The document provides a profile of Tractors and Farm Equipment Limited (TAFE), outlining that it is India's third largest tractor manufacturer with a 25% market share in India, manufacturing over 170,000 tractors annually across six plants. TAFE has a long partnership with AGCO Corporation and produces tractors under the Massey Ferguson, TAFE, and Eicher brands that it exports to over 75 countries. The company employs over 2,500 engineers and specialists across its various manufacturing facilities in India, Turkey, and China.
Tvs motors summer internship report a study on customer satisfaction towards ...Priyansh Kesarwani
A study on Customer satisfaction towards TVS Motors in Kanpur City
Objective of the study:
• To know the customer satisfaction level towards services of TVS Motors.
• To know the problems presently faced by the customers at TVS Motors.
• To study the post-sales service performance.
• To know the new area of improvement.
Tata motors final project on consumer satisfaction.Joydip Roy
This document provides an overview of the sales and distribution systems of Tata Motors and Fiat in India. It discusses Tata Motors' dealership model, which the author studied as part of an internship. It also describes the automobile industry in India, major players, vehicle price segments, and trends in domestic sales. The author's research methods including conducting surveys of customers and potential customers.
The document is a project report submitted by Saransh Gupta about improvements to the warehouse at Eicher Tractors. It includes a declaration by Saransh Gupta, an acknowledgements section thanking those who supported the project, and background information about Eicher Tractors and its parent company TAFE. The key points are:
1) Saransh Gupta submitted a project report on warehouse improvements at Eicher Tractors as part of a summer training program.
2) Eicher Tractors is a leading tractor manufacturer in India and is a subsidiary of TAFE Motors and Tractors Limited.
3) TAFE later acquired Eicher's tractor, engine, and gear businesses in
This document provides an overview of Tata Motors Limited's summer internship report on analyzing the strategic marketing of Tata Motors in New Delhi. The 3-page summary includes:
1) An introduction to the objectives, methodology, and overall positive opinion of Tata Motors among customers.
2) Acknowledgement and thanks to those who supported and guided the project.
3) An outline of the report's contents which cover topics like company profile, history, product mix, SWOT analysis, research objectives and findings.
The document provides an organizational study of TVS Sundram Iyengar & Sons Private Limited. It includes an introduction to the TVS Group and the purpose of the study. It then describes various departments within the company like human resources, finance, sales, production, IT, and administration. Each department section outlines the functions and processes. The document also discusses industry trends, company overview, vision, milestones and awards. In summary, it provides an in-depth look at the organizational structure and operations of TVS Sundram Iyengar & Sons Private Limited.
The document is a project report submitted by Pushkar Chaturvedi for his Master's degree that studies the growth prospects of the Indian auto component industry and the position of Wheels India Ltd within it. It includes an acknowledgement, declaration, abstract, table of contents, and initial chapters introducing the auto component industry in India and providing a company profile of Wheels India Ltd.
This document appears to be a student project report comparing the performance of Alliance Insurance Company to its competitors in India. It includes an introduction covering the history and development of the general insurance industry in India. It then provides profiles of Alliance Insurance Company and its products. The remainder of the report outlines the objectives, scope, methodology and findings of the comparative performance analysis conducted between Alliance and other insurance companies.
Comparative study of maruti suzuki and tata motors with reference to after sa...GANESH AWATADE
This document provides an overview of Maruti Suzuki India Ltd, the largest automobile manufacturer in India. Some key points:
- Maruti Suzuki is a joint venture between the Indian government and Japanese company Suzuki Motor Corporation.
- It has the largest market share in India at 37% and is the market leader in passenger vehicles.
- The company produces a wide range of vehicles from small hatchbacks to sedans and SUVs. It has a large sales and service network across India.
- In addition to manufacturing and sales, Maruti Suzuki also provides financing, insurance, and sells used vehicles to support its customers.
Tvs motors summer internship report a study on customer satisfaction towards ...Priyansh Kesarwani
A study on Customer satisfaction towards TVS Motors in Kanpur City
Objective of the study:
• To know the customer satisfaction level towards services of TVS Motors.
• To know the problems presently faced by the customers at TVS Motors.
• To study the post-sales service performance.
• To know the new area of improvement.
Tata motors final project on consumer satisfaction.Joydip Roy
This document provides an overview of the sales and distribution systems of Tata Motors and Fiat in India. It discusses Tata Motors' dealership model, which the author studied as part of an internship. It also describes the automobile industry in India, major players, vehicle price segments, and trends in domestic sales. The author's research methods including conducting surveys of customers and potential customers.
The document is a project report submitted by Saransh Gupta about improvements to the warehouse at Eicher Tractors. It includes a declaration by Saransh Gupta, an acknowledgements section thanking those who supported the project, and background information about Eicher Tractors and its parent company TAFE. The key points are:
1) Saransh Gupta submitted a project report on warehouse improvements at Eicher Tractors as part of a summer training program.
2) Eicher Tractors is a leading tractor manufacturer in India and is a subsidiary of TAFE Motors and Tractors Limited.
3) TAFE later acquired Eicher's tractor, engine, and gear businesses in
This document provides an overview of Tata Motors Limited's summer internship report on analyzing the strategic marketing of Tata Motors in New Delhi. The 3-page summary includes:
1) An introduction to the objectives, methodology, and overall positive opinion of Tata Motors among customers.
2) Acknowledgement and thanks to those who supported and guided the project.
3) An outline of the report's contents which cover topics like company profile, history, product mix, SWOT analysis, research objectives and findings.
The document provides an organizational study of TVS Sundram Iyengar & Sons Private Limited. It includes an introduction to the TVS Group and the purpose of the study. It then describes various departments within the company like human resources, finance, sales, production, IT, and administration. Each department section outlines the functions and processes. The document also discusses industry trends, company overview, vision, milestones and awards. In summary, it provides an in-depth look at the organizational structure and operations of TVS Sundram Iyengar & Sons Private Limited.
The document is a project report submitted by Pushkar Chaturvedi for his Master's degree that studies the growth prospects of the Indian auto component industry and the position of Wheels India Ltd within it. It includes an acknowledgement, declaration, abstract, table of contents, and initial chapters introducing the auto component industry in India and providing a company profile of Wheels India Ltd.
This document appears to be a student project report comparing the performance of Alliance Insurance Company to its competitors in India. It includes an introduction covering the history and development of the general insurance industry in India. It then provides profiles of Alliance Insurance Company and its products. The remainder of the report outlines the objectives, scope, methodology and findings of the comparative performance analysis conducted between Alliance and other insurance companies.
Comparative study of maruti suzuki and tata motors with reference to after sa...GANESH AWATADE
This document provides an overview of Maruti Suzuki India Ltd, the largest automobile manufacturer in India. Some key points:
- Maruti Suzuki is a joint venture between the Indian government and Japanese company Suzuki Motor Corporation.
- It has the largest market share in India at 37% and is the market leader in passenger vehicles.
- The company produces a wide range of vehicles from small hatchbacks to sedans and SUVs. It has a large sales and service network across India.
- In addition to manufacturing and sales, Maruti Suzuki also provides financing, insurance, and sells used vehicles to support its customers.
This document is a project report for an internship at Apollo Tyres Ltd. It includes an acknowledgements section thanking those who supported the project. It then provides a declaration that the project information is true. The contents section outlines the different parts of the report, which will include an introduction to Apollo Tyres and their marketing strategies, methodology used in the project, analysis and findings from a market share survey and dealer satisfaction survey, recommendations, and conclusion.
This document is a comprehensive project report on a study of consumer satisfaction towards non-gear two wheelers of Honda in Rajkot City. It contains general information about Honda as a company, including its establishment, growth, production capacity, network expansion, and awards received. It also provides an overview of the automobile industry in India and globally, outlining major players and trends. The report is submitted by two MBA students, Akash Detroja and Darshan Rajyaguru, under the guidance of their faculty member Krishna Unadkat as part fulfillment of their MBA program requirements.
This document is a report on a summer internship project for Bajaj Bikes conducted by Varun Tonk. The report includes sections on the company profile, objectives, research methodology, marketing mix plan involving segmentation, targeting, positioning, the 4Ps of product, price, place, and promotion. It also includes data analysis and interpretation, conclusions, recommendations, and limitations. The report provides an overview of Bajaj as one of the largest two and three-wheeler manufacturers in India and discusses the company's history, philosophy, products, market share and research and development efforts.
TVS Motor Company was established in 1911 and began manufacturing vehicles in the 1980s. It had a long collaboration with Suzuki from 1982-2001 to produce motorcycles under the TVS-Suzuki brand. Currently, TVS is India's third largest two-wheeler manufacturer and produces a range of products from mopeds to premium motorcycles. Some of its popular models include the TVS Sport, TVS Apache series, and Scooty Pep+. The company aims to provide customers with high quality, fuel efficient vehicles.
a project report on MAHINDRA & MAHINDRA . Here you will get all the data of product of MAHINDRA & MAHINDRA. made by me , best helpful for BBA student forn intership report.
This document is a project report submitted by Bhargava SaiKumar Sudikonda to TVS Motor Company as part of an internship. The report analyzes competitors of TVS Jupiter scooter and customer reservations about purchasing the Jupiter in Vijayawada and Guntur regions. The objective is to make recommendations to increase Jupiter sales. Mystery shopping and customer surveys were conducted to understand factors influencing scooter purchase decisions. Key findings include low brand image for TVS, less awareness of Jupiter compared to Activa, limited sales executive knowledge, and the importance of showroom ambience. Recommendations focus on improving sales executive product knowledge and changing marketing strategy from push to pull.
A study on customer satisfaction towards honda activaHardik Ranpariya
This document provides a literature review on customer relationship management (CRM) strategies in the automobile industry, specifically related to Honda Motors. It discusses how Honda uses a customer loyalty program called Good Life Passport to build relationships. It also describes Honda's CRM and dealer management system for integrating sales across 1200 dealers in India. The literature highlights the importance of having the right product, distribution, CRM, and after-sales service to compete in the automobile sector. Overall, the review examines how Honda and other companies like Hero MotoCorp, Caterpillar, and Bajaj Auto use CRM to improve customer value, service, and brand differentiation.
M&M complete analysis done in the year 2013, from july 2013-october 2013 with the help of our respective college staff. Special thanks to the Dean Prof. Bhattacharjee & visiting faculty prof. Abhay Srivastava.
project report on mahindra and mahindraamit prasad
The document discusses Yogesh Kumar's project report on his industrial training at Mahindra & Mahindra, which was submitted in partial fulfillment of the requirements for a Bachelor of Technology degree. It includes declarations by Yogesh Kumar and his supervisor, as well as acknowledgements and a table of contents outlining the chapters to be included in the report. The report will cover Yogesh Kumar's experience during his industrial training at Mahindra & Mahindra and analyze various aspects of the company.
