from the coo’s desk · 2017-08-05 · punching machine (frame and engine) iii. central control of...
TRANSCRIPT
1
Dear Acers
As we seek new frontiers, new challenges await us. These challenges will question your learning, your assumptions. You have to learn to unlearn. Imbibe what is in front of you with an open mind.
We have come a long way from where we were two years ago. The pace of change has been appreciable and we should laud ourselves. The marketplace though is changing at an even faster pace. We need to focus more. I would like to start with the CBG team who have grown exponentially and are breaking newer grounds in terms of product and customer reach. They have a healthy order book with a stable near- to-medium perspective. The PTG team has grown in High performance taps, solid carbide tools and carbide raw material as well. The results are
slowly visible but the seeds have been sown for a bumper harvest in the medium term.
We have taken two definitive initiatives- Talent Pool Program and Key Account Management. Talent pool was our endeavour to strengthen our upcoming young talent and give them exposure to leadership facets. We would certainly be extending this program further with a scope kept to widen the pool. It is a long term approach and we will be investing more into such initiatives. Now, the Key Account Management function is finding its feet with success in a few pockets. We will be adding more KAMs to ride on the success achieved.
International markets have been our focus and continues to remain so. There have been fragmented successes, and we expect a couple Ravi
an amalgamation of ideas
ISSUE 06 • NOVEMBER 2016 FORBES & COMPANY LIMITED - ENGINEERING DIVISION
of good breakthroughs in the short term. Resource building has been done for the export team to cater to the untapped opportunities.
We finished the first phase of consolidating our factory at Waluj. The solid carbide set-up is up and operational. The team has done a good job in quick time to take up this work.
Last but not least, financial stability is of utmost importance. Our profits are exceeding expectations. Topline growth, though, still has to catch up. Let us work towards achieving it.
May all your dreams and aspirations be fulfilled.
From the COO’s desk
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Eureka Moments
Enquiry generation method:
Regular Visit to Customer
Customer Category: Existing
Customer, New Plant
Challenge: Selection of particular
VIN plate for marking. VIN plates are
places in 5X4 box matrix.
Objective: To eliminate error and
selection of correct VIN plate.
Proposal: To use 5X4 Pika Pika ID
Plate SPM. A unique development
by Bradma using TMP3200 and
other electro-pneumatic BOM.
Customer: Four wheeler
manufacturer
Marking Machine Model:
TMP3200/420
Component: VIN Plates
Order Value – R74.23 L
Sequence of Operation
hand safety button.
aluminium extrusion.
in fixture.
selection of plate.
1100mm. Can be adjustable up to
100 mm.
AMS, PROJECTS
ARCHITECT FOR SUCCESS VIKRANT CHAUDHARY & KANISHK RAGHUVANSHI, DELHI [email protected]@forbes.co.in
RHS from Rear side.
from front / operator side.
levelling pads.
with glass see through window.
components.
to stationed PLC for picking up
name plate
forwarded to marking system
(Data will be available in VTS).
respective name plate & load it in
a fixture.
start button.
automatically.
below the marking head.
automatically.
automatically.
cylinder.
component manually
Poka Yoke and Safety Features
Poka Yoke
Finger safety sensor is mounted
on the fixture the main purpose of
this is to avoid the accident during
operations if operator puts hands
in between the clamping will not
get operated Marking will not be
start unless the fixture will slide/
move below the marking Machine
Clamping fixture will work only on
Pick of the Plate from PICA-PICA
will raise the alarm & need to be
acknowledge by the operator
Safety Features
Finger safety sensor which will close
the system if operator puts hands
in Cycle start Two hand safety so
that operator will work with both
hands Safety guards of Acrylic for
Transformer/ Line filter/ AC terminal
which will prevent as a leak proof
ELCB to be used in panel to avoid
the Earth leakage
3
Enquiry generation method: Regular Visit to Customer
Customer Category: Existing Customer,
Challenge: 2D code marking and reading on balance shaft.
