DIAGNOSTIC STUDY REPORT(DSR)
ORGANISATION
Year of Establishment 2000
HEAD OFFICE
OFFICE TELE.
FAX N.A.
E - MAIL
Business Activity
WEBSITE
WORKS
A B C G
SHIFT OPERATION
YES YES YES YES
0800- 1600- 0000- 0900-
SHIFT TIMING
1600 0000 0800 1700
STAFF 2 2 1 8
WORK
REGULAR WORKERS 14 14 4
FORCE
CASUALS 18 16 14
CURRENT SALES TURN OVER
145.15
Rs.LAKHS TILL 31-09-12
ORGANISATION STRUCTURE (DOWN UPTO SUPERVISOR LEVEL)
Operations
Tarlok Singh
Plant Layout & Manufacturing process flow
Plant layout of the unit and process flow chart
PLANT LAYOUT OF DYNAMIC ENGINEERING INDUSTRIES
MAIN GATE
DG SET ROOM
SECURITY
BOOTH
OFFICE
SUPER
CNC CNC CNC 02
VISOR WIP
TABLE 07 05
CNC CNC CNC CNC CNC
08 01 06 03 04
D
P P SR D E
D D MI E B
E
I I SC. BK K
M/ T. B T.
Cs LI N K LI
WASHING
GAUGES E T. N
AREA E
ROUGHING AREA
D
P P SR D E
D D MI E B
E
I I SC. BK K
M/ T. B T.
Cs LI N K LI
WASHING
GAUGES E T. N
AREA E
ROUGHING AREA
CNC 10
INSPECTION SPARE
AREA MACHINES
CNC 09 CNC 11
AL DE BKT.DRILLING
MAINTNE-
NANCE STORES
ROOM
WORKER
STORES
TOILET
AIR
STEEL SCRAP COMPRESS SHOT BLASTING SPARE MACHINES
AREA OR
TOTAL AVG. TIME OF AVG.TOTAL TOTAL TOTAL
QTY CHANGE CHANGE CHANGE CHANGE OVER
OVER OVERS OVERS/YEAR TIME/YEAR
DESCRIPTION /PRODUCT /MONTH
(A) (B) (C.) (D)=(C.)*12 (E)=(B)*(D)
MOLDS NA
DIES NA
CUTTING TOOLS 46
FIXTURES 505 20 MINS 400 MINS 8000 MINS 96000 MIN
Visual Base lining Summary
CURRENT STATUS
FOCUS AREA NO AWARENESS EDUCATION ON HAND HOLDING ADVANCED ROLE MODEL
TRAINING IN IMPLEMENTATIO
PROGRESS N
5s & Kaizen
*
Safety
*
Visual Control
*
Storage
*
Maintenance
*
Quality
Certification: ISO:9001 2008 (YES/NO), if No then what certification ? ISO:9001 2008
Customer PPM NIL
Inhouse PPM 5000
Supplier PPM. NA
CURRENT STATUS
NO AWARENESS EDUCATION ON HAND HOLDING ADVANCED ROLE MODEL
Quality Practices TRAING IN
PROGRESS
IMPLEMENTATIO
N
Suggestion scheme
*
Quality Circles
*
Shop floor meetings
*
Monthly meetings
*
Use of problem solving
techniques *
Continuous Improvement
(Kaizen) *
Cost of Quality
*
Identification of Seven wastes 2.6
Evaluation on a scale of 1 to 5. (5 being ‘completely lean’ and 1, ‘completely traditional’.)
SCALE DESCRIPTION
5 - Completely Lean Fully follows Lean principles in both letter and spirit and thereby enjoys
benefits of high efficiency fully meeting customer requirements.
4 - Largely Lean Follows lean principles in many areas with few of the traditional practices
3 – Moderate Follows a mix of lean and traditional practices equally
2 - Largely Traditional Follows Traditional practices largely – just getting aware of lean practices
and practicing in few of the areas
1 - Completely Traditional No existence of any Lean practices
7 WASTES -Mr.TIMWOOD
SHORT FULL DESCRIPTION CURRENT LEVEL COMMENTS
T TRANSPORTATION 2
I INVENTORY 2
M MOTION 2
W WAITING TIME 3
O OVER PRODUCTION 3
O OVER PROCESSING 3
D DEFECTS 3
D.E.BKT - AL 0022 D
CUSTOMER SUPPLIED COMPONENT
INSPECTION & STORAGE
ROUGH & FINISH BORE DIA.