Summer Training Report on Financial Performance Analysis for MBAMegha Bansal
This document provides an overview of a summer training project report on the financial performance analysis of Surya Roshni Limited conducted over 45 days. It includes an acknowledgement, declaration, abstract, table of contents, and lists of tables and charts. The report analyzes the company's financial statements from 2013-2016 using various techniques like common size statements, ratio analysis, comparative statements, and cash flow analysis to evaluate the company's financial performance and position over time.
Tata Motors has a global footprint across various countries in Asia, Africa, Europe, and South America. It has assembly operations, technical centers, and collaborations that support its wide range of commercial and passenger vehicles. The company leverages various resources including its large R&D establishments, strong financial position, robust supply chain and dealer networks, and strategic partnerships to strengthen its market position globally.
Mahindra & mahindra project repot by (makshud khan)Makshud Khan
The document discusses customer satisfaction with Mahindra and Mahindra vehicles based on a study conducted in Deoghar, Jharkhand. It provides details about Mahindra's product portfolio and strategies to improve customer satisfaction. The research methodology involved collecting primary data through 150 questionnaires and secondary data from websites and magazines. Key findings were that Mahindra has a good market share in Deoghar for SUVs and customers are generally satisfied with the design, services, and facilities provided compared to other brands. The conclusion is that Mahindra is offering good customer satisfaction in Deoghar.
"Study on factors influencing capability and usability of Consumers Durables-LG Brand shop MOT [Moment Of
Truth] on Consumer Behaviour"says the various Moment of Truth that the Customer encounter when entering into the brand shop .
Various Moment of Truth that the customer encounters are
Visual Merchandising or Point of Display over the products, Employee Behaviour with theCustomers and after that Measuring the Customer Satisfaction that Customer get after interactingwith the Moment of truth they encounter.
The main Objective of the given project was to study the impact of MOT [Moment of Truth] on Customer Buying Behaviour and observing SSE‘s [Shop Sales Executives] Behaviour in dealing with Customers and also analyzing and measuring the Customer Satisfaction and Experience.
This project basically deals with the Evaluation of Individual Brand shop of LG on the basis of MOT [Moment Of Truth] and Shop Sales Executives behavioural aspects.
This document is a summer training report submitted by Saurabh Kumar Lohal towards the partial fulfillment of a Bachelor of Business Administration degree. It discusses the marketing strategy of Maruti Suzuki (PVT) Limited. The report includes an introduction to the Indian automobile industry, Maruti Suzuki's product range and market presence, a SWOT analysis of the auto sector, research methodology, company profile, data analysis and interpretations, conclusions, and recommendations. It also acknowledges the guidance received from the project supervisor.
The document provides background information on Bajaj Auto Limited and Hero Motorcorp, two major motorcycle manufacturers in India. It discusses the history and growth of both companies. For Bajaj, it notes it was founded in 1926 and now has a distribution network in 50 countries, with a technical tie-up with Kawasaki. For Hero, it outlines how the company originated from Hero Cycles in the 1940s and formed a successful joint venture with Honda in 1984. The document also includes SWOT analyses of both companies and their profiles.
Tata Motors Company Analysis Report 2015-2016Rahul Gulaganji
This document provides an overview of Tata Motors, an Indian automotive manufacturing company. It discusses Tata Motors' history, beginning in 1945 as a manufacturer of locomotives. In 1954, Tata Motors entered the commercial vehicle sector through a joint venture with Daimler-Benz. Tata Motors launched its first passenger vehicle, the Tata Sierra, in 1991. It later launched other popular models like the Indica and Nano. In 2008, Tata Motors acquired Jaguar Land Rover from Ford. The document provides details on Tata Motors' various subsidiaries and joint ventures involved in manufacturing passenger vehicles, commercial vehicles, buses, and other automotive products and components.
The document provides information about performance appraisal at Tata Motors. It first discusses Tata Motors, including its history, operations, and products. It then discusses performance appraisal in general terms. Finally, it describes research conducted to evaluate Tata Motors' performance appraisal process, including findings, conclusions, and suggestions.
The automobile industry in India in 2017 and 2018
Industry profile
sales and growth of automobiles in India and in world
In detail about the auto industry in India in 2017
the share of different cars and car models in India
different cars and originated countries
domestic automakers in India
This document is a project report submitted by MD Mujaffar to Madurai Kamaraj University for a Master's degree in Business Administration. The report examines training and development practices at Bilt Graphic Paper Projects Limited. It includes an introduction on human resource management and training concepts, an acknowledgements section, and outlines of future chapters on the company profile, conceptual framework, data analysis, conclusions, and bibliography. The overall aim is to analyze Bilt Graphic's training programs and evaluate their effectiveness in developing employee skills and performance.
This document provides an industrial training project report on work in process (WIP) management conducted by Angel Bajaj at Global Institutes of Management & Emerging Technologies. It includes an acknowledgement, certificate of approval, introduction on Honda Motorcycle & Scooter India Private Ltd (HMSI) and its products, plant layout, organizational structure, and an overview of quality control tools used in the project such as cause and effect diagrams, Pareto diagrams, and histograms.
1) The tractor market in India is over 500,000 units annually, led by Mahindra Tractors with 38% market share. Other top players include TAFE with 25%, John Deere with 9%, and ITL and New Holland each with around 9-10% market share.
2) Monsoon rains play a major role in annual sales, with a 10% dip seen in 2015-16 due to monsoon failure, though TAFE saw little change in turnover. A rise of 10% in the total market was expected for 2016 due to good monsoons.
3) TAFE has been in business since 1960 in Chennai, India. It holds 25% of the Indian
This document is a project report for an internship at Apollo Tyres Ltd. It includes an acknowledgements section thanking those who supported the project. It then provides a declaration that the project information is true. The contents section outlines the different parts of the report, which will include an introduction to Apollo Tyres and their marketing strategies, methodology used in the project, analysis and findings from a market share survey and dealer satisfaction survey, recommendations, and conclusion.
This document is a comprehensive project report on a study of consumer satisfaction towards non-gear two wheelers of Honda in Rajkot City. It contains general information about Honda as a company, including its establishment, growth, production capacity, network expansion, and awards received. It also provides an overview of the automobile industry in India and globally, outlining major players and trends. The report is submitted by two MBA students, Akash Detroja and Darshan Rajyaguru, under the guidance of their faculty member Krishna Unadkat as part fulfillment of their MBA program requirements.
This document is a report on a summer internship project for Bajaj Bikes conducted by Varun Tonk. The report includes sections on the company profile, objectives, research methodology, marketing mix plan involving segmentation, targeting, positioning, the 4Ps of product, price, place, and promotion. It also includes data analysis and interpretation, conclusions, recommendations, and limitations. The report provides an overview of Bajaj as one of the largest two and three-wheeler manufacturers in India and discusses the company's history, philosophy, products, market share and research and development efforts.
TVS Motor Company was established in 1911 and began manufacturing vehicles in the 1980s. It had a long collaboration with Suzuki from 1982-2001 to produce motorcycles under the TVS-Suzuki brand. Currently, TVS is India's third largest two-wheeler manufacturer and produces a range of products from mopeds to premium motorcycles. Some of its popular models include the TVS Sport, TVS Apache series, and Scooty Pep+. The company aims to provide customers with high quality, fuel efficient vehicles.
a project report on MAHINDRA & MAHINDRA . Here you will get all the data of product of MAHINDRA & MAHINDRA. made by me , best helpful for BBA student forn intership report.
This document is a project report submitted by Bhargava SaiKumar Sudikonda to TVS Motor Company as part of an internship. The report analyzes competitors of TVS Jupiter scooter and customer reservations about purchasing the Jupiter in Vijayawada and Guntur regions. The objective is to make recommendations to increase Jupiter sales. Mystery shopping and customer surveys were conducted to understand factors influencing scooter purchase decisions. Key findings include low brand image for TVS, less awareness of Jupiter compared to Activa, limited sales executive knowledge, and the importance of showroom ambience. Recommendations focus on improving sales executive product knowledge and changing marketing strategy from push to pull.
A study on customer satisfaction towards honda activaHardik Ranpariya
This document provides a literature review on customer relationship management (CRM) strategies in the automobile industry, specifically related to Honda Motors. It discusses how Honda uses a customer loyalty program called Good Life Passport to build relationships. It also describes Honda's CRM and dealer management system for integrating sales across 1200 dealers in India. The literature highlights the importance of having the right product, distribution, CRM, and after-sales service to compete in the automobile sector. Overall, the review examines how Honda and other companies like Hero MotoCorp, Caterpillar, and Bajaj Auto use CRM to improve customer value, service, and brand differentiation.
M&M complete analysis done in the year 2013, from july 2013-october 2013 with the help of our respective college staff. Special thanks to the Dean Prof. Bhattacharjee & visiting faculty prof. Abhay Srivastava.
project report on mahindra and mahindraamit prasad
The document discusses Yogesh Kumar's project report on his industrial training at Mahindra & Mahindra, which was submitted in partial fulfillment of the requirements for a Bachelor of Technology degree. It includes declarations by Yogesh Kumar and his supervisor, as well as acknowledgements and a table of contents outlining the chapters to be included in the report. The report will cover Yogesh Kumar's experience during his industrial training at Mahindra & Mahindra and analyze various aspects of the company.
Summer Training Report on Financial Performance Analysis for MBAMegha Bansal
This document provides an overview of a summer training project report on the financial performance analysis of Surya Roshni Limited conducted over 45 days. It includes an acknowledgement, declaration, abstract, table of contents, and lists of tables and charts. The report analyzes the company's financial statements from 2013-2016 using various techniques like common size statements, ratio analysis, comparative statements, and cash flow analysis to evaluate the company's financial performance and position over time.
Tata Motors has a global footprint across various countries in Asia, Africa, Europe, and South America. It has assembly operations, technical centers, and collaborations that support its wide range of commercial and passenger vehicles. The company leverages various resources including its large R&D establishments, strong financial position, robust supply chain and dealer networks, and strategic partnerships to strengthen its market position globally.
Mahindra & mahindra project repot by (makshud khan)Makshud Khan
The document discusses customer satisfaction with Mahindra and Mahindra vehicles based on a study conducted in Deoghar, Jharkhand. It provides details about Mahindra's product portfolio and strategies to improve customer satisfaction. The research methodology involved collecting primary data through 150 questionnaires and secondary data from websites and magazines. Key findings were that Mahindra has a good market share in Deoghar for SUVs and customers are generally satisfied with the design, services, and facilities provided compared to other brands. The conclusion is that Mahindra is offering good customer satisfaction in Deoghar.
"Study on factors influencing capability and usability of Consumers Durables-LG Brand shop MOT [Moment Of
Truth] on Consumer Behaviour"says the various Moment of Truth that the Customer encounter when entering into the brand shop .
Various Moment of Truth that the customer encounters are
Visual Merchandising or Point of Display over the products, Employee Behaviour with theCustomers and after that Measuring the Customer Satisfaction that Customer get after interactingwith the Moment of truth they encounter.
