2. Work Experience Summer 2013
Karambir Sidhu Work Experience 16th
July 2013
•I am presenting what I have learned over the last few weeks and how I can use
it at university and when I graduate.
3. Induction- Health and Safety
•Personal Protection Equipment
–Protects
•Eyes
•Feet
•Ears
•Hands
•If in doubt ASK!
•If anything is faulty, REPORT IT!
•When an accident occurs always GUARD, PLAN, ACTION
4. Commercial Overview
•Sales- Most important feature is relationship between clients, buyers, sellers
etc.
•Make a good first impression
•The hardest part is to build a good relationship with the client.
•Steel Market is always changing and firms need to adapt to this change.
5. Buying
• Purchases are controlled by the factory master system.
• Everything works on a 5 week plan
– 5 Weeks are used as a compromise between building stock and making a quick profit
• Week 1- Admin week to suggest what needs to be bought, cut etc.
• Week 2- The parts are readied
• Week 3- Processing e.g. bending, chamfering etc.
• Week 4- Assembly takes place with a final check on the final product
• Week 5- Delivery
• From here Nick receives the suggestions for manufacturing and purchasing.
6. Buying Continued
• Most important tab in FM is stock tab, everything is stored here.
• Orders:
- Normal orders are kept on the system, the procedure starts with an MRP, a purchase
order is created, order is then sent to supplier and a confirmation of delivery is
requested
- Abnormal orders e.g. for transport a transport supplier is contacted, or for tooling the
tooling supplier is contacted and the order is manually raised.
• Once order is confirmed in full, it can be registered on the system
• Audits are stamped to confirm delivery, inspection and FM registration
7. Suppliers
• Suppliers need to be approved by the purchasing dept.
• A Supplier approval document is sent to them.
• If the criteria is met they get approved.
• Quality and punctuality are key factors which are measured
8. Manufacturing
• Everything is a work in progress.
• Weeks 1-5 occur simultaneously for different products.
• Longer lead times are used to build up stock.
• EBQs are used to reduce average costs and manufacturing time in long
run.
9. Machine Shop Overview
• Customers send the orders which are put into the system to upload a
schedule
• We run a MRP, work to list produces dates and breaks the product
down.
• Route cards are used to keep control of stock.
• Movement notes make a note of transported stock.
• Faulty parts are quarantined.
10. Adding Parts to FM
• Piece parts and assemblies are put onto the ERP system
• We can add routes, and details on how much stock we need to bring in
• From here we can add their drawings.
• Everything is now in one location.
11. Quality Control
• Judgment is used to remove any faulty parts.
• Shop floor quality control involves checking to see:
if machines are correct
whether instruments are being used properly etc.
• Back room staff quality control has:
a quality manager
a quality engineer
an inspector who is in charge of everything on the shop floor, he arranges the checks
and the order of them.
• The Quality Manager is in charge of everything quality related and is
responsible for regulatory. He has sole responsibility for everything ISO.
• The Quality Engineer is more systems based, he makes the system
more streamlined and removes any unnecessary processes.
12. Advanced Quality Systems
• One person enforces the quality manual.
• Only need to demonstrate these points.
• Scope and exclusions outline responsibilities and chain of command.
• The Business Process Model shows the main points of the quality manual.
13. Costing Customer Enquiries
• Drawings are sent from various customers and are sent to Ian.
• Drawings are used to:
– see how the product can be made.
– estimate how long it will take to produce a certain part
– estimate how much it will cost to make.
• In some cases we may need to hire a subcontractor to carry out the work for
us.
14. Production Meetings
• Production meetings are carried out everyday to discuss the fabrication
shop, the machine shop, the cutting shop and the customer issues.
• Anything in the red column is late, which must be minimised as much as
possible.
• Progress sheets are sent to customers to keep them in the loop.
Boris Johnson?
15. Standard Operating Procedure
• SOP is used to show us which PPE is required for the job, along with a list
of parts
• It is designed to standardise the build
• The format for all SOPs is the same
• Each sheet it shows how to set up the equipment with the help of diagrams.
• Both the worker and the supervisor need to sign it to say they are both
happy with it.
• Plate usage is maximised by nesting, a nest sheet contains:
– A part number on each part which tells you what you are cutting.
– A profile sheet which shows all the part numbers on the nest, and their quantities
16. Risk Assessment
• Involves identifying risks and minimising them.
• For similar cases one assessment will be sufficient.
• Score threats out of 10.
• Score likelihood out of 10 and multiply by threat score.
• 1-19 is low, 20-49 is medium, 50-100 is high.
• When complete Phil signs the risk assessment it is laminated and put on the
SOP.
17. Machines
• Majority of machines are fully automated. University ones aren’t.
• Different machines are used for different situations
– Smaller machines e.g. Dahlih are used for small, easy to make parts
– Larger machines e.g. Soraluce are used for chassis
• Each machines comes with a set up sheet with written instruction and diagrams.
• Supervisors perform a first off and a last off.
18. Plasma and Gas Cutting
• Plasma tends to be cheaper than gas as it:
– Cuts quicker
– Can cut more parts in total
• Plasma is easier to dress, whereas the gas cutter require intensive grinding.
• Gas uses more heat than plasma and tends to distort the sheet, makes it
harder.
• Gas gives a more square cut than plasma.
19. Conclusion
• Over the last 2-3 weeks I have gained:
– a lot of knowledge about how businesses work
– how what I have learned from University can be applied to the real world
– I would like to thank you all for giving me the opportunity to work here and for welcoming me
into the company and making me feel like one of you.
• Thank you for listening and if there are any question I would be happy to
answer them.
