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PRODUCTIVITY IMPROVEMENT
OF GROVER INDUSTRIES
SUBMITTED BY :-
INDERPREET SINGH BEDI
JAGMEET SINGH BAJAJ
JASHANDEEP SIINGH DHILLON
KRITI SHARMA
PROBLEMS FACED AND PROJECT GOALS
 Grover Industries is a small scale gear manufacturing company.
 The company has as an inefficient production system which leads to
bottlenecks, rework and scrap and hence leads to lower productivity.
 Goal :- The project aims at increasing the productivity of the
manufacturing process by using the various operational methodology and
techniques.
OBJECTIVES
 New effective production layout which would streamline the
manufacturing process.
 Reduce the Non-Value added activities.
MACHINERY AVAILABLE
 Four CNC machines for turning and facing operations
 Four Lathe machines for turning
 Four Milling (Horizontal) machines for teeth cutting
 Four Gear Hobbing machines for special teeth cutting (for cutting splines
and cutting sprockets )
GEAR MANUFACTURNG PROCESS
SHAFT
CUTTING
TURNING MILLING
GEAR
HOBBING
WELDING
HEAT
TREATMEN
T
FINISHING
PACKAGING
& SHIPPING
PRODUCT DESCRIPTION
The company manufactures six types of products
PRODUCT CATEGORIZATION
The products were categorized into 3 different part families
Product 1
Product 2 Product 4A
Product 3A
Product 5A
Product 4B
Product 3B
Product 6
Product 5B
OLD LAYOUT
PRODUCTIVITY IMPROVEMENT
 LAYOUT DESIGN
 WORK REDISTRIBUTION THROUGH WORK METHOD AND TIME STUDY
 BY DECREASING NON- VALUE ADDED ACTIVITIES
 BY APPLYING GENERAL OPERATIONAL MANAGEMENT TECHNIQUES
NEW LAYOUT
By using the principle of Group Technology and Cellular Manufacturing, the manufacturing process
was streamlined and was divided into three cells for three part families.
CELL-1
CELL-2
CELL-3
NEW LAYOUT - DIFFERENTIATION
DIFFERENTIATING BETWEEN VALUE ADDED, SEMI-
VALUE ADDED & NON-VALUE ADDED ACTIVITES
VALUE ADDED ACTIVITIES
SEMI-VALUE ADDED ACTIVITIES
NON-VALUE ADDED ACTIVITIES
TIME STUDY
LOAD CHART
 There were 17 stations before and the breakdown of the VA,SVA and NVA
is shown below :-
0
10
20
30
40
50
60
70
80
90
100
LOAD CHART _BEFORE
60%
16%
24%
VA,SVA,NVA
1 2 3
LOAD CHART
0
20
40
60
80
100
Shaft
cutting 1
Lathe 1 Lathe 2 CNC 1 CNC 2 Miliing 1 Miliing 2 Gear
Hobbing 1
Gear
Hobbing 2
Cell 1
VA SVA NVA
0
20
40
60
80
100
Shaft cutting 2 Lathe 3 CNC 3 Miliing 3 Gear Hobbing 3
Cell 2
VA SVA NVA
0
20
40
60
80
100
Shaft cutting 3 Lathe 4 CNC 4 Miliing 4 Gear Hobbing
4
Cell 3
VA SVA NVA
62%16%
22%
VA,SVA,NVA
VA SVA NVA
MATERIAL REQUIREMENT PLANNING
Sample MRP Sheet proposed for raw material purchasing
THANK YOU

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Productivity improvements using Operations Management in Manufacturing industry

  • 1. PRODUCTIVITY IMPROVEMENT OF GROVER INDUSTRIES SUBMITTED BY :- INDERPREET SINGH BEDI JAGMEET SINGH BAJAJ JASHANDEEP SIINGH DHILLON KRITI SHARMA
  • 2. PROBLEMS FACED AND PROJECT GOALS  Grover Industries is a small scale gear manufacturing company.  The company has as an inefficient production system which leads to bottlenecks, rework and scrap and hence leads to lower productivity.  Goal :- The project aims at increasing the productivity of the manufacturing process by using the various operational methodology and techniques.
  • 3. OBJECTIVES  New effective production layout which would streamline the manufacturing process.  Reduce the Non-Value added activities.
  • 4. MACHINERY AVAILABLE  Four CNC machines for turning and facing operations  Four Lathe machines for turning  Four Milling (Horizontal) machines for teeth cutting  Four Gear Hobbing machines for special teeth cutting (for cutting splines and cutting sprockets )
  • 5. GEAR MANUFACTURNG PROCESS SHAFT CUTTING TURNING MILLING GEAR HOBBING WELDING HEAT TREATMEN T FINISHING PACKAGING & SHIPPING
  • 6. PRODUCT DESCRIPTION The company manufactures six types of products
  • 7. PRODUCT CATEGORIZATION The products were categorized into 3 different part families Product 1 Product 2 Product 4A Product 3A Product 5A Product 4B Product 3B Product 6 Product 5B
  • 9. PRODUCTIVITY IMPROVEMENT  LAYOUT DESIGN  WORK REDISTRIBUTION THROUGH WORK METHOD AND TIME STUDY  BY DECREASING NON- VALUE ADDED ACTIVITIES  BY APPLYING GENERAL OPERATIONAL MANAGEMENT TECHNIQUES
  • 10. NEW LAYOUT By using the principle of Group Technology and Cellular Manufacturing, the manufacturing process was streamlined and was divided into three cells for three part families. CELL-1 CELL-2 CELL-3
  • 11. NEW LAYOUT - DIFFERENTIATION
  • 12. DIFFERENTIATING BETWEEN VALUE ADDED, SEMI- VALUE ADDED & NON-VALUE ADDED ACTIVITES VALUE ADDED ACTIVITIES SEMI-VALUE ADDED ACTIVITIES NON-VALUE ADDED ACTIVITIES
  • 14. LOAD CHART  There were 17 stations before and the breakdown of the VA,SVA and NVA is shown below :- 0 10 20 30 40 50 60 70 80 90 100 LOAD CHART _BEFORE 60% 16% 24% VA,SVA,NVA 1 2 3
  • 15. LOAD CHART 0 20 40 60 80 100 Shaft cutting 1 Lathe 1 Lathe 2 CNC 1 CNC 2 Miliing 1 Miliing 2 Gear Hobbing 1 Gear Hobbing 2 Cell 1 VA SVA NVA 0 20 40 60 80 100 Shaft cutting 2 Lathe 3 CNC 3 Miliing 3 Gear Hobbing 3 Cell 2 VA SVA NVA 0 20 40 60 80 100 Shaft cutting 3 Lathe 4 CNC 4 Miliing 4 Gear Hobbing 4 Cell 3 VA SVA NVA 62%16% 22% VA,SVA,NVA VA SVA NVA
  • 16. MATERIAL REQUIREMENT PLANNING Sample MRP Sheet proposed for raw material purchasing