FILING OF ALL SHARP EDGES
DRILLING OF DIA.5.2 HOLES
MILLING OF LUG FACES
DRILLING OF DIA.2.2 - 2 HOLES
CLEANING & VISUAL INSPECTION
PACKING
DESPATCH
PROCESS FLOW DIAGRAM
GEAR 4TH DRIVE - 2013869/F
CUSTOMER SUPPLIED FORGING
INSPECTION & STORAGE
ROUGH MACHINING
FINISH TURNING - OIL SLOT SIDE
FINISH TURNING & KIDNEY SLOT MILLING
DEBURRING
INSPECTION - PREDESPATCH
RUST PREVENTIVE APPLICATION
PACKING
DESPATCH
PROCESS FLOW DIAGRAM
SRE BKT. - SM0081B
CUSTOMER SUPPLIED COMPONENT
INSPECTION & STORAGE
MACHINING OF BEARING DIA.
FILING OF SHARP EDGES
DRILLING OF DIA.2.4 - 2 HOLES
DRILLING OF DIA.3.9 - 3 HOLES
DRILLING OF DIA.3.9
DRILLING OF DIA.9.0
DRILLING OF DIA.3.0
DRILLING OF DIA.3.9 - 3 HOLES
COUNTER & REAMING
TAPPING OF M5 - 4 HOLES
TAPPING OF M5 -THRU
TAPPING OF M5 THRU - 3 HOLES
TAPPING M3
WASHING & DEBURRING
INSPECTION
DESPATCH
PROCESS FLOW DIAGRAM
SMDE BKT. - SMDE 152
CUSTOMER SUPPLIED COMPONENT
INSPECTION & STORAGE
SHOT BLASTING
ROUGH & FINISH O.D.TURNING
ROUGH & FINISH (SOLENOID MTG.FACE)
FILING OF SHARP EDGES
DRILLING OF MOUTING HOLE DIA.11DIA.
DRILLING OF DIA.5.5
MILLING OF SHROUD DIA.
TAPPING - M6
WASHING&DEBURRING
CLEANING & VISUAL INSPECTION
INSPECTION -PREDESPATCH
PACKING
DESPATCH
LEAN MANUFACTURING CLUSTER
Lean Manufacturing Cluster Team
Company Name :
Company Address: 0
DATE OF FORMATION OF LMC TEAM:
Ref. NAME DESIGNATION TEAM ROLE DEPTT. EXPERIENCE in MOBILE NO. E-MAIL
years Total (with
the company)
1 PROPRIETOR CAPTAIN 27
2 WORKS MANAGER VICE CAPTAIN 22
3 HEAD Q.A. TEAM MEMBER Q.A. 18
4 HEAD ACCOUNTS TEAM MEMBER ACCOUNTS 16
5 SUPERVISOR TEAM MEMBER M/C SHOP 13
6 SUPERVISOR TEAM MEMBER DRILLING 18
7 OPERATOR TEAM MEMBER CNC 18
8 OPERATOR TEAM MEMBER CNC 8
9 SUPERVISOR TEAM MEMBER MAINTENANCE
###
Inventory
NAME OF COMPANY 0 DATE
0 PREPARED BY
ADDRESS OF COMPANY
APPROVED
MONTHS
Metrics Units
Jan.25 Fab.25 Mar.25 Apr.25 May.25 Jun.25 July.25 Aug.25 Sep.25 Oct.25 Nov.25 Dec.25
Raw Material (RM) Rs. Lakhs
Finished Goods(FG) Rs. Lakhs
Work In Progress(WIP) Rs. Lakhs
Non Moving ITEMS Rs. Lakhs
Scrap Rs. Lakhs
Total Inventory Rs. Lakhs 0 0 0 0 0 0 0 0 0 0 0 0
Sales Turnover Rs. Lakhs
Inventory Turnover No. of times #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0!