Objective:
and testing data
Proposal:
Bradma
Customer:
Model:
Component:
Order Value – R
Customer Requirement
and testing data
Forbes Scope of Work :
monitoring
grade configuration
existing machines for data transfer
Customer Scope of Work :
AMS, LASERS
basis.
generated serial number.
Parameters Interlinked with 2D marking
Opn. M/c Description Parameters System Forbes requirement for software development
laser2D marking of sl. no. auto generated
Vantage Distance
Balancingdata
in that file.
bearing dia.
face
2 nos. Diameter sizes manufacturer either to send test result on
Vantage Distance
leak testing machine
Vantage distance
2D
number
Client
Central
marking
Client
2
Client
3
Client
Client
5
Client
of insertion
dimensiions
measurement
of insertion of
and ball
of insertion of gear
Customer serial number
marking
Vantage
balancingmachine
gauge
Vantage
Vantage
markingmachine
Scan 2D codeprinted on
balanced shaft
input
output
TCP / IPcommunication
output
Client Computer
Server Computer
Stage 2 OP30Vantage Press
Pressing Forceand distance travelled
Existing machine
computers IP addressis required
Communication
33
ARCHITECT FOR SUCCESS
4
Enquiry generation method: Regular Visit to Customer
Customer Category: New Customer
Challenge: To replace competetor’s machines with high performance Telesis units
Proposal : To use TMP1000 as a low cost solution
Remark: we were trying to get breakthrough with this customer since many year. Chetan Oza, Hitesh and Prashant Shah knoked the breakthrough with back to back orders from this customer. as a result of their business engagement with customer, we got order from their Chennai plant as well.
Customer: Automobile parts manufacturer
Model: TMP1000
Order Value – R 12.60 L
Enquiry generation method: Regular Visit to Customer
Customer Category: Existing Customer. New Order
Challenge:
i. Traceability of Chassis number and Engine number punched on Frame and Engine
ii. To eliminate errors in number punching machine (Frame and Engine)
iii. Central control of number being punched
iv. Duplicate number checking
v. System control for every number being marked
vi. Database creation and report generation of number being marked.
vii. 100% matching of VIN and EIN number with respect to Invoice
Customer: Two Wheeler manufaturer
Model: Bradma Software
Order Value – R 22.00 L
Forbes Scope of Work :
every stage for data capturing and monitoring
logistic and Invoicing at the time of truck loading
computer to individual marking machines.
Customer Scope of Work :
these operation / machines are placed.
machines.
AMS, PINSTAMPS
AMS, AUTOMATION
Enquiry generation method: Regular Visit to Customer
Customer Category: New Customer,
Objective: Name Plate Marking
Proposal: To use BFL20A
Customer: Industrial Tools and Equipment manufacturer
Model: BFL20A
Component: Name plate
Order Value – R 9.50 L
AMS, LASER
PROPOSAL
and Engine
network connection between PPC, server and client computers.
printed at marking station
computer and Printers at every marking stage & in Logistic.
near loading bay.
ARCHITECT FOR SUCCESS KANISHK RAGHUVANSHI, DELHI DSO [email protected]
ARCHITECT FOR SUCCESS CHETAN OZA, AHMEDABAD DSO [email protected]
ARCHITECT FOR SUCCESS TEJAS SINKAR, PUNE [email protected]
o
w
A
e
5
Enquiry generation method: Door Knocking
Customer Category: Existing Customer
Challenge: Marking on Shock absorber.
Objective: to improve visibility of marking quality/Branding
Scope: Design, Manufacture and Supply of Number Marking Machine & Installation and commissioning of Optic fibre Laser Number Marking Machine for 3 cylinder Gasoline and 4 cylinder diesel head.
Component Details:TGDI Gasoline 3 - Cylinder Head.4 Cylinder Diesel Head.The details of material and weight are as follows:
Description Material Condition
3- Cyl Head Gasoline semi-finished.
Aluminium Alloy ALSi9Cu3 , 85+/-5 BHN
4- Cyl Head Diesel semi finished.
Aluminium Alloy ALSi9Cu3 , 85+/-5 BHN
PROPOSAL
AMS, AUTOMATIONCustomer: Heavy engines manufacturer
Model: FQ20
Component: Gasoline Engine Block
Order Value – R 39.00 L
Component Flow:Right to Left of the operator, component orientation: Top face up and Front face leading, Intake Face towards Operator Side.