The main Objective of the given project was to study the impact of MOT [Moment of Truth] on Customer Buying Behaviour and observing SSE‘s [Shop Sales Executives] Behaviour in dealing with Customers and also analyzing and measuring the Customer Satisfaction and Experience.
This project basically deals with the Evaluation of Individual Brand shop of LG on the basis of MOT [Moment Of Truth] and Shop Sales Executives behavioural aspects.
This document is a summer training report submitted by Saurabh Kumar Lohal towards the partial fulfillment of a Bachelor of Business Administration degree. It discusses the marketing strategy of Maruti Suzuki (PVT) Limited. The report includes an introduction to the Indian automobile industry, Maruti Suzuki's product range and market presence, a SWOT analysis of the auto sector, research methodology, company profile, data analysis and interpretations, conclusions, and recommendations. It also acknowledges the guidance received from the project supervisor.
The document provides background information on Bajaj Auto Limited and Hero Motorcorp, two major motorcycle manufacturers in India. It discusses the history and growth of both companies. For Bajaj, it notes it was founded in 1926 and now has a distribution network in 50 countries, with a technical tie-up with Kawasaki. For Hero, it outlines how the company originated from Hero Cycles in the 1940s and formed a successful joint venture with Honda in 1984. The document also includes SWOT analyses of both companies and their profiles.
Tata Motors Company Analysis Report 2015-2016Rahul Gulaganji
This document provides an overview of Tata Motors, an Indian automotive manufacturing company. It discusses Tata Motors' history, beginning in 1945 as a manufacturer of locomotives. In 1954, Tata Motors entered the commercial vehicle sector through a joint venture with Daimler-Benz. Tata Motors launched its first passenger vehicle, the Tata Sierra, in 1991. It later launched other popular models like the Indica and Nano. In 2008, Tata Motors acquired Jaguar Land Rover from Ford. The document provides details on Tata Motors' various subsidiaries and joint ventures involved in manufacturing passenger vehicles, commercial vehicles, buses, and other automotive products and components.
The document provides information about performance appraisal at Tata Motors. It first discusses Tata Motors, including its history, operations, and products. It then discusses performance appraisal in general terms. Finally, it describes research conducted to evaluate Tata Motors' performance appraisal process, including findings, conclusions, and suggestions.
The automobile industry in India in 2017 and 2018
Industry profile
sales and growth of automobiles in India and in world
In detail about the auto industry in India in 2017
the share of different cars and car models in India
different cars and originated countries
domestic automakers in India
This document is a project report submitted by MD Mujaffar to Madurai Kamaraj University for a Master's degree in Business Administration. The report examines training and development practices at Bilt Graphic Paper Projects Limited. It includes an introduction on human resource management and training concepts, an acknowledgements section, and outlines of future chapters on the company profile, conceptual framework, data analysis, conclusions, and bibliography. The overall aim is to analyze Bilt Graphic's training programs and evaluate their effectiveness in developing employee skills and performance.
This document provides an industrial training project report on work in process (WIP) management conducted by Angel Bajaj at Global Institutes of Management & Emerging Technologies. It includes an acknowledgement, certificate of approval, introduction on Honda Motorcycle & Scooter India Private Ltd (HMSI) and its products, plant layout, organizational structure, and an overview of quality control tools used in the project such as cause and effect diagrams, Pareto diagrams, and histograms.
1) The tractor market in India is over 500,000 units annually, led by Mahindra Tractors with 38% market share. Other top players include TAFE with 25%, John Deere with 9%, and ITL and New Holland each with around 9-10% market share.
2) Monsoon rains play a major role in annual sales, with a 10% dip seen in 2015-16 due to monsoon failure, though TAFE saw little change in turnover. A rise of 10% in the total market was expected for 2016 due to good monsoons.
3) TAFE has been in business since 1960 in Chennai, India. It holds 25% of the Indian
A study on ratio analysis at vst tillers tractors finalAnantha Bellary
The document provides an overview of the tractor industry in India from 1945 to 1997. It discusses the history and growth of the industry from initial imports to local production starting in 1961. By the 1990s, India had emerged as one of the world's leading producers of wheeled tractors. The largest manufacturers as of 1997 were Mahindra and Mahindra, TAFE, Escorts Ltd., and Punjab Tractors. The average tractor size was around 35HP but was expected to increase to 45HP by 2020. The document also summarizes various tractor models and manufacturers including Ford, Mitsubishi, Swaraj, HMT, and Mahindra Gujarat.
The document provides an analysis of the Indian tractor industry, including market trends, key players, and factors impacting growth. Some key points:
- The Indian tractor market has grown at an average rate of 8-10% annually over the past decade. Market share is dominated by 6 major players controlling 95% of sales.
- Tractor penetration rates remain low in India compared to other countries, indicating significant room for growth. Over 80% of Indian farms are small-scale and underpenetrated.
- Industry sales are impacted by factors like monsoon patterns, minimum support prices, exports, and financing availability. The 41-50 HP tractor segment has seen the largest growth in market share in recent years.
Project report on mahindra & mahindra ltd. (tractors division)Paras Dhingra
This document provides an overview of Mahindra & Mahindra Ltd., an Indian automotive manufacturing company. It discusses the company's history beginning in 1945, facilities and subsidiaries globally. The company manufactures tractors, utility vehicles, passenger cars and other vehicles. It has two main divisions - automotive and farm equipment. The document outlines the company's various products, competitors like Maruti Suzuki and Hind Motors, functional departments, business development operations including marketing strategies, and financial performance over time.
The document summarizes the progress of a project to redesign the operator's area of a TAFE tractor. It describes benchmarking of competitors, studying existing designs, user research through interviews and observations, identification of user needs, concept development and iteration, and application of ergonomic principles. The goal is to create a more user-centric, ergonomic, and aesthetically-pleasing design for the tractor controls and operator space.
Global supply chain in ranbaxy paonta sahib manufacturing facilityAnkur Srivastava
This is a project report made by me on the Global Supply Chain Process of Ranbaxy Laboratories Ltd., one of the world's largest Pharmaceutical Manufacturers; and its impact on its Global Business. The related study was done in the year 2011 and report was prepared then.
Mahindra & Mahindra and Tractor and Farm Equipment Limited (TAFE) are two major tractor manufacturers in India. Mahindra is the largest tractor manufacturer in India with over 50% market share. It offers a wide range of tractor models and provides additional services like financing and farmer training through its Samriddhi centers. TAFE is the second largest manufacturer and offers Massey Ferguson, TAFE, and Eicher branded tractors. While TAFE tractors are more affordable, Mahindra tractors are more efficient over the long run. Both companies focus on rural markets and implement corporate social responsibility programs in areas like education, health, and the environment.
HMT Machine Tools Ltd Ajmer Practical Summer Training PresentationSiddharth Bhatnagar
This presentation provides an overview of HMT Machine Tools Ltd. in Ajmer, India. It discusses the company's establishment, departments, manufacturing processes, products, achievements and customers. Key points include:
- HMT was established by the Indian government in 1953 and diversified into various industries over time. The Ajmer unit focuses on CNC grinding machines.
- Major departments include manufacturing, assembly, foundry, maintenance, inspection and HR.
- The foundry produces metal castings using processes like pattern making, sand moulding, and metal melting.
- Notable products are CGM-225, GTC28, and CGM-175 CNC grinding machines.
-
This document discusses communication challenges in a multigenerational workforce and analyzes strategies to improve effectiveness. It first provides an overview of the four main generations currently in the workforce: Traditionalists, Baby Boomers, Generation X, and Millennials. It describes key differences between the generations in values, work ethics, job mobility, compliance, and motivators. The document then discusses how organizational communication theories can be applied to build collaboration between generations. Specifically, it argues managers must understand generational characteristics to communicate effectively and motivate employees. A more collaborative environment that meets generational needs could improve efficiency, effectiveness, and teamwork.
- Hindustan Aeronautics Limited (HAL) is India's largest aerospace company, playing a major role in India's defence aviation.
- HAL provides training and development programs for its employees both internally and externally to enhance skills. Training is provided through the HAL Management Academy and other agencies.
- A survey of 50 HAL officers found that while 45% attended 6-15 training programs in the last 5 years, 40% attended only 0-5, indicating a need for more even monitoring of training participation across employees.
This document discusses optimizing inbound logistics costs for an automobile manufacturer through a case study at TAFE. It presents the existing decentralized warehouse system and associated high costs. The objectives are to introduce a centralized warehouse, optimize carrier selection using packaging heuristics, and implement barcode technology to minimize errors. The methodology involves selecting an optimal warehouse location and layout, estimating costs for the new system, and developing a transportation model from warehouse to plant. Introducing a centralized warehouse is expected to optimize total inbound logistics costs.
The tractor industry plays an important role in India's economy as agriculture contributes significantly to GDP. Tractors were initially imported but local production began in 1961 with 5 manufacturers. By now, one third of global tractor production is in India, with the market growing at a CAGR of 10% over 4 decades. The key states for tractor demand are Uttar Pradesh, Karnataka, Maharashtra, Tamil Nadu and Gujarat. While Mahindra & Mahindra leads the industry, factors like monsoon patterns and government support have fueled overall industry growth.
The document presents findings from a study on the effect of the 2008 financial crisis on investors' investment patterns in India. The study found that while the crisis impacted some sectors more than others, investors remain optimistic about the long-term growth prospects of both the Indian and US economies. Most preferred future investment sectors included services and savings accounts.
Reliance Communications is India's largest telecommunications network covering almost a billion people. It has the world's largest fiber optic and submarine cable network. Reliance Communications pioneered making wireless service affordable in India, driving down costs and expanding coverage. It is a market leader in multiple segments such as wireless data, enterprise data services, international voice, and more. Reliance Communications has extensive retail, infrastructure, IT and network operations to support over 45 million consumers and enterprises.
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Study and improve training procedures vis a vis employee satisfactionSupa Buoy
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1. A Study on Effectiveness of Existing Layout at TAFE Ltd., 1
ST.JOSEPH’S COLLEGE OF BUSINESS ADMINISTARATION
18, Residency Road, Bangalore 560 025
A Study on Effectiveness of Existing Layout
at TAFE Limited
Project Report
Submitted in partial fulfillment of the requirements
for the award of
The Post Graduate Diploma in Management
(A TWO YEAR FULL TIME PROGRAM IN MANAGEMENT)
Submitted by
Polisetty Sai Chaitanya
Roll No. 14023
PGDM 2014-16
2. A Study on Effectiveness of Existing Layout at TAFE Ltd., 2
ST.JOSEPH’S COLLEGE OF BUSINESS ADMINISTARATION
18, Residency Road, Bangalore 560 025
CERTIFICATE
This is to certify that the project report entitled “A Study on
Effectiveness of Existing Layout at TAFE Ltd.,” is an authentic record
of the project carried out by Mr.Polisetty Sai Chaitanya (Reg.No.14023)
in partial fulfillment of the requirements for the award of The Post
Graduate Diploma in Management.
