Professional Documents
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Krishna Ltd.
OBJECTIVE OF STUDY:
1. Evaluation of current machine utilization and improvement
Question: 01
Objectives of the study were met by the
consultant, i.e. (i) The current M/C
utilization, (ii) Improvement suggestions,
(iii) Suggestion for future capacity
requirements & 2 month stock, All are
addressed.
However the study DOES NOT consider
some of the important aspects*.
* Same will be discussed in next sections.
Question: 02
(Improvement of Shop Supervision)
Provision can be made, so that all lines receive equal supervision.
Question: 02
(Improvement of Shop Supervision)
Shop
Supervision
Study
NO
Adequate ?
YES
YES
Higher level
involvement needed.
No. of supervisor
needs to be increased
Study of
probable
reasons
Dedicated
supervisor for
each area ?
NO
Target to be given
to supervisors
related to m/c
utilization
Adequate no. of
supervisor as per
standard ?
YES
NO
YES
Proper
training to
be given
YES
Supervisor busy
with other work ?
NO
NO
NO
Departmental
supervision needed
YES
Supervisor s are
excessive friendly
with operators ?
Question: 03
(Weakness in work sampling study)
Individual machine wise study was not done. Grouped machines were
studied. Which does not give a clear picture about the individual
machine utilization.
Idle due to operator has been given as one of the highest
contributing factor for machine idle time, but break up for the same
was not given.
Standards for machine utilization of similar shops were not
considered.
Question: 04
(Capacity Determination: Option 01)
Annual Demand 2 Month Stock
Group I
Group II
Speedometers
203000
33833.33333
Pressure Gauges
212700
35450
24.4
864.98
Temperature Gauges
118560
19760
20000
3333.333333
4500
750
7.1
300000
50000
Hub drive
10000
Warning lamp
82560
62 2097.67
Hours / Week
No. of Machines
OT/Machine/Week
Group IV
2233
82 2774.33
91 3225.95
17.3 613.285
85
1679.6
151 503.333
150
500
133.7 445.667
5.325
67
50.25
66
3300
350
1666.666667
42.6
71
13760
15
206.4
Total
66
Group III
11.2 18.6667
5.3
72.928
11.7
26.4
8.5
167.96
21.8 72.6667
8.775
44
13.6 22.6667
0
3272.78 Total
5.1
70.176
7048.71 Total
8130.39 Total
946.754
135.552
156.354
62.938
18.2068
10
13
13.5552
12.0272
10.4897
6.06894
Question: 04
(Capacity Determination: Option 02)
Introduction of 3rd Shift
Assumptions:
Working Hours = 8 Hrs
Break = 1 Hr (Considering Night Shift)
No. of
working
days
Daily
working
Hrs
Total
working
Hrs
300
2100
13
21000
27300
12600
6300
10
12
7048.705
2100
20
10
II
8130.394667
2100
23
12
III
3272.775
2100
IV
946.7543333
2100
55
28
18
14
11
10
28
18
14
11
10
1344000 1296000
1344000
TOTAL MACHINES
TOTAL OPERATORS
WAGES (400/Day) Rupees
NOT
FEASIBLE
1320000 1440000
Question: 04
(Capacity Determination: Option 02)
Introduction of 3rd Shift
Comparison of OT and 3rd Shift
Month Required
4
6
8
10
12
Over time
GR 1
10
7
5
4
3
7048.7
GR 2
12
8
6
5
4
8130.4
GR 3
5
3
2
2
2
3272.8
GR 4
1
1
1
1
1
946.75
Total Cost
1344000
1296000
1344000
1320000
1440000
OT Cost (2 times of
Normal wage)
1939862.9
Annual Demand
ANNUAL DEMAND CALCULATION
Annual Demand
Group I
Pressure Gauges
212700
Temperature Gauges
118560
20000
151
3020
150
3000
133.7
2674
4500
7.1
31.95
67
301.5
11.7
52.65
300000
66
19800
2100
Hub drive
10000
42.6
426
11.2
112
Warning lamp
82560
15
1238.4
Cables
24.4 5189.88
Total
Total Available Hrs/Mc/Yr
No. of Machines
OT/Machine/Week
Allowance
Available Time
Shortage
42292.2 Total
66
13398
82
Group IV
203000
Faremeters
12586
Group III
Speedometers
62
Group II
16646
91 19355.7
17.3 3679.71
85 10077.6
8.5 1007.76
5.3 437.568
48782.4 Total
26.4
264
0
19636.7 Total
21.8
13.6
436
136
5.1 421.056
5680.53
4500
4500
4500
4500
10
13
45000
58500
27000
13500
0.16
0.22
0.2
0.15
37800
45630
21600
11475
4492.23
3152.37
-1963.4
-5794.5
Group
I
II
III
IV
Machine Hrs
Shortage for
Net M/C hrs
Required for 2
Available M/C Hrs/Year/Machine
2
4
6
8
annual demand
required
month stock
7049
4492
11541
2100
33
16
11
8
8130
3152
11283
2100
32
16
11
8
3273
-1963
1309
2100
4
2
1
1
947
-5794
-4848
2100
0
0
0
0
TOTAL MACHINES
69
34
23
17
TOTAL OPERATORS
17
NOT FEASIBLE NOT FEASIBLE NOT FEASIBLE
WAGES (400/Day) Rupees
1632000
Month
Required
4
6
8
10
12
GR 1
0
0
5
4
3
11541
GR 2
0
0
6
5
4
11282
GR 3
0
0
2
2
2
1309
GR 4
Total Cost
0
0
1
1
1
NA
NA
1632000
1680000
1584000
0
OT Cost (2 times
of Normal wage)
2413200
2413200
2413200
2403200
2413200
10
12
7
5
6
5
1
1
0
0
14
11
14
11
1680000 1584000
Question: 05
Scheduling
Backward scheduling
Determining a production schedule by working backwards from
the due date (or time) to the start date (or time).
Simultaneously computing the materials and time required at
every operation or stage.
Different heuristics like branch and bound technique can be used.
As per the target date set by the sales departments, the job
priorities will be set wrt the manufacturing lead time and the
penalties associated with it.
Question: 06
Trivial and Useful Suggestion
Following recommendations were found to be trivial:
directly output depended. All the jobs do not have equal cycle time. Better
alternatives are available like a) Halsey plan b) Rowan plan c) Emerson plan)