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XLRI BM-BATCH OF 2013

TRF Plant Visit


Operations Management
K V Lakshmi Priyanka B11025 Kanhaiya Agarwal B11026 Koustubh Chattopadhyay B11027 Kunal Negi B11028 Lourdh Prince Pazil B11029 Mario Ashwin Fernando B11030 Mayank Raina B11031 Mohammed Abaubacker Ali B11032

TRF Plant Visit


Pre-visit classification of the company on the PP Matrix: Since the company manufactures customized equipments and is involved in turnkey contracts it is expected to be a project/job shop. Pre-visit classification on basis of Decoupling point: Since it is a project/job shop, the decoupling point will lie at the supplier side.

Observations during the plant visit: 1. Basic Processes involved in the operation consisted of: Cutting Cutting processes were characterized by two types of cutting namely Gas cutting using BOC gases and Saw cutting Welding/Fabrication Assembly Machining Machining involves processes like milling, turning, slotting, fitting and boring 2. General purpose machinery used in the operation were : Lathe machines-(manual and CNC) Grinding machines Milling machines Slotting machines Welding equipment Gas cutting equipment Cranes: 5 tonne and 10 Tonne Eskoda Machinery (Possessed only by TRF) 3. Following material handling facilities were used in the plant: Fork lifters Overhead cranes Tractor trailers Transfer Trolleys

4. Basic Raw materials: The raw materials are kept at one corner of the plant in the open air. There is no shed or cover for the raw materials, this maybe because the raw materials are in the nature of very large pieces which are not affected by sun, rain or other environmental factors. The raw materials are in the nature of steel pipes of various dimensions, standard forgings, steel tracks, tubes for idler, steel plates, structural steel, hubs-for pulleys. The nature of the plant was partly project, which is engineered to order and partly standardized delivery. Hence, the raw materials also reflected the same pattern. Some materials like standard forgings, pipes, plates etc were bought at standard shapes and sizes. While certain materials were non- standardized and had been procured for specific deliveries. 5. Basic construction of the plant : The roof of the plant was painted with aluminum and was made of corrugated steel. There were 4 different shops/bays are differentiated on the basis of size and functionality. There were drilling, boring, fabricating and gas cutting facilities. The frames along the walls of the plant were made of steel. This facilitates the sliding of the cranes for smooth transportation. There were railway tracks for movement of small carriages. The girders seen was mainly of I shaped beams made of steel. The columns were also made of vertical steel structure of large diameter, to support the heavy weight transmissions above. 6. Bay Facilities: The plant has 4 bays. The operations and function of each of the bays are as follows: Bay 1: The first bay in the plant basically operates with small machines. Compared to other bays the bay is smaller in size and handles smaller materials. The bay possesses cranes with the capacity of 10 tons. Some of the operations that take place in the bay are Pipe Cutting and Bear Cutting Bay 2: The second bay serves the purpose of material preparation. The bay provides a place for Centralized Cutting and serves the other bays. There are 2

types of cutting technologies used here namely Gas Cutting and Plasma Cutting. The bay has 3 cranes with the capacity of 10 tons each Bay 3: The 3rd bay serves the purpose of fabrication and wielding. It serves as the input for the 4th bay. The bay also possesses 3 cranes with the capacity of 10 tons each Bay 4: The 4th bay serves the purpose of machining and assembly. The bay is larger in dimensions (250m x 60m) than the other bays and has a much larger capacity. The bay has boring machines that are of two types : Automatic(CNC) and Manual. The bay possesses 3 cranes : 1 with a capacity of 60 tons and 2 with the capacity of 15 tons each. 7. Utility Facilities: Medical Facilities: The plant has a Works Dispensary with a doctor and compounder to attend to the workers in case of bad health or any injury. Each bay also maintains a First Aid Box to tend to any small injuries Power: The complete power requirement of the plant is provided by TISCO. The plant has 4 transformers to regulate the power flow Gas: Gas required for the cutting and other processes is obtained and stored in tanks in the backside from where they are routed through pipes in to the plant 8. Quality Management: The production process is divided into four steps: cutting, welding, assembly and machining. After each step a quality check is performed by the quality assurance department of the plant. In case the product fails the quality test at any stage it is sent for verification to the respective department. Once the final product is formed and checked for quality, the client is invited to inspect the product. Moreover before the production starts, the quality check is also performed at the time of procuring raw material 9. Documentation and Visual Control: Documents relating to product specifications in the form of Engineering Drawings are properly maintained by the officials. Also, documents to track progress of a job and work performed on each machine are maintained and updated regularly.

