Case study _cp foundry
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C.P. Foundry Works is a foundry established in 1942 located in Nagpur, India. It produces cast iron products for customers like Mahindra & Mahindra and Johnson Lifts. The main processes include melting, mould making, core making, pouring, and cleaning. The company implements 5S and Kaizen for continuous improvement. Three Kaizen examples are provided: 1) Utilizing space for a fire extinguisher, 2) Arranging wires and cables systematically for safety, and 3) Disposing of unwanted material to save 5.54 square meters of space.
Case study _cp foundry
- 1. SHRI RAMDEOBABA COLLEGE OF ENGINEERING AND MANAGEMENT Department of Industrial Engineering Case Study C.P.FOUNDRY WORKS Presented by Ajinkya Sawarkar & Deepak Pandey IInd Semester Mtech 2019-20 Submitted to Dr. V.S. Deshpande
- 2. About Company NAME OF THE ORGANIZATION: C.P.FOUNDRY WORKS PLANT ADDRESS: P.O.UPPALWADI INDUSTRIALESTATE , KAMPTEE ROAD, NEAR PILI NADI, NAGPUR. E-MAILADDRESS: foundry_ngp@bsnl.in & foundry_ngp@yahoo.com CONTACT PERSON: MAQSOOD ALAM YEAR OF ESTABLISHMENT: 1942 Major customers : 1. Mahindra & Mahindra Ltd. 2. Johnson Lifts MAHINDRA & MAHINDRA JOHNSON LIFTS
- 3. Company Products CI ROLLING MILL COUPLINGS CI ROLLING MILL STAND CI GRATE STEEL ROLLING MILL PARTS CI SANITARY GRATE CI METRIC WEIGHT CI MANHOLE COVER CI TILES CI FLYWHEEL
- 4. Main Processes o MELTING o MOULD MAKING o CORE MAKING o POURING o FOUNDRY SAND SYSTEM o CLEANING AND FINISHING
- 5. 5 S Zone Wise Layout ZONE 1 OFFICE ZONE 2 PRODUCTION AND PATTERN ZONE 3 MELTING ZONE 4 LAB ZONE 5 STORE AND OUTSIDE AREA ZONE 6 INDUCTION ZONE 7 DISPATCH
- 6. Kaizen From the Japanese words “kai-” which means “change” and “-zen” which means “good.” Kaizen is defined as a continuous effort by each and every employee (from the CEO to field staff) to ensure improvement of all processes and systems of a particular organization. Kaizen process aims at continuous improvement of processes not only in manufacturing sector but all other departments as well.
- 7. 5S 5S represents Japanese words that describe the steps of a workplace organization process. Seiri - (Sort) Seiton - (Straighten, Set) Seiso - (Shine, Sweep) Seiketsu - (Standardize) Shitsuke - (Sustain)
- 8. The five S methodology helps a workplace remove items that are no longer needed (sort). Organize the items to optimize efficiency and flow (straighten). Clean the area in order to more easily identify problems (shine) Implement color coding and labels to stay consistent with other areas (standardize) and Develop behaviors that keep the workplace organized over the long term (sustain). It can also referred as 7S adding Safety and Spirit to it. 5S
- 9. Red Tag Summary Zone No. Zone Name 1st 2nd 3rd 4th Red Tagging Campaign Red Tagging Campaign Red Tagging Campaign Red Tagging Campaign 5/7/2018 22/10/2018 Red tag Found Red Tag Clear Pending Red Tag Red tag Found Red Tag Clear Pending Red Tag Red tag Found Red Tag Clear Pending Red Tag Total Red tag Found Total Red Tag Clear Total Pending Red Tag 1 OFFICE 3 2 1 2 PRODUCTIO N 14 8 6 3 3 3 MELTING 2 0 2 2 2 4 LAB 1 1 0 5 STORE AND GREEN AREA 8 0 8 6 INDUCTION PLANT 2 2 0 7 DELIVERY/D ISPATCH 0 8 9 Total 30 13 17 5 0 5
- 10. Red Tag Summary 0 2 4 6 8 10 12 14 16 Total RED TAG Captured – 35 Total Red Tag Cleared – 13 % Clearance – 37.14
- 11. Worst Point Photograph Zone No.2 Improvement: - SPACE UTILIZED Shop: PATTERN ROOM Item: PATTERN 23.02.2018 11.11.2018 Before:- UNEVEN PATTERNS PLACED After:- ARRANGE PATTERN
- 12. Worst Point Photograph Zone No.6 Improvement: - AREA SPECIFIED Shop: INDUCTION FURNACE Item: AREA NAME BOARD DISPLAYED 03.11.2019 03.11.2019 Before:- AREA NOT SPECIFIED After:-AREA SPECIFIED
- 13. Worst Point Photograph Zone No.5 Improvement: - MATERIAL STACKING Shop: OUTSIDE AREA Item: FOOTSTEP , SURFACE BOXES 16/06/19 24/07/19 Before:- CASTINGS NOT ARRANGE PROPERLY After:- PAINTING AND STACKING OF CASTINGS
- 14. Worst Point Photograph Zone No.6 Improvement: - CLEAN AREA Shop: INDUCTION FURNACE Item: RACKS 31/01/2019 21/07/2019 Before:- Unwanted & wanted material kept in mixed condition After:-Unwanted material disposed off & wanted material kept properly. Spaced saved 10.61sq.m.