Prof. V.J.Lawrence
Associate Professor
Rev.Dr.S.Peter S.J. Prof.Edwin L Castelino
Director Dean
3. A Study on Effectiveness of Existing Layout at TAFE Ltd., 3
4. A Study on Effectiveness of Existing Layout at TAFE Ltd., 4
DECLARATION
I hereby declare that the project report entitled “A Study on effectiveness of Existing
Layout at TAFE Limited” has been prepared by me during the period from 15 April
2015 to 30 May 2015 under the guidance or Mr.Kumaresan Deputy Manager, TAFE
Limited and Prof. Lawrance, Faculty Member, St.Joseph’s College of Business
Administration, Bangalore.
I also declare that this project has not been submitted nor shall it be submitted in
future to any other University or Institution for the award of any other Degree or
diploma.
Signature …………………………………..
Polisetty Sai Chaitanya
Dated the 30th May, 2015
5. A Study on Effectiveness of Existing Layout at TAFE Ltd., 5
ACKNOWLEDGEMENT
Words are only representations of our regards and gratitude that we have
towards our actions and their inherent associations. As a matter of fact, without co-
operation, no thought could be coined into real action. Consistent motivation and
invaluable support throughout any project is an issue that cannot be quantitatively
measured. These acknowledgements are only a fraction of regards towards their
gestures.
“Vital to every operation is co-operation”. We really agree to this wonderful
quotation put forth by Mr. Frank Tyger. This project was successful due to the co-
operation extended by people who have truly contributed towards it. We gratefully
acknowledge Mr.Lawrence, St. Joseph’s College of Business Administration
Bangalore who’s deep sharing and synergy has moved us many levels beyond our
own thinking. We express our deep sense of gratitude to ma`am who has been a
source of inspiration throughout the course of this work with her inestimable advice
and moral encouragement.
We are thankful to following persons for their valuable inputs and their kind
co-operation and guidance which helped us in carrying out this project study.
• Mr. Prem Ramesh, Deputy General Manager, Production Engineering Department
TAFE Ltd.,
• Mr. Kumaresan, Deputy Manager, Production Engineering Department TAFE Ltd.,
• Mr. Nirmal Kumar, SeniorEngineer, Production Engineering Department TAFE
Ltd.,
We take this responsibility to express our profound and sincere gratitude to
St. Joseph’s College of Business Administration, Bangalore for providing us
with the opportunity to explore the corridors of the corporate world and gather
invaluable knowledge and practical experience via the Production and Operations
Management project. Finally, we would like to thanks those people who all are
attached to this Project directly or indirectly.
6. A Study on Effectiveness of Existing Layout at TAFE Ltd., 6
Table of content
S.No. Description Page No.
1 Executive Summary …………………………………………………. 8
2 Company Profile …………………………………………………….
• AGCO ………………………………………………………….
• Warwick Manufacturing Group, UK …………….…………..
• Nature of Business …………………………………………..
• Nature of Products …………………………………………..
• Other Information about the Plant …………………………
9
11
11
11
12
13
3 Introduction to the project …………………………………………..
• Topic of Study ……………………………………………….
• Background of the research topic ………………………….
• Review of Literature in the area of study ………………….
• Existing practices of the organization in the area of study..
14
14
14
15
16
4 Design of Study ………………………………………………………
• Objectives of the Study ……………………………………...
• Scope of the Study …………………………………………..
• Tools and Techniques for collection of data ……………….
• Operational definition of concepts …………………………..
19
19
19
20
26
5 Analysis of Data ………………………………………………………
• Data Collection ………………………………………………..
• Man activity chart ……………………………………………..
• Cell Ergonomics ………………………………………………
29
29
33
33
6 Conclusion ……………………………………………………………. 57
7 Bibliography ………………………………………………………….. 58
7. A Study on Effectiveness of Existing Layout at TAFE Ltd., 7
List of Tables and Graphs
SNo. Description Page No.
1 Table -1 Cycle time details for machines …………………………. 29
2 Graph - 1 Cycle time ………………………………………………… 30
3. Table - 2 Production volume details for machines ………………. 30
4. Graph - 2 Production Volume ……………………………………... 31
5. Graph - 3 Comparison of Cycle time and Production Volume …. 32
6. OIB Axle Housing Assembly ………………………………………... 34
7. OIB Wheel Axle Bolt Press …………………………………………. 38
8. Axle Housing Sleeve Press …………………………………………. 40
9. Turkey End Cover Assembly ……………………………………….. 42
10. End Cover Assembly ………………………………………………… 45
11. HLC Cylinder Sub Assembly ……………………………………….. 59
12. HLC Assembly ………………………………………………………... 52
8. A Study on Effectiveness of Existing Layout at TAFE Ltd., 8
Executive summary
Now-a-days there is a tremendous growth in the industrial sector, particularly
the manufacturing sector. The project is about how effectively the plant layout is
performing at the TAFE ltd., who is the 3rd largest manufacture of tractors.
In the current scenario, the fast growing needs the company have to deliver
the products on the due date or earlier to the due date to gain the customers and
increase the market share. In order to achieve the peak of the production the
company have to design the layout according to the some standards which would
help the company to meet the target.
In this project, it presents about how effectively the company is performing, to
find the performance of the company there are several parameters are to be
considered. They are operator movements, ergonomics of operator by using these
parameter we can find the efficiency of the plant layout. The organization and
education institution should keep on research on the plant layout design and find the
easier way for high production and new technology which should benefit for the
company and the customers.
9. Company Profile
A Study on Effectiveness of Existing Layout at TAFE Ltd., 9
COMPANY PROFILE
Tractors and Farm Equipment Limited (TAFE), is an Indian tractor major
incorporated in 1960 at Chennai, with an annual turnover of INR 96 billion
(2013-14). The third-largest tractor manufacturer in the world and the second
largest in India by volumes, TAFE wields 25% market share of the Indian tractor
industry with a sale of over 170,000 tractors (domestic and international)
annually.
TAFE's partnership with AGCO Corporation and the Massey Ferguson
brand for 53 years is a stellar example of its commitment to building long-term
relationships with its stakeholders, through fair and ethical business practices.
TAFE has earned the trust of customers through its range of products that
are widely acclaimed for its quality and low cost of operation. A strong
distribution network of over 1000 dealers effectively backs TAFE's three iconic
tractor brands of Massey Ferguson, TAFE and Eicher. TAFE exports tractors,
both in partnership with AGCO and independently, powering farms in over 75
countries which includes developed countries in Europe and the Americas.
From a humble beginning with just one tractor model in 1961, TAFE today
is recognized as a high quality mass-manufacturer with an extensive product
range to meet the expectations of every farmer and every farm mechanization
need. TAFE's R&D facilities are centers of excellence renowned for their
innovative design and engineering expertise and have been recognized by the
Department of Scientific and Industrial Research, Government of India.
Extensive research and testing ensures that TAFE's products meet its exacting
performance standards.
TAFE's plant at Turkey manufactures a range of tractors for distribution in
Turkey through AGCO's dealer network, while another new facility has been
setup at China to cater to TAFE's ever growing global sourcing needs and value
addition to its Indian and worldwide operations. TAFE acquired Eicher's tractors,
gears and transmission components and engines business in 2005 through a
wholly owned subsidiary, TAFE Motors and Tractors Limited (TMTL).
10. Company Profile
A Study on Effectiveness of Existing Layout at TAFE Ltd., 10
With six tractor plants, an engine’s plant, two gears and transmission
components plants, two engineering plastics units, two facilities for hydraulic
pumps and cylinders and one batteries plant besides other facilities, TAFE
employs over 2500 engineers apart from a number of specialists in other
disciplines.
TAFE believes in sound corporate governance and is reputed for being a
consistent profit-making company and ethical business practices. TAFE's
commitment to CSR involves contribution to the environment and society while
facilitating growth of all stakeholders with equal fervor, embodying the role of a
responsible corporate citizen. TAFE's social focus has been significant since
inception and it contributes towards education, healthcare, agriculture,
community development and supporting traditional art forms.
TAFE is committed to the Total Quality Movement (TQM). In the recent past
various plants of TAFE have garnered, three 'TPM Excellence Awards' from the
Japan Institute of Plant Management, the 'Frost & Sullivan - IMEA Award' for
significant progress towards reliable processes, the 'Regional Contributor Award' for
quality supplies from Toyota Motor Company, Japan, and the 'Manufacturing Supply
Chain Operational Excellence - Automobiles Award' at the second Asia
Manufacturing Supply Chain Summit for its supply chain transformation, as well as a
number of other regional awards for TPM excellence. Its tractor plants are certified
under ISO 9001 and under ISO 14001 for their environment friendly operations. In
2008, Business Standard awarded TAFE the 'Star Award for Unlisted Companies'
and in 2013the Public Relations Council of India conferred TAFE with the 'Corporate
Citizen of the Year'
TAFE is a part of the Amalgamations Group based at Chennai, one of India's
largest light engineering groups, comprising of 41 companies, involved in the design,
development and manufacture of diesel engines, automobile components, light
engineering goods, plantations and services.
TAFE has a number of associations with industry and technology leaders
such as AVL of Austria, Warwick Manufacturing Group of the UK, Carraro and
Ricardo from Europe and from Massey Ferguson in its pursuance of product quality
and overall excellence. TAFE Motors and Tractors Limited has technology transfer
11. Company Profile
A Study on Effectiveness of Existing Layout at TAFE Ltd., 11
agreements with Ricardo of UK for engines and with SISU of Finland for higher HP
tractors.
AGCO
TAFE has an ongoing collaboration with AGCO Corporation, Duluth,
Georgia. AGCO is one of the world's largest manufacturer and distributor of
Agricultural Equipment, selling its products in over 140 countries. The
collaboration has lasted for 50 years and is built on mutual trust and respect for
each other's competencies. These competencies are individually and collectively
leveraged for mutual benefit across geographies through innovative
arrangements for specific markets.
Warwick Manufacturing Group, UK
At TAFE we have been working with the Warwick manufacturing Group
now known as WMG since the late nineties in managing change at TAFE
through company wide initiatives. With their wide exposure to manufacturing
technologies, materials and sustainability and operations and business
management, they have facilitated TAFE to manage the changing environment
in our industry through collaboratively devised approaches to our business that
have helped ensure sustainable success despite its cyclic nature.