The visual control was inadequate as there was no labelling on the materials and it was difficult to track the flow of material. There was no colour coding in any form. However work instructions and target were posted at different places 10. Safety: Safe working load mentioned on cranes. Some areas had safety railings. Areas which did not have them were because of the large parts that were being fabricated there. When overhead cranes are not in use, the chains attached to them are suspended well over 15ft above the ground There was a large sign board which read that entry was prohibited without safety goggles, gloves, leather shoes and safety fit dresses. The bay area has a display board with step by step instructions for an emergency plan. This includes barricade area, turn off power, call rescue fire fighters, check impact on other equipment, analyse root cause and take preventive measures. The same board also lists contact persons and emergency contact numbers (Eg: fire department). Every person entering the bay area must wear a safety helmet. Machining equipments are spaced properly so as to avoid any accidents due to collision. Electricity units have voltage stabilizers. A large poster urged employees to report accidents as well as near miss situations. Posters with captions like Loss of Limb, Loss of Activity, Productivity is another name for Safety were displayed at strategic points. One poster shows the right and wrong way of lifting heavy loads. A large Green Cross Safety board is displayed just outside the bay area. It lists cases of minor injuries, major injuries, fatal injuries, last aid cases, last major injury and number of injury free working days. The statistics were encouraging as most working days were injury free suggesting that proper safety norms were being followed by the employees. Acceptable and actual values for noise and illumination levels were also recorded. Last recorded noise level was 85db and illumination level was 350lux. Work area where critical and potentially dangerous work was carried out was cordoned off with plastic tapes. A metallic wedge is used to prevent cylindrical pipes and bar stock from rolling over. Fabricated pipes waiting to be moved to paint area are fastened together with metallic strips. The Bay area has 3 large exits points for quick evacuation of workers in case of any emergency. A large amount of scrap metal was piled up near the gas cutting area. This stack could slip and slide causing damage to equipment and finished good kept in its vicinity. There was also danger to workers working in that area.

One equipment had dangling wires which could possibly be shortened There was a sign which warned people not to look at an arc with bear eyes. 3 doctors were available round the clock to provide first aid and attend to casualty. Bay areas have first-aid boxes with box number clearly written on it along with people responsible for it. Some heavy WIP was left on the pathway. This could pose danger to workers. Equipments were periodically tested and next due date for testing was mentioned on some of them.

11. Storage of Material: The materials are stored near the processing equipments until the process is complete. Unless all the components of an equipment to be manufactured undergo one step, the components are stored together near the processing machine and only after all the components have been processed in that step, the materials are sent together to the next machine. Utility materials are stored outside in the yard. 12. The pre-visit classification regarding the position of the firm on the PP Matrix and the position of the decoupling point was correct. We correctly identified that the firm is a Project/Job shop and the coupling point is at the supplier side. 13. The two strengths of the company are: Majority of the workers were motivated towards their work and they work keeping in mind the target to be achieved The quality management aspect ensures that the product delivered is never compromised on the part of quality 14. The two opportunities for the company are: As mentioned the visual control was inadequate and can be improved upon a lot to make the production task easier and comfortable Secondly, there was no provision for monitoring the adherence to working hour schedule by the workers. If something along the lines of biometric employee time clock is implemented, it may improve the production of the unit 15. Unless otherwise mentioned by the client, ISO standards were followed by the company

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