The document outlines the process flow for product design and development at STUL, including: 1. The key steps in the process from receiving a customer enquiry to production planning. This includes activities like developing specifications, costing, negotiations, order booking, design development, programming, and planning production. 2. The roles and responsibilities of the proposed design department teams for handling different types and categories of orders like regular non-standard products, door products, and R&D jobs. 3. Estimated timelines for design and development activities for different product varieties, from initial study to programming and folder preparation. Timelines range from around 8-24 days depending on the product complexity and variety.

1. Process Flow for STUL
Abbreviations – S.O. = Sales Order , P.O. = Purchase Order, S.O.W. = Scope of Work, BOM = Bill of Material , MOM = Minutes of Meeting
Enquiry From
Customer
Study of the product
/BOM & Give offer
Negotiation &
Receive order
Clear Input
specification and
process planning
Book Sales Order
and Prod. Plan with
proper Del. Sch.
Input – Customer
Enquiry Letter, Std
Enquiry form,
Specification sheets,
Drawings, Product
Description / detail,
Sample
Process – Response to
customer, meeting &
discussions, understand
requirement
Output – Preliminary
specifications & sketches
Resp. – CDS / RDS
Mktg - Doors
AS – Non-doors
Input – Preliminary
specifications, sketches,
Specification sheets,
Drawings, Sample,
Customer’s feed back
Process – Prepare
preliminary BOM,
Consumable List,
Bought out List,
Estimate of Production
Time, Tooling
requirements, equipment
list, resource planning &
Sample production
Output – Estimating /
costing sheet, Minimum
price calculations,
Quotation
Resp. – CDS / RDS
Mktg - Clarifications
AS – Process (Design)
MKF – Process (Pricing)
Chandrika - Records
Input – Quotation,
Estimation / costing
sheet, Minimum price
calculations, Customers
feed back
Process – Negotiations,
recalculations,
corrections, Final
quotation
Output – Purchase order
from customer,
specifications freezing,
Terms Freezing
Resp. –
Mktg / CDS / RDS –
Negotiation &
Finalization
AS – Design Input &
Process
Input – S.O., P.O.,
Freezed specifications,
MOM, SOW, Drawings,
Samples, sketches,
customer’s change note
Process – Modeling,
Development Drawing,
clarification from
customer, Process
planning, MRP / BOM
preparation, NCT
Listing, Programming,
Change note, all
modifications
Output – Folder, MRP
updation, CNC
Programme, Process
sheet, Specification sheet
Resp. – AS / Laxmi /
Sameer / Design Team
Input – CNC
Programme Folder, MRP
Entries,
Process – Production
Planning, Material
Planning, Vendor
Planning, Purchase
Planning, Resource
Scheduling & Loading,
Dispatch planning
Output – Delivery Plan,
Work Orders, Purchase
Orders,
Resp. – PPC / AS /
Purchase

2. Activities of Design Department – Order, Type & Category
Input – Actual scenario
at Shop Floor / QC
reports / Scrap & Sheet
details, Part details
Process – Change /
corrections /
modification in
programme, verification
Output – Programme
Resp. – Ajay / Jiten /
Anuradha
Y01 Type Orders
Only – “B” Category
(Non-Doors)
ISO / Quality
Requirements
Programme Change /
Modifications
Y02 Type Orders
(Doors)
Input – S.O., P.O.,
Freezed specifications,
MOM, SOW, Drgs,
Samples, sketches,
customer’s change note
Process – Modeling,
Development Drawing,
clarification from
customer, Process
planning, MRP / BOM
preparation, NCT
Listing, Programming,
Change note, all
modifications
Output – Folder, MRP
updation, CNC
Programme, Process
sheet, Specification sheet
Resp. – AS / Laxmi /
Sonawane / Anuradha
Input – S.O., P.O.,
Freezed specifications,
MOM, SOW, Drgs,
Samples, sketches,
customer’s change note
Process – Modeling,
Development Drawing,
clarification from
customer, Process
planning, MRP / BOM
preparation, NCT
Listing, Programming,
Change note, all
modifications,
Standardization
Output – Folder, MRP
updation, CNC
Programme, Process
sheet, Specification sheet
Resp. – AS / Sameer /
Ajay / Jiten
Input – Data, MOM,
Specification Sheets,
Drgs, QC Reports,
Procedures
Process – Report
preparation, Filling,
Maintaining, verification
Output – Reports,
formats, feedbacks
Resp. – AS / Laxmi
ERP Requirements
Input – Data, MOM,
Specification Sheets,
Drgs, Part / Assly
details, Process Planning
Process – Report
preparation, Filling,
Maintaining, verification
Output – Reports,
formats, feedbacks,
System Updation
Resp. – AS / Sameer

3. Team – I Team – II Team – III
Design Department (Proposed)
Vacant
Design Officer
Modeling
Programming
Lakshminarayana
Design Officer
Non Std (Regular Party)
ISO
Anuradha
Design Officer
Modeling
Programming
Sameer
Executive - Planning
Doors
ERP
Ajay
Design Executive
Doors
Programming
Sonawane
Design Engineer
R & D / Non routine
Modeling / Drafting
Jiten
Non Routine / R & D
Programming
Amitabh Shrivastava
Sr. Manager - Engineering