TGDI Gasoline 3-
Cylinder Head: 10 kg
TGDI Gasoline 3-
Cylinder Head: 10 kg
4-Cylinder Diesel Head: 12kg
4 Cylinder Diesel Head: 12kg
Machine Cycle Time:Floor to floor cycle time for is 90 seconds.
Input Condition Of Component: Component with semi-finish machined
Component Loading/ Unloading:
machine component will be transferred on Input P&F Hard chrome plated roller conveyor 0.75 of Number Marking Machine
Sensors to be provided at input conveyor to start the conveyor once component is sensed by Sensor
which will allow only one component to enter inside the marking station.
machine for the centring of the component.
be provided for smooth transfer of the components.
from the ground level.
conveyor with Automatic Stopper arrangement to be considered along with next conveyor full confirmation sensor.
Operation Sequence:
transferred on Input P&F Conveyor of Number Marking Machine.
Input Conveyor of Machine will sense the presence of Component and conveyor will start. At the same time it will identify the type of Cyl Head i.e. either 3-Cylinder or 4 cylinder head. Component will come to machine on 0.75m long P&F roller conveyor and stop against the pneumatic stopper of singling device.
will allow only one component at a time to go inside the machine for Number Marking.
on P&F conveyor of number marking machine.
operated guided locators will enter into compression face dowel holes as per the model from bottom side and
Locating Pins to be considered, will be decided during
Sensor and component presence Sensors on Number Marking machine, machine will select the programme accordingly.
component enclosure will cover the component from
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all sides, so that there will not be any direct exposure to Laser beam and its radiations. Duel poka-yoke to be considered for enclosure position confirmation.
station which will maintain the same focal distance for both the models which is essential for proper
number and as per order machine will mark the alphanumeric number and 2D matrix code on specified location.
mark the same 2D matrix code at different location
consider the same.
Safety Requirements:
area.
like :
connection.
of.
its all operation immediately.
9. Poke Yoke / Interlock Requirements:-
start until the component is properly located on the
enclosure bottom position.
ARCHITECT FOR SUCCESS
7
Enquiry generation method: Regular Visit to Customer
Customer Category: Existing Customer, New Order
Challenge: Achieving Cycle Time
Objective: to improve visibility of marking quality.
Proposal: To use Pin Marking Machines
Sequence of Operations –
i. Crown wheel will be traveling over a motorized conveyer
ii. There will be set of 06 crown wheel placed one above the other
iii. Once the crown wheel set received at marking area, operator will stop conveyer
iv. Operator will drag the marking machine suspended with the help of spring balancer
v. Operator will place the machine over the crown wheel
vi. Operator will press Clamp button to clamp the crown wheel
Enquiry generation method: Door Knocking
Customer Category: New Customer
Challenge: Marking on Solid Carbide Tools
Objective: to improve visibility of marking quality/Branding.
Proposal: To use fibre laser
Customer: Cutting tool manufacturer
Model: BFL20A
Component: Drills & End mills.
Order Value – R 10.00 L
Enquiry generation method: Door Knocking
Customer Category: Existing Customer
Challenge: Marking on Shock absorber.
Objective: to improve visibility of marking quality/Branding.
Proposal: To use fibre laser
Customer: Auto component manufacturerr
Model: BFL20B
Component: Shock Absorber of Two wheeler bikes
Order Value – R 8.00 L
AMS, PROJECTS
AMS, LASERS AMS, LASERS
ARCHITECT FOR SUCCESS VIDYANAND GOSWAMI, KOLKATA DSO [email protected]
ARCHITECT FOR SUCCESS ASHISH JAISWAL, AURANGABAD [email protected]
ARCHITECT FOR SUCCESS ASHISH JAISWAL, AURANGABAD [email protected]
ARCHITECT FOR SUCCESS TEJAS SINKAR, PUNE [email protected]
vii. After clamping, operator will press PRINT Button to start marking
viii. After completion of marking on crown wheel, operator will declamp the machine and place it on another
ix. crown wheel.
x. Operator will again press PRINT button to mark on second crown wheel and so on
xi. After marking on 6 crown wheel, serial number will automatically change
xii. Cycle will repeat for another set of components.
