1. B.E Project
Tool management system solution
Labade Saurabh Vikas (B80420802)
Shewale Nikhil Subhash (B80420808)
Guided By:-
Prof. M.S.Rohokale
2. Mahindra Group is among the top 10 industrial houses in India. Mahindra & Mahindra,
the US $6.7 billion is the only Indian company among the top tractor brands in the
world. Mahindra’s Farm Equipment Sector has won the Japan Quality Medal, the only
tractor company worldwide to be bestowed this honor. It also holds the distinction of
being the only tractor company worldwide to win the Deming Prize. Mahindra is the
market leader in multi-utility vehicles in India. It made a milestone entry into the
passenger car segment with the Logan.
The Group has a leading presence in key sectors of the Indian economy,
including the financial services, trade and logistics, automotive components,
information technology, after-market and infrastructure development.
With over 64 years of manufacturing experience, the Mahindra Group has built
a strong base in technology, engineering, marketing and distribution which are keys to
its evolution as a customer-centric organization. The Group employs over 50,000
people and has several state-of-the-art facilities in India and overseas.
COMPANY PROFILE
THE MAHINDRA GROUP – An Overview
3. The Mahindra Group has ambitious global aspirations and has a presence on
five continents. Mahindra products are today available on every continent except
Antarctica. M&M has one tractor manufacturing plant in China, three assembly plants in
the United States and one at Brisbane, Australia. It has made strategic acquisitions
across the globe including Stokes Forgings (UK), Jeco Holding AG (Germany) and
Schoneweiss & Co GmbH (Germany). Its global subsidiaries include Mahindra Europe
Srl. based in Italy, Mahindra USA Inc. and Mahindra South Africa.
M&M has entered into partnerships with international companies like Renault
SA, France, and International Truck and Engine Corporation, USA. The US based
Reputation Institute ranked Mahindra among the top 10 Indian companies in its ‘Global
2000: The World’s Best Corporate Reputations’ list.
4. ABSTRACT
This work has been carried out for the purpose of improving productivity and
effectiveness of system for the integrated management of tools within a company, By
integrating planning, inspection and tool-room functions, automated tool management can
ensure optimum utilization of tools and manpower on the selected machines, guaranteeing
their effective outcome.
The first stage of the work consisted of defining and developing a Tool Management
System whose central nucleus is a unified Data Base for all of the tools, forming part of the
company's Technological Files (files on machines, materials, equipment, methods, etc.),
interfacial with all of the company departments that require information on tools.
The top management team comments and recomends us various improvement factor
and possiblities to achive the desired goal. Again the corrective action is taken for
improvement and the new set goal are again to be achived.
5. Problem definition
Developing work instructions and guidelines for processes and controlling
minimum inventory requirement for proper management in tooling department.
Joint venture of Mahindra and Navistar ended in July 2013, so by change of the
policies the tool engineering department immerged out as an independent
department from the production department.
So to regulate its proper functioning there was need of developing work
instructions and guidelines for processes and controlling minimum inventory
requirement for proper management.
So as per the increasing need of the production there is need for optimum work
output required from individual at grass root level, so as to satisfy the customer
demand.
6. OBJECTIVES
Proper management of all processes involved under tool engineering department.
Reduce training period for new associate and improve their skill utilization.
To reduce the downtime on production line due to improper tool management.
Improvement in performance of the production System.
High levels of machine utilization.
Optimum tool selection for fine finished product.
Reduction in variety and number of tools used.
Optimized industrial purchasing
Supplying tools to machines at proper time with proper pre-setting and regulated
backup of spare tool.
7. LITERATURE SURVEY
TOOL MANAGEMENT
• Tool management is needed in metal working so that the information regarding the
tools on hand can be uniformly organized and integrated
• Tool management is divided into documentation (master data) and logistics
(transaction data). The documentation includes information needed for a trouble-free
and a comprehensible production process. Logistics deals with demand planning,
supplies and tool location. This includes, on one hand, the location in the warehouse
and the purchasing of individual parts with the corresponding consumption report.
The Tool Management System divides tool room functions into the following sections:
• Data Management.
• Reports.
• Imports of data from remote bar code scanning devices.
• Input, process & posting tool room usage transactions.
9. Design, CAD: Design of tools required in production are provided by manufacturing
engineering department.
Purchasing, warehousing: The required tools are purchased from the selected vendors and
stored in ware house
Tool assembly/disassembly: The tools bought may be either assembled or separate
components so they are stored as per in the requirement.
Inspection, presetting, measuring: Whenever the tool is needed for production then it is
inspected and presetting is done as per the required measures and then allowed for
production.
Production: The tool is utilized on the production line and its various parameters are
monitored so to improve its performance.
Tool repairs: once the tool life is done of the used tool it is again inspected and further
processed for reshaping.
Quality assurance: The tool is send to respective vendor for the reshaping process and then,
while it is again being added to inventory it is goes through quality assurances.
Incoming goods/ outgoing goods: All this trafficking of the tool is monitored and various
procedures are followed as per the norms.
Controlling/ management: The governing staff for the various processes has a control over
the processes, so as to develop optimum menagerie solution.
Work preparation, CAM: Thus all the above processes are computerized and making the
tasks more easy and work efficient.
10. METHODOLOGY
The Tool Management System divides tool room functions into the following sections:
• Data Management
• Reports
• Imports of data from remote bar code scanning devices
• Input, process & posting tool room usage transactions:
Important Key Factors to Be Followed While Designing TMS Solution:-
When designing the tool management system, one should consider the following steps:
Collect all current and possible future user and system requirements.
Analyze the system ( i.e. the data processing and the systems hardware and software
constraints)
Design an appropriate data structure and data base for describing tools and then
Specify, and design programs that are capable of accessing this data base as well as
communicating with the real time production planning and controlling system.