Nature of Business
1. TAFE Motors and Tractors Limited (TMTL)
2. Application Business
3. Engineering Plastics
4. Power Sources
5. TAFE Access
6. TAFE Reach
7. Southern Tree Farms
12. Company Profile
A Study on Effectiveness of Existing Layout at TAFE Ltd., 12
Nature of Products
1. Tractors
2. Harvesters
3. Engines &Gensets
4. Gears & Transmission System
5. Batteries
6. Hydraulic Pumps
Players in the Industry along with the Market Share
The study conducted in the Tractor Division, where assembly of tractor and
painting is done. Here two brand name tractors are assembled. They are
1. TAFE
2. Massey Ferguson
M&M
46%
TAFE
23%
Escorts
13%
John Deere
11%
Sonalika
2%
HMT
3%
Others
2%
Market Shares
13. Company Profile
A Study on Effectiveness of Existing Layout at TAFE Ltd., 13
Other Information about the Plant
Current operation = 200 Tractors per day
Capacity operation = 230 Tractors per day
Time Taken to assemble a tractor is 4 minutes
Product Range = 25 HP to 100 HP
Models
National = 70 Models and 45 variants
Export = 55 Models and 275 variants
No.of Components = 9932
No.of Employees = 1200 persons
14. Introduction to the project
A Study on Effectiveness of Existing Layout at TAFE Ltd., 14
Introduction to the Project
Topic of Study
Facility layout means planning for the location of all machines, utilities,
employee workstations, customer service areas, material storage areas, offices and
computer rooms and for the flow pattern of materials and people around into and
within the buildings. Through facilities layouts, the physical arrangement of these
process within and around the buildings, the space necessary for the operation of
these process and provided the space required for support functions. As process
planning and facility layout planning information continuous interchange between the
two planning activities, because each affects the other objective of the facility layout
study is to minimize the total cost, the cost comprises of construction cost,
installation cost, material handling cost, ease of future expansion, production cost,
machine down time cost, in-process storage cost, safety cost, ease of supervision.
Operation layout design criteria
1. Efficient loading and unloading
2. Ease of inventory counts
3. Effective stocking
4. Effective use of layout
5. Increase the productivity
Background of the research topic
Facilities should be designed so that they can be easily expended or adjusted
to meet changing production needs. Flexible manufacturing system most often are
highly automated facilities having intermediate-volume production of a variety of
products. Their goals to minimize changeover and setup times for producing the
different products while still achieving close to assembly line production rates.
Objectives of a good layout
1. Movement of people and material
2. Production capacity
3. Labour efficiency in terms of ergonomics
15. Introduction to the project
A Study on Effectiveness of Existing Layout at TAFE Ltd., 15
4. Space utilization
5. Ease of supervision and maintenance
Principles for Ideal Layout
1. Minimum travel
2. Sequence
3. Usage and flexibility
4. Safety and satisfaction
5. Compactness and minimum investments
Provide optimum space to organize equipment and facilitate of goods and to
create safe and comfortable work environment. To promote order in production
towards a single objective and optimum use of work force and equipment.
Review of Literature in the area of study
Efficiency of a plant layout can be increased by redesigning the plant layout
using string diagram and layout planning. It provide basic details about the flow of
material through shop floor and the interrelation of various activities.
One such research explain about the planning methods and procedures for
various types of production facilities. The type of layout design to be adopted and
implemented during layout design and has also provided the key elements for the
layout design. The type of flow of material and requirement of basic process is also
explained. Many industries use Activity Relationship Charts (ARC) and diagrams for
layout redesign and layout planning. The use of activity relationship charts in
designing the layout as provided a basic steps for layout planning.
A research conducted to identify and improve the plant layout of pulley’s
factory to eliminate obstructions in material flow and thus obtain maximum
productivity.
Another research focuses on the problems occurred during designing flexible
plant layout for manufacturing facilities were product demands are subjected to
variability. A flexible layout is one that maintains low material handling cost despite
fluctuations in the product demand levels.
16. Introduction to the project
A Study on Effectiveness of Existing Layout at TAFE Ltd., 16
A research conducted in the industry explains about the warehouse redesign
of a manufacturing plant layout and also problems faced during the redesign of
layouts.
A case study explains in detailed redesign of an existing production facility the
design of production differs from that of manufacturing layout and the analysis done
using group technology.
Existing practices of the organization in the area of study
1. Poka - Yoke
2. Cellular Manufacturing
3. Process layout
Poka – Yoke
• Poka – Yoke that help operators avoid mistakes in their work caused by
choosing the wrong part, leaving out a part , installing a part backwards etc.,
• It involve the implementation of fail – safe ways methods that detect or
prevent human machine error.
• It provides instant feedback and prevention of quality problems.
• It helps the operator and process work right the first time.
• Poka – Yoke refers to techniques that make it impossible to make mistake
and it also helps to drive defects out of product and process and substantially
improve quality and reliability.
• It helps the company of simple Poka – Yoke ideas and methods in product
and process design can eliminate both human and mechanical errors.
17. Introduction to the project
A Study on Effectiveness of Existing Layout at TAFE Ltd., 17
Cellular Manufacturing
Cellular manufacturing is a lean manufacturing approach that helps
company’s build a variety of products as little waste as possible. Equipment and
workstations arranged in a sequence that supports smooth material flow through
process with minimal transport or delay.
A manufacturing cell consists of people and machines of workstations
required for performing the process steps.
For example :
If a process for a product requires cutting, followed by drilling and
finishing, the cell could include the equipment for performing steps arranged in that
order.
It helps the company achieve to important goals of lean they are One-piece
flow and High-variety production.
One-piece flow
One-piece flow is the state that exists when products move through a
manufacturing process one unit at a time at a rate determined the needs of
customer.
High-variety production
By grouping similar products into families that can be processed on same
equipment in the same sequence. It helps to shorten change over time between
products.
18. Introduction to the project
A Study on Effectiveness of Existing Layout at TAFE Ltd., 18
Process layout
This type is generally used in systems where a product has to be
manufactured or assemble in large quantities. In process layout the machinery and
auxiliary services are located according to the processing sequence of the product
without any buffer storage within the line itself.
19. Design of the Study
A Study on Effectiveness of Existing Layout at TAFE Ltd., 19
Design of the Study
1. Objectives of the study
2. Scope of the Study
3. Tools and Techniques for collection of data
4. Operation definition of concepts
Objectives of the Study
To study the current flow pattern and relation of overall plant layout
Relocating the workstations for simpler flow and reduction in check points.
To improve the efficiency of the plant layout using facility layout planning
To increase production capacity of the plant.
To ensure optimum utilization of workforce and equipment.
To reduce movement of workers, raw materials and equipment.
Scope of the Study
Production and operations management concern with the conversion of inputs
into outputs, using physical resources, so as to provide the desired utilities to the
customer while meeting the other organizational objectives of effectiveness,
efficiency and adoptability. It distinguishes itself from other functions such as
personnel, marketing, finance etc., by its primary concern for conversion by using
physical resources.
Plant layout deals with the arrangement of machines and plant facilities. The
machines should be arrange that the flow of production remains smooth. There
should not be overlapping, duplication or interruption in production flow. Product
layout, where machines are arranged in a sequence required for the processing of a
particular product and in process layout, where machines performing the similar
process are group together are two popular methods of layout. The departments are
laid out in such a way that the cost of material handling is reduced. They should be
proper choice of material handling equipment. There are many software for planning
the process layout.
Group Technology, cellular manufacturing systems and flexible manufacturing
have made our concepts of layout planning undergo a tremendous change.
20. Design of the Study
A Study on Effectiveness of Existing Layout at TAFE Ltd., 20
In short, manufacturing facilities must be able to exhibit high levels of flexibility
and robustness despite significant changes in the operating requirements. However
the plant layout improvement, could be one of the tools to response to increasing
industrial productivity. Plant layout has became a fundamental basis of today’s
industrial plants which can influence parts of work efficiency. It is needed to
approximately plan and position employees, materials, machines, equipment and
other manufacturing supports and facilities to create the most effective plant layout.
Tools and Techniques for collection of data
1. Time study
2. String diagram
Time Study
Time study methods were originally proposed by Frederick Taylor and were
later modified two include a performance rating adjustments. They have now
became one of the most widely used means of work measurement. Basically by
using time study an analyst is taking a small sample of one worker’s activity and
using it to derive a standard for tasks of that nature time study or stopwatch, time
study is performed by timing a worker as the job is performed, summing the times for
the necessary element of the job, adjusting if an abnormal workspace was observed,
and then adding time for personal and rest breaks.
21. Design of the Study
A Study on Effectiveness of Existing Layout at TAFE Ltd., 21
The time study approach to work measurement use a stopwatch are other
timing device to determine the time required to complete given tasks. Assuming a
standard is being set the worker must be trained and must use the prescribed
method while the study is being conducted.
String Diagram
The string diagram is one of the simplest techniques of method study for
recording and examining movement of workers and materials. It is a tool for
analyzing the designing workspace in a such a way that the movement of material,
men, equipment etc., During a specified sequence of events the string diagram is
thus a form of flow diagram.
In this a thread is used to measure distance it is necessary that the string
diagram be drawn correctly to scale. It is most often used to supplement the flow
process chart. A string diagram can be used to plot the movement of material and is
done especially when a work study person wants to find out easily just how far the
materials travelled. The complete plan containing all the equipments, doorways,
pillars and partitions, which affect path of movement, are drawn to scale. A
measured length of thread is then taken and tide around the pins at the string points
of movement thus the string diagram is useful aid in explaining proposed changes to
company management, problem supervisors and employees.
1. Location of facilities
2. Plant layouts and material handling
3. Product design
4. Process design
5. Production and planning control
6. Quality control
22. Design of the Study
A Study on Effectiveness of Existing Layout at TAFE Ltd., 22
7. Materials management
8. Maintenance management.
LOCATION OF FACILITIES
Location of facilities for operations is a long-term capacity decision which
involves a long term commitment about the geographically static factors that affect a
business organization. It is an important strategic level decision-making for an
organization. It deals with the questions such as ‘where our main operations should
be based?’ The selection of location is a key-decision as large investment is made in
building plant and machinery. An improper location of plant may lead to waste of all
the investments made in plant and machinery equipments. Hence, location of plant
should be based on the company’s expansion plan and policy, diversification plan for
the products, changing sources of raw materials and many other factors. The
purpose of the location study is to find the optimal location that will results in the
greatest advantage to the organization.
PLANT LAYOUT AND MATERIAL HANDLING
Plant layout refers to the physical arrangement of facilities. It is the
configuration of departments, workcentres and equipment in the conversion process.
The overall objective of the plant layout is to design a physical arrangement that
meets the required output quality and quantity most economically.
According to James Moore, “Plant layout is a plan of an optimum
arrangement of facilities including personnel, operating equipment, storage space,
material handling equipments and all other supporting services along with the design
of best structure to contain all these facilities”. ‘Material Handling’ refers to the
‘moving of materials from the store room to the machine and from one machine to
the next during the process of manufacture’. It is also defined as the ‘art and science
of moving, packing and storing of products in any form’. It is a specialized activity for
a modern manufacturing concern, with 50 to 75% of the cost of production. This cost
can be reduced by proper section, operation and maintenance of material handling
devices. Material handling devices increases the output, improves quality, speeds up
the deliveries and decreases the cost of production. Hence, material handling is a
prime consideration in the designing new plant and several existing plants.