4. Responsibilities of Teams
Team – I
Members – Lakshmi / Vacant / Anuradha
1) Regular Customer’s Non Standard Y01 Type “B” Category orders
2) Study all relevant data
3) Clarifications from customer
4) Process Planning
5) Generation of Item Code
6) Making Standard BOM
7) Making Annexure
8) Modeling
9) Drafting
10) Execution & Problem Solving
11) Programming
12) Nesting / CAMing
13) ISO Activities
14) Folder Preparation
15) Change Note implementation
16) Updating old documents & programme
Etc
Team – II
Members – Sameer / Ajay
1) All Customer’s Y02 Type orders
2) Study all relevant data
3) Clarifications from customer
4) Process Planning
5) Generation of Item Code
6) Making Standard BOM
7) Making Annexure
8) Modeling
9) Drafting
10) Execution & Problem Solving
11) Programming
12) Nesting / CAMing
13) ERP Activities
14) Folder Preparation
15) Change Note implementation
16) Standardization
17) Updating old documents & programme
Etc
Team – III
Members – Sonawane / Jiten
1) All Customer’s R&D Job orders
2) Study all relevant data
3) Clarifications from customer
4) Generation of Item Code
5) Making Annexure
6) Modeling
7) Drafting
8) Process Planning
9) Execution & Problem Solving
10) Tooling
11) Programming
12) Nesting / CAMing
13) Folder Preparation
14) Shop Floor problems regarding Programming
15) Scrap Layout
16) Modifications / Validation of Prototype
17) Any other non routine jobs
Etc

5. Expected Time for Design & Development Activities
Variety – I: Multi Product variant having more than 75 parts for in-house manufacturing
Variety – II: Single Product having 30 to 75 parts for in-house manufacturing
Variety – III: Single product having less than 30 parts for in-house manufacturing
Ratio of conventional to NCT Parts: 1:2 (assumed)
Sr.
No.
Activity Variety (Time in days) Remarks
I II III
Team – I: Y01 Type orders “B” Category
01 Study all relevant data 2 1.5 1
02 Clarification list 0.5 0.25 0.25
03 Get all clarifications 1 1 1 Dependant on
customer’s response
04 Process Planning 3 2 1
05 Generation of Item Codes, Making
Standard BOM, Making Annexure
2 1.5 1
06 Modeling & Drafting 7 3 1.5
07 Nesting / Caming / Programming 5 2 1
08 Folder Preparation 2 1 1
09 Execution & Problem Solving As and when required
10 Change note implementation 2 1 1 --Do--
11 ISO Activities --Do--
12 Update old documents &
programming
--Do--
13 Any other work assigned --Do--
Total 24.5 12.25 7.75
Team – II: Y02 type orders
01 Study all relevant data 2 1 0.5
02 Clarification list 0.5 0.25 0.25
03 Get all clarifications 2 1 1 Dependant on
response from Sales /
Customer
04 Process Planning 1 0.5 0.5 Only editing
05 Generation of Item Codes, Making
Standard BOM, Making Annexure
2 1 1
06 Modeling & Drafting 3 2 1 If required
07 Nesting / Caming / Programming 4 2 1
08 Folder Preparation 2 1 1
09 Execution & Problem Solving As and when required
10 Change note implementation 2 1 1 --Do--
11 ERP Activities --Do--
12 Update old documents &
programming
--Do--
13 Standardization --Do--
14 Any other work assigned --Do--
Total 18.5 9.75 7.25
Team – III: R&D Job orders
01 Study all relevant data 3 2 1
02 Clarification list 1 0.5 0.25
03 Get all clarifications 3 2 1 Dependant on
response from Sales /
Customer
04 Conceptualizing & Designing 5 3 2 If required
05 Process Planning 4 2 1
06 Tooling 5 3 2 If required

6. Sr.
No.
Activity Variety (Time in days) Remarks
I II III
07 Generation of Item Codes, Making
Annexure
2 1 1
08 Modeling & Drafting 7 4 2
09 Nesting / Caming / Programming 5 2 1
10 Folder Preparation 2 1 1
11 Prototype building 10 7 4 If required
12 Execution & Problem Solving
13 Validation & Modification of
Prototype
4 3 2
14 Standard scrap layout planning 2 1 1
15 Shop Floor Problems regarding
programming
As and when required
16 Non routine jobs – in-house
requirements
As and when required
17 Standardization If required
18 Any other work assigned As and when required
Total 53 30.5 19.25
Notes –
1. Time shown is purely estimated and should be compared with present averages.
2. Monthly review and modifications are to be done for finalization (at least for 3months).
3. Output of teams are greatly dependent on procedural delays, frequency of priority change,
sales / customer’s response and co-operation of other departments.
4. Rather fixing Design Project timing in this manner, we must opt for pessimistic, optimistic &
most likely timings.
5. Detailed study of elements may give further clear picture and perfect timing.
6. Your suggestions & comments are welcomed.