Customer: Auto component manufacturer
Model: TMP1000/400
Component: Crown & Pinion
Order Value – R 8 L
Enquiry generation method: Door Knocking
Customer Category: Existing Customer
Challenge: Marking on Cawl.
Objective: to improve visibility of marking quality/Branding
AMS, LASERSProposal: To use SC5000 with Bradma Automation
Customer: Four wheeler manufacturer
Model: SC5000
Component: Cawl
Order Value – R 40.00 L
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Tap series: SC5
Size: HPT 5X0.8 SC5 DIN 371
Component: Cam Shaft
Work material: S.G Iron
Type of hole: Blind hole
Hole dia: 4.2 mm
Drill depth: 15.0 mm
Tapping depth: 12.0 mm
Machine: VMC
Tapping direction: Vertical
Speed (Vc) / Feed: 1500 RPM /
1200 mm/rev
Coolant: Water Soluble Oil
Tool Life: 5.1 mtrs
Competitor tool life: 4.2 mtrs (Emuge)
Tap series: SC
Size: HPT 7/16 UNC SC5 3BX TC PM
Component: Transmission Housing
Work material: Grey Cast Iron
Type of hole: Blind hole
Hole dia: 9.40mm
Drill depth: 30 mm
Tapping depth: 25 mm
Machine: Makino HMC
Tapping direction: Horizontal
Speed (Vc) / Feed:1150 RPM /
2086 mm/rev
Coolant: Water Soluble Oil
Tool Life: 20 mts
Competitor tool life: 7 mts
Tap series: SB (Low Helix)
Size: HPT 1/2 UNC SC5 3B HSSE
Component: Transmission Housing
Work material: Grey Cast Iron
Type of hole: Blind hole
Hole dia: 10.80mm
Drill depth: 30 mm
Tapping depth: 25 mm
Machine: SPM - Horizontal Gang
Tapping Machine
Tapping direction: Horizontal
Speed (Vc) / Feed: 300 RPM /
585 mm/rev
Coolant: Water Soluble Oil
Tool Life: 5.6 mtrs
Competitor tool life: 5 mtrs
Tap series: SCF5
Size: HPT 10X1 SCF5
Component: Shackle Pin
Work material: Forged Steel (25HRC)
Type of hole: Blind hole
Hole dia: 9.0 mm
Drill depth: 35 mm
Tapping depth: 15 mm
Machine: CNC Lathe
Tapping direction: Horizontal
Speed (Vc) / Feed: 250 RPM /
Coolant: Water Soluble Oil
Tool Life: 20mtrs
Competitor tool life: 8 mtrs
AUTOMOTIVE (TWO WHEELER)
AUTOMOTIVE (TRACTOR INDUSTRY)
AUTOMOTIVE (TRACTOR INDUSTRY)
AUTOMOTIVE
ARCHITECT FOR SUCCESS NAGENDRA - DELHI [email protected]
ARCHITECT FOR SUCCESS K. SENTHIL RAVI - CHENNAI [email protected]
ARCHITECT FOR SUCCESS K. SENTHIL RAVI - CHENNAI [email protected]
ARCHITECT FOR SUCCESS S. VINOTH - CHENNAI [email protected]
9
By Invite Only
RAVI [email protected]
Dear Forbes team members,
While I am a recent entrant into the team, I feel excited to see good talent around. We need to continue to leverage the combination of talent, clear roadmap for our goals & discipline to do what we are committed to.
As our COO. Mr. Ravi Prem mentioned in the last edition of “Symphony”, we work towards growth through innovation, technology & customer service. Customer service is what we will be known for in market. Hence we all must strive to provide a great “customer experience” to our customers & distributors, because it is the single largest influencer to make customer come back to us again & again. An excellent customer experience can make us stand out in the market among intense competition.