23. Design of the Study
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PRODUCT DESIGN
Product design deals with conversion of ideas into reality. Every business
organization have to design, develop and introduce new products as a survival and
growth strategy. Developing the new products and launching them in the market is
the biggest challenge faced by the organizations. The entire process of need
identification to physical manufactures of product involves three functions: marketing,
product development, manufacturing. Product development translates the needs of
customers given by marketing into technical specifications and designing the various
features into the product to these specifications. Manufacturing has the responsibility
of selecting the processes by which the product can be manufactured. Product
design and development provides link between marketing, customer needs and
expectations and the activities required to manufacture the product.
PROCESS DESIGN
Process design is a macroscopic decision-making of an overall process route for
converting the raw material into finished goods. These decisions encompass the
selection of a process, choice of technology, process flow analysis and layout of the
facilities. Hence, the important decisions in process design are to analyse the
workflow for converting raw material into finished product and to select the
workstation for each included in the workflow.
PRODUCTION PLANNING AND CONTROL
Production planning and control can be defined as the process of planning the
production in advance, setting the exact route of each item, fixing the starting and
finishing dates for each item, to give production orders to shops and to follow up the
progress of products according to orders.
The principle of production planning and control lies in the statement ‘First
Plan Your Work and then Work on Your Plan’. Main functions of production planning
and control includes planning, routing, scheduling, dispatching and follow-up.
Planning is deciding in advance what to do, how to do it, when to do it and
who is to do it. Planning bridges the gap from where we are, to where we want to go.
It makes it possible for things to occur which would not otherwise happen.
24. Design of the Study
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Routing may be defined as the selection of path which each part of the
product will follow, which being transformed from raw material to finished products.
Routing determines the most advantageous path to be followed from department to
department and machine to machine till raw material gets its final shape.
Scheduling determines the programme for the operations. Scheduling may be
defined as ‘the fixation of time and date for each operation’ as well as it determines
the sequence of operations to be followed.
Dispatching is concerned with the starting the processes. It gives necessary
authority so as to start a particular work, which has already been planned under
‘Routing’ and ‘Scheduling’. Therefore, dispatching is ‘release of orders and
instruction for the starting of production for any item in acceptance with the route
sheet and schedule charts’.
The function to report daily the progress of work in each shop in a prescribed
proforma and to of follow-up is investigate the causes of deviations from the planned
performance.
QUALITY CONTROL
Quality Control (QC) may be defined as ‘a system that is used to maintain a
desired level of quality in a product or service’. It is a systematic control of various
factors that affect the quality of the product. Quality control aims at prevention of
defects at the source, relies on effective feed back system and corrective action
procedure.
Quality control can also be defined as ‘that industrial management technique
by means of which product of uniform acceptable quality is manufactured’. It is the
entire collection of activities which ensures that the operation will produce the
optimum quality products at minimum cost.
• The main objectives of quality control are:
• To improve the companies income by making the production more acceptable
to the customers i.e., by providing long life, greater usefulness,
maintainability, etc.
• To reduce companies cost through reduction of losses due to defects.
25. Design of the Study
A Study on Effectiveness of Existing Layout at TAFE Ltd., 25
• To achieve interchangeability of manufacture in large scale production.
• To produce optimal quality at reduced price.
• To ensure satisfaction of customers with productions or services or high
quality level, to build customer goodwill, confidence and reputation of
manufacturer.
• To make inspection prompt to ensure quality control.
• To check the variation during manufacturing.
MATERIALS MANAGEMENT
Materials management is that aspect of management function which is
primarily concerned with the acquisition, control and use of materials needed and
flow of goods and services connected with the production process having some
predetermined objectives in view.
The main objectives of materials management are:
• To minimize material cost.
• To purchase, receive, transport and store materials efficiently and to reduce
the related cost.
• To cut down costs through simplification, standardisation, value analysis,
import substitution, etc.
• To trace new sources of supply and to develop cordial relations with them in
order to ensure continuous supply at reasonable rates.
• To reduce investment tied in the inventories for use in other productive
purposes and to develop high inventory turnover ratios.
MAINTENANCE MANAGEMENT
In modern industry, equipment and machinery are a very important part of the
total productive effort. Therefore, their idleness or downtime becomes are very
expensive. Hence, it is very important that the plant machinery should be properly
maintained.
26. Design of the Study
A Study on Effectiveness of Existing Layout at TAFE Ltd., 26
The main objectives of maintenance management are:
1. To achieve minimum breakdown and to keep the plant in good working
condition at the lowest possible cost.
2. To keep the machines and other facilities in such a condition that permits
them to be used at their optimal capacity without interruption.
3. To ensure the availability of the machines, buildings and services required
by other sections of the factory for the performance of their functions at optimal
return on investment.
Operational definition of concepts
1. Job shop production
2. Batch production
3. Mass production
4. Continuous production
5. Effectiveness
6. Efficiency
7. Productivity
8. Lead-time
9. Work station
10.Material Handling
11.Benchmarking
12.Brainstorming
Job shop production
Job shop production are categories by manufacturing of one or few quantity of
products designed and products as per the specification of customers within prefixed
time and cost.
A job shop comprises of general purpose machines arranged into different
departments. Each job demands unique technology requirements, demands
processing on machines in a certain sequence.
27. Design of the Study
A Study on Effectiveness of Existing Layout at TAFE Ltd., 27
Batch production
Batch production is a form of manufacturing in which the job process through
the function departments or batches and each lot may have a different routing. It is
characterized by the manufacture of limited number of products produced at regular
intervals and stocked awaiting.
Mass Production
Manufacture of discrete parts or assemblies using a continuous process are
called Mass production. This production system is justified by very large volume of
production. The machines are arranged in a line or product layout. Product layout
and process standardization exists and all outputs follow the same path.
Continuous production
Production facilities are arranged as per the sequence of production
operations from the first operation to the finished product. The items are made to
flow through the sequence of operation through material handling devices such as
conveyors, transfer devices etc.,
Definition of key terms
Effectiveness
Effectiveness means doing the right things to create the most value for the
company. It can be measured by the actual outputdivided with the expected output.
Efficiency
Efficiency means doing something at the lowest possible cost. It can be
measured by dividing resources planned to be used with resources actually used.
Productivity
Productivity is a common measure of how well a country, industry, or
business unit is using its resources. This can be measured by dividing the outputs
with the inputs.
28. Design of the Study
A Study on Effectiveness of Existing Layout at TAFE Ltd., 28
Lead-time
This is the time between placing an order and receiving the finished goods or
service.
Workstation
The space or area of a facility in which individuals or operators perform tasks.
This ranges from an assembly station in a factory to a cube in an office.
Material handing
Material handing is defined as providing the right amount of the right material,
in the right condition, at the right place, at the right time, in the right position, in the
right sequence, and for the right cost, by using the right methods.
Benchmarking
A tool to improve business processes by looking what other companies are
doing. It is often beneficial to observe firms in other branches.
Brainstorming
Brainstorming is one of the simplest and familiar creativity techniques. It helps
to generate the ideas for a solution of the problem. The outcome of brainstorming
can be a list of ideas, which lead to an approach or the solution itself.
29. Analysis of Data
A Study on Effectiveness of Existing Layout at TAFE Ltd., 29
Analysis of Data
Data Collection
To determine the effectiveness of the layout, the details regarding the
performance of the cell or needed. So by doing the times study, information is
collected. Time study was conducted by taking number or trails. The complete cycle
of events have been divided into work elements. The time required for carrying out
each element is measured using a stop watch in continuous mode. Trails were taken
in different periods to have a good accuracy. The results of the time study are shown
all the details regarding, the cell layout and ergonomics like loading and unloading
points were collected and presented. The table below shows the cycle time of each
station for the final product of their respective parts.
Cycle time details for machines :
S.
No.
Work Element
Machines
Machining
Time
(Sec)
Loading
Time
(Sec)
Unloading
Time
(Sec)
Cleaning
Time
(Sec)
Cycle
Time
(Sec)
1 PTO shaft press
110 5 5 4 124
2 Center Housing
assembly 200 15 60 NA 275
3 OIB wheel axle
bolt press
300 17 10 5 332
4 OIB axle housing
assembly 150 12 7 NA 169
5 Axle housing
sleeve press
360 7 10 NA 377
6 Turkey end
cover assembly
240 8 5 NA 253
7 End cover
assembly
170 5 5 6 186
8 HLC cylinder sub
assembly
270 20 10 7 307
9 HLC assembly
650 10 15 NA 675
Table – 1 Cycle time details for machines
30. Analysis of Data
A Study on Effectiveness of Existing Layout at TAFE Ltd., 30
Production volume details for machines :
S.
No.
Parts Cycle
Time
(sec)
Output
per cycle
Total time
available
(sec)
Production
volume
per month
(Nos.)
1 PTO shaft press 124 1 1310400 10565
2 Center Housing assembly 275 1 1310400 4765
3 OIB wheel axle bolt press 332 1 1310400 3947
4 OIB axle housing
assembly
169 1 1310400 7754
5 Axle housing sleeve
press
337 1 1310400 3476
6 Turkey end cover
assembly
256 1 1310400 5180
7 End cover assembly 186 1 1310400 7045
8 HLC cylinder sub
assembly
307 1 1310400 4268
9 HLC assembly 675 1 1310400 1941
0
100
200
300
400
500
600
700
800
Cycle Time (Sec)
31. Analysis of Data
A Study on Effectiveness of Existing Layout at TAFE Ltd., 31
Calculation of cycle time and production volume
Cycle time = machining time + loading time + unloading time + cleaning time
= 110 + 5 + 5 + 4
= 124 seconds.
Production volume = Total time available (sec)
cycle time (sec)
= 1310400
124
= 10568 parts
0
2000
4000
6000
8000
10000
12000
PTO shaft
press
Center
Housing
assembly
OIB wheel
axle bolt
press
OIB axle
housing
assembly
Axle
housing
sleeve
press
Turkey end
cover
assembly
End cover
assembly
HLC
cylinder
sub
assembly
HLC
assembly
Production volume per month (Nos.)
32. Analysis of Data
A Study on Effectiveness of Existing Layout at TAFE Ltd., 32
Comparison of Cycle time (sec) and Production volume per month (Nos.)
From the data collection phase, information are collected directly by observing
shop floor and it indicates performance of the shop floor (viz., man and machine,
utilization, part travel, production volume etc.,) Hence they have to be further
process to obtain the performance of cell.
Any manufacturing cell includes, all the resources needed for product
manufacturing. The resources have to be utilized to maximum extent to obtain the
desired output from the cell. Hence to evaluate the performance of cells, the
utilization of resources, along with the factors that affects the utilization of the
resources. In order to do so, the following factors have to be considered to know
about the performance of the cell.