11. Tooling data in tool management system, typically going to be used by several
subsystems, as well as human beings. These are as follows:-
• The production planning subsystem.
• Process control.
• Part programming.
• Tool preset and tool maintenance.
• Tool assembly (manual or automated).
• Stock control and material storage.
12. Main sections of tool management and planning:-
1. Tooling Planning and Management .
2. Fixture Management .
3. SAP work instructions.
4. Skill evaluation and skill matrix with standard
deviation.
14. Tool management and planning involves following process:-
1. Current Tool Modification Management.
2.New Machine and Tool Introduction/Change.
3.Tool Re-sharpening.
4.Tool Presetting.
5.In and Out flow of tools.
6.MPCR (Manufacturing Process Change Request).
7.Defining the tool life.
8.Training and Skill Monitoring.
9.Tool Cost Monitoring.
10.Inventory Monitoring.
11.Tool Traceability and Codification.
12.RGP process.
15. Daily inspection: -
Collection of Worn out
tools from manufacturing
production (14.1)
TCF data verification (14.2)
Start
Tool presetting activity (14.3)
Tool presetting for machining
inserts
Tool presetting for machining
tool
Checking on ZOLLER presetting machine
Tool Inspection (14.5)
AA
General Flow of the activity – Tool
Presetting
A
17. Fixture management involves following process:-
1.Preventive maintenance and verification of Fixture.
2. Break Down maintenance of Fixture.
3. Fixture modification management.
18. Spare
fixture
used..?
Fixture Break
down
Start
Breakdown notice
Action for Fixture
Maintenance
Procurement &
maintenance of MSL
Critical spare
identification and
MSL maintenance
No
Yes
History card up-gradation
End
Rework
.General Flow of the activity –
Break Down maintenance of Fixture:
19. SAP work instructions INVOLVES FOLLOWING PROCESSES:-
1. Work Instruction for Consumable items pick up from SAP.
2. Work Instruction for quality inspection in SAP.
3. Work Instruction for vendor line item display and payment history from
SAP.
4. Work Instruction for PR creation in SAP.
5. Work Instruction for Production booking and stock check in SAP.
6. Work from PO-order by material in SAP.
7. Work Instruction for tool consumption in SAP.
8. Work Instruction for tool cost in SAP.
SAP:-It stands for systems , applications and products in data processing . It means for
planning resources in an organization.
21. Skill matrix:
“Skills management is the practice of understanding, developing and deploying people and
their skills. Well-implemented skills management should identify the skills that job roles
require, the skills of individual employees, and any gap between the two.”
It is an integral part of our Visual Management System (VMS).
• It is a simple visual tool to aid in the management, control & monitoring of skill levels.
• It displays all tasks & skills required to work in an area or team.
• It displays all current team members.
• For each team member it displays current competency/ability levels for each task.
• It is a simple tool to aid resource planning.
Skill level indicators for the associates work evaluation:-
Training for level 1 Training for level 2 Training for level 3 Training for level 4
Untrained
( I don't know)
Level - 1
( I know & work
with Assistance)
Level - 2
( I know & work
without Assistance)
Level - 3
( I can Do )
Level - 4
( I can Teach )
Training for next Level
(Hatch Pattern
Indication)
22.
23. Skill matrix index:-Skill matrix index indicates the level of the employee for the
particular machining operation and improvement required in necessary field.
24. Process map and regulations for tool room:
To describe the operations performed in the tooling system and to
increase productivity as per quantity as well as quality requirement and
to look upon various ways for cost reduction opportunity.”
28. CONCLUSION
In the development of this manual, the characteristics and architecture of a Tool
Management System have been completely defined and operating modes have
been established for its correct utilization within the company by all of the
departments using tools.
Thus after succesfully impliminting above procedures for tool engineering
department, the expected target must be suffised.
Management review meeting is conducted monthly, in which the performance
with respect to given targets and our own presetted targets review is displayed.
The Top Management team comments and recomends various improvement
factor and possiblities to achive the desired goal.
Again the corrective action is taken for improvement and the new set goal are
again to be achived.
29. BIBLIOGRAPHY
• “Tool Management in Manufacturing Systems Equipped with CNC
Machines”,Giovani tani(Nov 1997), Belo Horizonte, Vol 7, N" 2, p.177-187,
University di Firenze, France.
• “Tool Life And Tool Quality-A summary Of The Activities of The ICFG Subgroup
Tool Life”, M.H¨ansel, T.Harnau (6TH INTERNATIONAL TOOLING
CONFERENCE), Thyssen Krupp Presta AG, Essanestrasse,FL-9492 Eschen,
Principality of Liechtenstein.
• “Tool Life, Wear Rates, And Surface Quality In Hard Turning”,Ty G. Dawson and
Thomas R. Kurfess ,The George W. Woodruff School of Mechanical Engineering
Georgia Institute of Technology Atlanta, Georgia.
• “Production (operations) management”, prof. L.C. Jhamba.
• “Manufacturing and operations management”, prof. L.C. Jhamba.
• Company documents:
-Tooling formats.
-Associates skill evaluation map(HR department).
-Tool part codes
-Min. max. Values of tools.
-Fixture’s master list.
-References for sap as work procedures.
30. PAPER PUBLICATION
We have recently published a technical paper on “Tool Management System
Incorporated with Skill Matrix” in INTERNATIONAL JOURNAL OF ENGINEERING
AND TECHNICAL RESEARCH(IJETR),which is published on 31st May 2014,the details
are as below:
Paper ID: IJETR/02/1785
Paper title : Tool Management System Incorporated with Skill Matrix.
Authors: Labade Saurabh ,Shewale Nikhil,Guided By- Prof.M.S.Rohokale.