- 15. Sort & Set Activity done in Store • Analysis of current situation • Getting list of materials from Production Lines • SDQ From Buyers (Concerned Person From Company) • Physical verification of material (with store to production line) • Temporary location with coloured chalk or removable stickers • Labelling of Every Required items with Proper location
- 17. New Store Photographs New Rack Arrangement Sorting of Tools
- 19. Kaizen 1 Company: C.P. FOUNDRY WORKS Dept : LAB Result : FIRE EXTINGUSHER Month : 5 MAR 2019 Subject : SPACE UTILIZATION Process : SAFETY Before Improvement ( Photo or Explanation drawing) After Improvement ( Photo or Explanation drawing) 1. Manpower, Man hour Saving 2. Physical Distribution (Transporting distance) 3. Space Saving 4. Commanisation, Unification 5. Weight Reduction 6. Energy Saving 7. Yield 8. Quality Improvement 9. 5s Yes 10. Cost Reduction. 11. Safety Yes 12. Horizontal Application 13. Productivity improved Earlier : NO FIRE EXTINGUSHER Now : SPACE IS UTILIZED FOR FIRE EXTINGUSHER Cost Saving per year Date of Implementation 26 TH JULY 2018 Benefits : SPACE UTILIZED. SAFETY IMPROVED. Suggested by MR. TAHIR SIR Approved by MR. TAHIR SIR
- 20. Kaizen 2 Company: C.P. FOUNDRY WORKS Dept : OFFICE Result : WORKPLACE 5S & SAFETY IMPROVED Month : 23 RD FEB 2018 Subject : PROPER ARRANGEMENT OF WIRES , CABLES & COMPUTER EQUIPMENTS Process : SYSTEMATIC ARRANGEMENTS OF WIRES , CABLES & COMPUTER EQUIPMENTS Before Improvement ( Photo or Explanation drawing) After Improvement ( Photo or Explanation drawing) 1. Manpower, Man hour Saving 2. Physical Distribution (Transporting distance) 3. Space Saving 4. Commanisation, Unification 5. Weight Reduction 6. Energy Saving 7. Yield 8. Quality Improvement 9. 5s Yes 10. Cost Reduction. 11. Safety Yes 12. Horizontal Application 13. Productivity improved Earlier : WIRES , CABLES & COMPUTER EQUIPMENTS ARE TANGLLED & UNSAFE FOR USE Now : WIRES , CABLES & COMPUTER EQUIPMENTS ARE ARRANGED SYSTEMATICALLY Cost Saving per year Date of Implementation 26 TH JULY 2018 Benefits : SAFETY IMPROVED. HOUSEKEEPING & 5S IMPROVED. Suggested by MR. JOSHI SIR Approved by MR. TAHER SIR
- 21. Kaizen 3 Company: C.P. FOUNDRY WORKS Dept : moulding area Result : 5S IMPROVED Month : 24 FEB 2019 Subject : SPACE SAVED Process : DISPOSED OF UNWANTED MATERIAL Before Improvement ( Photo or Explanation drawing) After Improvement ( Photo or Explanation drawing) 1. Manpower, Man hour Saving 2. Physical Distribution (Transporting distance) 3. Space Saving YES 4. Commanisation, Unification 5. Weight Reduction 6. Energy Saving 7. Yield 8. Quality Improvement 9. 5s Yes 10. Cost Reduction. 11. Safety 12. Horizontal Application 13. Productivity improved Earlier : MOLDING BOXES AND WOODEN MATERIAL LYING ON AREA Now : DISPOSED OFF MATERIAL AND CLAEA N AREA 5.54 SQ.M. SPACE SAVED Cost Saving per year Date of Implementation 24 TH FEB 2019 Benefits : SPACE SAVED. (5.54 SQ.M.) HOUSEKEEPING IMPROVED. Suggested by MR. MAQSOOD SIR Approved by MR. TAHER SIR
- 22. Thank You