1. Man activity chart
2. Cell Ergonomics
0
2000
4000
6000
8000
10000
12000
PTO shaft
press
Center
Housing
assembly
OIB wheel
axle bolt
press
OIB axle
housing
assembly
Axle
housing
sleeve
press
Turkey
end cover
assembly
End cover
assembly
HLC
cylinder
sub
assembly
HLC
assembly
Cycle Time (Sec)
Production volume per month (Nos.)
33. Analysis of Data
A Study on Effectiveness of Existing Layout at TAFE Ltd., 33
Man activity chart
In the man activity chart we will look at the following stations, how they were
efficient and it also represent the ergonomics, movements of operator, distance
travelled and production volume. The data collected using the stop watch study and
string diagram.
Cell Ergonomics
The job of the operator is primary loading and unloading parts. Hence
ergonomics concern with lifting and placing parts in machines and operating work
holding devices. In this system, human performance in detecting and correcting cell
malfunctions will establish utilization and thus the production efficiency. The existing
cell has been studied and the ergonomics of a worker is designed. There are no
unnecessary movements and operator fatigue is less, when working continuously.
As far as the ergonomic concern in the company, they have been following
the standards which is feasible to the workers with less fatigue and strain. They were
following some techniques in order to enhance the productivity. They are
1. Machinery and controls, so as to minimize mental and physical strain on
the worker to enable the improvement in efficiency.
2. They were maintaining a peaceful environment for performing the task
most affectively and conducive.
3. They have designed the working environment in such a way that lighting,
ventilation, temperature, noise, vibrations, color, safety etc.,
34. Analysis of Data
A Study on Effectiveness of Existing Layout at TAFE Ltd., 34
OIB AXLE HOUSING ASSEMBLY ( in mts.,)
Operations Sequence Tools used Forward Backward Right Left Bending
Down
Stretching up Remarks
To Fro To Fro To Fro To Fro To Fro To Fro
Taking OIB
from TOD
Scanning the
sticker on the
moniter
Barcode
Scanner
0.5 0.5
Stretching
forward to pick
up the
barcode
scanner
Taking axle
shaft from the
trolley
0.5 0.5
Turning back
to pick up the
axle shaft
Taking friction
plate and
intermediate
plate from the
trolley
0.5 0.5 Turning back
Checking disc
length
Disc guage 0.5 0.5
Stretching
forward to pick
up the guage
Taking
reaction pin
from the
storage rack
0.5 0.5 0.75 0.75
Stretching
forward to pick
up the reaction
pin
Taking
accutator
from the
trolley
0.5 0.5
Turning back
to take the
accelator
Cont…
35. Analysis of Data
A Study on Effectiveness of Existing Layout at TAFE Ltd., 35
Taking friction
plate and
intermediate
plate from the
trolley
0.5 0.5 Turning back
Putting
grease and
'O' ring and
again
applying
grease
0.75 0.75 1.00 1.00
Stretching
towards left for
taking 'O' ring
Taking brake
boot bracket
from the
trolley
1.5 1.5 1.00 1.00
Operator is
bending down
to pick up boot
bracket in the
trolley
Scanning the
brake boot
bracket for
checking
hours (4 hrs)
curing time
Barcode
Scanner
0.5 0.5
Putting
Gasket
0.5 0.5
Applying
loctite
0.5 0.5
Bending down
to pick up
loctite
Cont…
36. Analysis of Data
A Study on Effectiveness of Existing Layout at TAFE Ltd., 36
Putting brake
lever from the
trolley
0.5 0.5
Putting
fasteners and
washers from
the storage
rack
0.5 0.5
Tightening
fasterners
using Nut
runner
Nut runner
(Power tool)
0.5 0.5
Bending down
to pick up the
Nut runner
Tightening
the stud using
torque
wrench
Torque
wrench
0.6 0.6
Putting Nut
and cotter pin
0.5 0.5
Taking carrier
plate from the
pressing
machine
1.5 1.5
Travel back to
carry tip
carrier (heavy
weight)
Putting screw
and tightening
Power
screw driver
0.5 0.5 0.5 0.5
Stretching up
to catch the
power screw
driver
Cont…
37. Analysis of Data
A Study on Effectiveness of Existing Layout at TAFE Ltd., 37
Punching the
screw
Hammer
and rod
0.5 0.5
Checking the
gap with filler
gauge
Filler gauge
Moving to the
trolley for
main
assembly line
Cycle time = 169 seconds
Production volume = 7754 parts
Distance travelled by the operator = 31.2 meters
38. Analysis of Data
A Study on Effectiveness of Existing Layout at TAFE Ltd., 38
OIB WHEEL AXLE BOLT PRESS ( in mts.,)
Operations Sequence Tools used Forward Backward Right Left Bending
Down
Stretching up Remarks
To Fro To Fro To Fro To Fro To Fro To Fro
Wheel Axle
Pressing
Taking wheel
axle from trolley
2 2 0.5 0.5
Operater is
bending down
Taking seal
labrith plate
from storage
rack
0.5 0.5 1 1
Stretching
upward
towards left
Taking Bolt
from storage
rack and putting
on wheel axle
0.5 0.5
Taking bearing
from the trolley
and inserting on
the wheel axle
0.75 0.75
Travelling
towards right
side to pick up
bearing
Operating
Hydraulic
machine for
pressing
bolt
Taking drive
cover from right
side
Bearing
press tool
2 2
Carring heavy
weight
Pressing
the bearing
with
machine
Putting half ring
from storage
rack
Using
hammer
and screw
driver
0.5 0.5
Cont…
39. Analysis of Data
A Study on Effectiveness of Existing Layout at TAFE Ltd., 39
Checking
the half ring
Adjusting the
half ring
Filler gauge
tool
0.5 0.5
Putting 'O'
ring from
storage bin
0.5 0.5
Locating 'O'
ring
Spanner
Putting
wheet axle
in carrier
press
Taking carrier
from trolley
using hoist
1.5 1.5
Putting
bearing
Taking
bearing from
bearing stand
1 1
Pressing
the carrier
and bearing
using
pressing
machine
Forwarded to
the shim size
stickering
1 1 0.5 0.5
Stretching
upward to pick
up the sticker
Cycle time = 332 seconds Production volume = 3947 parts
Distance travelled by the operator = 24.00 meters
40. Analysis of Data
A Study on Effectiveness of Existing Layout at TAFE Ltd., 40
AXLE HOUSING SLEEVE PRESS ( in mts.,)
Operations Sequence Tools used Forward Backward Right Left Bending
Down
Stretching up Remarks
To Fro To Fro To Fro To Fro To Fro To Fro
Scanning
the shim
using
scanner
Using barcode
scanner
travelling to
shimming
gauge
Barcode
Scanner
1.5 1.5
Moving
backward
diagonally
Putting shim on
axle according
to the size
mentioned
0.5 0.5
Putting 'O' ring
from the
storage rack
and locating
Spanner 0.5 0.5
Moving to the
sleeve press
machine
0.5 0.5
Pushing the
wheel axle
and carrier to
left
Pressing
the axle
sleeve with
40kg/cm2
Mounting
Ring gear
Taking ring
gear from
trolley
2 2
Travelling in
backward
direction
Cont…
41. Analysis of Data
A Study on Effectiveness of Existing Layout at TAFE Ltd., 41
Mounting
Carrier on
Ring gear
Taking Carrier
from carrier
press trolley
Hoist 1 1
Turning back
to pick up the
carrier
Putting washers
and bolts from
storage rack
0.5 0.5
Tightening stud
with Nut runner
Nut runner
(Power tool)
0.5 0.5 0.5 0.5
Bending down
to pick up the
Nut runner
Locking the bolt
with Torque
wrench from
storage rack
Torque
wrench
0.5 0.5
Cycle time = 377 seconds
Production volume = 3476 parts
Distance travelled by the operator = 16.00 meters
42. Analysis of Data
A Study on Effectiveness of Existing Layout at TAFE Ltd., 42
Turkey end cover assembly ( in mts.,)
Operations Sequence Tools
used
Forward Backward Right Left Bending
Down
Stretching up Remarks
To Fro To Fro To Fro To Fro To Fro To Fro
Turkey end
cover
assembly
Picking end
cover from the
trolley and
keeping on the
pressing
machine
0.5 0.5
Operator
carrying heavy
weight
picking bearing
from stroage
rack and
inserting on the
end cover
0.5 0.5
Streching
forward to pick
up the bearing
Picking lock
tool and
pressing
bearing using
pressing
machine
End
cover
lock tool
0.5 0.5
Picking end
cover lock from
storage rack
and inserting in
the end cover
over bearing
0.5 0.5
Taking bearing
pressing guide
tool and
keeping over
the bearing
Bearing
pressing
guide
tool
0.5 0.5
Picking heavy
weight of
bearing press
tool
Cont…
43. Analysis of Data
A Study on Effectiveness of Existing Layout at TAFE Ltd., 43
Turning back
side of the end
cover
Picking end
cover oil seal
from storage
rack
0.5 0.5
Applying loctite
(603) inside the
oil seal
0.25 0.25
Bending down
to pick up the
loctite
Inserting oil
seal in the end
cover and
pressing with oil
seal pressing
tool
Oil seal
pressing
tool
Pasting the
barcode sticker
and waiting for
to dry the loctite
(15 minutes)
0.5 0.5
Streching
forward to
pickup the
barcode
sticker
Picking shaft
from the trolley
Hoist 0.5 0.5
Turning back
to pick up the
shaft
Inserting shaft
into the end
cover and
pressing with
machine
Cont…
44. Analysis of Data
A Study on Effectiveness of Existing Layout at TAFE Ltd., 44
Removing the
end cover from
pressing
machine and
putting into
TOD
0.5 0.5
Operator is
carrying heavy
weight of end
cover
Putting lock
washer into the
shaft
0.25 0.25
Bending down
to pick up lock
washer
Cycle time = 253 seconds
Production volume = 5180 parts
Distance travelled by the operator = 10.00 meters
45. Analysis of Data
A Study on Effectiveness of Existing Layout at TAFE Ltd., 45
END COVER ASSEMBLY ( in mts.,)
Operator 1
Operations Sequence Tools
used
Forward Backward Right Left Bending
Down
Stretching up Remarks
To Fro To Fro To Fro To Fro To Fro To Fro
End cover
assembly
Collecting end
cover from the
washing machine
using conveyor
1.5 1.5
Pulling the end
cover from the
right side to
the pressing
machine
Putting end cover
in the pressing
machine
0.5 0.5
Putting bearning
over the green oil
seal over the end
cover from the
trolley
0.5 0.5
Putting shim over
the bearing from
the storage rack
0.25 0.25 0.75 0.75
Putting circlip
guide tool over
the end cover
Putting circlip
from the trolley
0.5 0.5
Turning back
to pick up the
circlip
Pressing the
bearing
Bearing
press
tool
0.25 0.25
Cont…
46. Analysis of Data
A Study on Effectiveness of Existing Layout at TAFE Ltd., 46
Putting green oil
