 2nd june 2011
Order no. 5024
Volume :- 100 tones
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Order no. 5024
Processing stage Cost at thestage
Time lag inprocess
Calculation Amount
Slitting 35000 24 days. 35000*10%*24/365 230.1Rolling 38000 1 days 38000*10%*1/365 1.12Galvanizing 50000 5 days 50000*10%*5/365 68.49Colour coating 58000 - 90000*10%*0/365 0Dispatch 60000 - 95000*10%*0/365 0
Total 309.74
C ost saving after C ost saving after optimization production time.optimization production time.
C ost saving for whole order
= 309.74*150
= 30974 rs
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A ll orders in b rief O rder no. Standard
timeActualtime
volume C ost saving /tonne
Total C ostsaving
5024 7 days 37 days 100 tonnes 309.74 rs 30974 rs
5049 12-15 days 27 days 624 tonnes 109.58 rs. 68377 rs
5065 11 days 13 days 175 tonnes 41.095 rs 7192 rs5074 7-9 days 17 days 155 tonnes 68.49 rs 10616 rs
5030 10-11 days 38 days 150 tonnes 309.74 46461 rs
Total. 1204 tonnes 163162 rs
Y early production = 500000 Y early production = 500000 tonnestonnes. .
Approximately saving per year = 163162 * 500000 / 1204Approximately saving per year = 163162 * 500000 / 1204
= 6,77,58,305= 6,77,58,305 rsrs
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Recommendation.C ompany can reduce scrap collecting time. i.e. 20-30min by 5-10 min.By reducing fault in machineries by way of maintenanceand repairs of machineries from time to time.
The inventory should transfer to the ne x t processwithout halt.The firm must use J-I-T inventory control tenchnique inproduction to minimize production process time.The technical specification(spec) should not be lated.
Their must appropriate link e x ist between all departmentinclude marketing, PP C , costing.
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TH A NK U
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