seal from the
trolley
0.5 0.5
Turning back to
pick up the green
oil seal
Pressing using
the machine
Oil seal
guide
tool
0.25 0.25
Stretching
forward to pick
up the oil seal
guide tool
Turning
backside of
the end
cover
Putting mud block
after turning the
end cover
Bearing
press
tool
0.25 0.25 0.5 0.5
Turning back to
pick up the mud
block from the
trolley
Taking shaft from
the trolley putting
on the end cover
Hoist 0.5 0.5
Turning back to
collect the shaft
from the trolley
Pressing the
shaft using press
machine
0.25 0.25
Pusing end
cover with shaft
into the pressing
machine
Forwarded to
TOD
Cont…
47. Analysis of Data
A Study on Effectiveness of Existing Layout at TAFE Ltd., 47
Operator 2
Operations Sequence Tools
used
Forward Backward Right Left Bending
Down
Stretching up Remarks
To Fro To Fro To Fro To Fro To Fro To Fro
End cover
sub
assembly
Collecting from
the TOD
0.5 0.5
Pulling end
cover with
shaft from the
TOD
Taking 'O' ring
from storage rack
0.75 0.75
Stretching
forward
towards right
to pick up 'O'
ring
Taking sleeve
from the storage
rack and putting
over the shaft
0.75 0.75
Stretching
forward to pick
up the sleeve
Applying loctite
from the storage
rack
0.5 0.5
Stretching
forward to pick
up the loctite
Putting sleeve
over the shaft
and tightening the
sleeve
Nut
tighter
tool
0.5 0.5 0.75 0.75
Stretching up
to catch the
nut tighter tool
Taking sleeve nut
from the storage
rack
0.5 0.5
Stretching
forward to
collect the
sleeve nut
Cont…
48. Analysis of Data
A Study on Effectiveness of Existing Layout at TAFE Ltd., 48
Tightening the
Sleeve nut
Nut
tighter
tool
0.5 0.5 0.75 0.75
Stretching up
to pick up the
tool
Moving end cover
to the main
assembly line
Cycle time = 186 seconds
Production volume = 7045 parts
Distance travelled by the operator = 24.00 meters
49. Analysis of Data
A Study on Effectiveness of Existing Layout at TAFE Ltd., 49
HLC CYLINDER SUB ASSEMBLY ( in mts.,)
Operations Sequence Tools
used
Forward Backward Right Left Bending
Down
Stretching up Remarks
To Fro To Fro To Fro To Fro To Fro To Fro
HLC
cylinder
sub
assembly
Taking piston
from the trolley
0.75 0.75
Turning back
to pick up the
piston
Taking piston
seal ring and
inserting over
the piston
0.5 0.5
Taking seal ring
guide tool and
putting over the
piston
0.6 0.6
Bending down
to pick up the
tool
Taking seal ring
from storage
rack and putting
over piston
Fitting the
piston using
seal ring guide
tool
Seal
ring
guide
tool
0.5 0.5
Taking cylinder
(outer body)
from the trolley
0.5 0.5
Carring heavy
weight
Cont…
50. Analysis of Data
A Study on Effectiveness of Existing Layout at TAFE Ltd., 50
Apply grease 0.5 0.5
Inserting piston
into the cylinder
Piston
guide
tool and
insert
tool
0.5 0.5
Putting stud
into cylinder
from storage
rack
0.5 0.5
Stretching
forward
Tightening the
stud
Nut
runner
(Power
tool)
0.5 0.5
Stretching
forward
Taking setting
bracket
0.5 0.5
Turning back
to correct the
setting bracket
Taking
fasterners from
the storage
rack
0.5 0.5
Stretching
forward
Putting
fasterners over
setting bracket
from the
storage rack
0.5 0.5
Cont…
51. Analysis of Data
A Study on Effectiveness of Existing Layout at TAFE Ltd., 51
Tightening the
Fasterners
Nut
runner
(Power
tool)
0.5 0.5
Stretching
forward to pick
up Nut runner
Taking PC and
DC lever from
the trolley
0.5 0.5 Turning back
Tightening
fasterners of
PC and DC
levers
Nut
runner
(Power
tool)
0.5 0.5
Stretching
forward to pick
up Nut runner
Moving to HLC
main assembly
Cycle time = 307 seconds
Production volume = 4268 parts
Distance travelled by the operator = 15.7 meters
52. Analysis of Data
A Study on Effectiveness of Existing Layout at TAFE Ltd., 52
HLC ASSEMBLY ( in mts.,)
Operator 1
Operations Sequence Tools
used
Forward Backward Right Left Bending
Down
Stretching up Remarks
To Fro To Fro To Fro To Fro To Fro To Fro
HLC
assembly
Taking HLC from
the trolley using
hoist
2.5 2.5 0.5 0.5
Travelling in
backward
direction and
bending down
Putting HLC in
washing machine
Operator is
training due to
heat
Taking the HLC
from the washing
machine and putting
on the trolley
1.5 1.5
Travelling in
backward
direction
Mounting washers
and bolt the storage
rack on the HLC
1.00 1.00
Tightening the bolts
Spanner,
Torque
wrench
0.5 0.5
Bending down
to take the
washers and
bolts
Taking trolley from
behind the washing
machine
1.00 1.00 3.00 3.00
Traveling left
and then
forward to get
the trolley
Picking the cylinder
from trolley and
putting into washing
machine
Cont…
53. Analysis of Data
A Study on Effectiveness of Existing Layout at TAFE Ltd., 53
Picking cylinder
from washing
machine and again
keeping in trolley
2.00 2.00
Operator is
carrying heavy
weight
Removing water
droplets using air
gauge
Air
gauge
0.5 0.5
Again moving trolley
to the respective
station
1.00 1.00 1.5 1.5
Taking kitting trolley
and washing the
parts
1.5 1.5
Pulling kitting
trolley near to
washing
machine
Picking parts from
washing machine
and keeping in the
kitting trolley
0.5 0.5
Turning back
to keep parts
in the trolley
Picking end cover
from the end cover
tray and putting in
the washing
machine
Hoist 1.00 1.00 0.5 0.5
Operator is
bending down
to pick up end
cover
After washing
picking the end
cover using hoist
and keeping on the
conveyor
Hoist 0.75 0.75
Operator is
straning due to
heat
Cont…
54. Analysis of Data
A Study on Effectiveness of Existing Layout at TAFE Ltd., 54
Operator 2
Operations Sequence Tools
used
Forward Backward Right Left Bending
Down
Stretching up Remarks
To Fro To Fro To Fro To Fro To Fro To Fro
Putting bolt and
washers from
storage rack to fix
the HLC
0.5 0.5
Putting 'O' ring
and disc over
load plate from
storage rack
0.4 0.4 0.35 0.35
Operator is
bending to
take disc
cover load
plate
Taking kitting
trolley from the
trolley line to
station
2.5 2.5
Operator is
travelling
straight and
right to take
the kitting
trolley
Taking Arm Ram
and connecting
rod pressing
using machine
1.5 1.5
Turning back
for pressing
Putting allen
screw on HLC
from storage rack
1 1
Putting washers
from trolley
0.5 0.5
Inserting lift shaft
into HLC from
trolley
0.5 0.5
Cont…
55. Analysis of Data
A Study on Effectiveness of Existing Layout at TAFE Ltd., 55
Locating DC link
and PC link from
the trolley to the
HLC
Hammer
and rod
0.5 0.5
Putting link shaft
from storage rack
0.75 0.75
Putting bush from
storage rack and
locating it
Bush
guide
tool
1 1
Turning back
to pick up the
bush
Putting 'O' ring
and seal ring
Bush
guide
tool
0.5 0.5
Putting lift arm
from the trolley
0.75 0.75
Putting load
washer from
storage rack
0.5 0.5
Putting control
spring from the
trolley and
locating it
Screw
driver
0.5 0.5
Locating HLC
cylinder from the
HLC sub
assembly line
Hammer 1 1
Operator is
carring heavy
weight
Locating
quardant from the
storage rack
Screw
driver
and
centre
screw
allen key
3 3
travelling in
backward
direction
carring heavy
load
Cont…
56. Analysis of Data
A Study on Effectiveness of Existing Layout at TAFE Ltd., 56
Checking draft
control and
position control
Pounds
and
checking
tool
1.5 1.5
Moving to the
main assembly
line
Putting bolt and
washers from
storage rack to fix
the HLC
0.5 0.5
Putting 'O' ring
and disc over
load plate from
storage rack
0.4 0.4 0.35 0.35
Operator is
bending to
take disc
cover load
plate
Taking kitting
trolley from the
trolley line to
station
2.5 2.5
Operator is
travelling
straight and
right to take
the kitting
trolley
Taking Arm Ram
and connecting
rod pressing
using machine
1.5 1.5
Turning back
for pressing
Cycle time = 675 seconds
Production volume = 1941 parts
Distance travelled by the operator = 72 meters
57. Findings and Recommendations
A Study on Effectiveness of Existing Layout at TAFE Ltd., 57
Findings
With the best knowledge of available techniques the solution to these type of
layout become more acceptable with the good points of different approach were
brought together.
As it was noted there are several points which make the problem more real.
The data that are posted in the operated movement chart has been carefully
collected and summarized.
The important factors should be assigned accurately to the type of movement
so that adjustment of the numbers in the travel chart could be affected
accordingly.
The data collection and posting into the operator movement chart is the most
important step before starting the analysis, because the techniques of
evaluation of layouts depends on the accuracy of the operator movement with
keeping the restrictions and assumptions in the mind.
we can find the effectiveness of the existing layout. From the data collected
using the methodology the existing layout of the rear axle assembly was doing
good in terms of productivity and ergonomically. Now the existing layout they
were achieving the peak of the desired production level in the rear axle
assembly.
Recommedations
For the main assembly line of tractor they can adopt the robotic technology.
By adopting the robotic technology they can reduce the human error and can
achieve the high precision.
With the help of robotic technology they can reduce the takt timeand the
production volume can be increased.
58. Bibliography
A Study on Effectiveness of Existing Layout at TAFE Ltd., 58
Bibliography
1. Dr.M.Khoshnevisan Francis, “Facility layout and location: An analytical
approach”, Prentice Hall, 2/E, Engle wood cliffs, NJ, 1993.
2. Shikdar A. Al-Hadhrami M., (2007) “Smart workstation design : an ergonomics
and methods engineering approach” International Journal of Industrial and
System Engineering.
3. Dr.V.Jayakumar, “Process planning and cost estimation”, Lakshmi
Publications, OMAN, 2011.
4. G.Sundaraja, Improving productivity of manufacturing using lean concepts,
International Journal of Lean Thinking.