We are leaders in markets we serve & this leadership needs to come from every one of us. It is not about
one’s title. Everyone is leader in his or her own sphere of influence. In his powerful innovative book on business management “The Laughing Warriors”, Dale Daunten offers a picture of a leader with a code to live by: THINK LIKE A HERO (who can I help today?), WORK LIKE AN ARTIST (what else can we try?), REFUSE TO BE ORDINARY (pursue excellence, then kill it), & CELEBRATE (but take no credit.)”
Finally, it’s important to enjoy what we do best for our customers every day & continue our focus on growth.
10
By Invite Only
How to Deliver Quality Product & Outstanding Customer service.
Making plan in large no. of SKU becomes very difficult. You have to depend on forecasting. Before staring for planning, organization should segregate their SKUs into 3 Class. Class A for Fast moving, Class B for Semi Fast Moving & Class C for Customer Special.
For Class A & Class B Sizes:-Class A & B are moving SKUs of which stock has to be there in system. Your 70-80% business is based on your fast moving SKUs. Hence you have to make sure that your materials should be ready to despatch at any time.
Automatic Re-order Point:- Class A Materials is fastest selling material which has to be in your stock. Every Customer purchase means more revenue but also bring your inventory level lower. You will order these materials before stock goes out of stock. If you order too early you’ll need to spend more on storing this excess item. If you order too late you will lose your customers.
To reduce this problem organization should start Automatic re-order point system wherein you
have to define in system Mini & Max Stock level & Re-Order Point. Once you set re-order point PR/PO will automatically generate once your FG stock goes to the Re-Order Point. This reorder point calculates considering your stock of all process including WIP, SFG & RM. This will help you make continuous production cycle without interrupting shortage of materials.
For Class C Sizes:-Minimum Order Qty:- Since it is customer special materials, order has to take with MOQ. Planning:- Planning of “C Class” materials should always based on your in hand orders. This can be done either on monthly basis or Weekly basis.
Planning process
11
Inventory ManagementStock out is one of the most common issue. Major issue for stock out is wrong planning. If you define your system for keeping Max & Min stock for Class A & Class B in RM, WIP, SFG & FG & applying automatic re-order point concept this can help to reduce chances of stock out. But if we are talking about Class C SKUs changes are very high because we will be planning production against to open order concept.
Improve Vendor/Sub-Contractor capacityIf organization is 40-50 % depends on sub-contractors. Following actions may help to reduce cycle time & improve their capacity. 1) Increase Vendor’s production capacity
with new technology or by improving their machine condition.
2) Provide place to the vendor in factory for reprocess our materials.
Imagine carrying a really heavy backpack around day in, day out. Sure, you can still move, but lugging it up a mountain will leave you exhausted. Imagine the sensation of dragging that extra weight around… and now imagine your business feeling the same way. Now you’re wondering: What could be that additional weight that’s dragging my business down? My products are selling well, my yearly revenue is increasing…
That’s what you’d think, but somewhere in your warehouse, there’s a high chance that with every change of specification in customer special sizes, that simply won’t sell this product to any other customer & that makes your stock dead. 90 – 95% dead inventory create from your Class C materialsFollowing are the issue which can increase your dead stock:-1) Wrong forecasting:- Forecasting is just an assumption which is
based on your historical data. There is no any software or any other tool which can give you exact forecasting. To avoid this issue organization should make production plan on against incoming order for Class C materials.
2) To full fill 100% customer requirement production will take 10% extra on order qty. This extra production increases your Non Moving stock. For example XYZ company order for 100 nos of tools with some special requirement. To complete the order, production will take with 10% tolerance to assume that some of the sizes may become scrap while producing these special materials and produced 108 nos. As per the order, materials will bill for 100 nos only and balance 8 nos. will goes your stock. Since it is special sizes for spl customer this may not be sale to other customer. Keeping this small small inventory increase your Non Moving stock
To avoid this issues order should be takes with 10% tolerance or company should offer this balance qty with extra discount on same time.. This will help you to keep healthy stock in warehouse and reduce your NM stock. Which help to increase your on time delivery to the customer.
Monthly Planning:-. Advance planning of next month has to be done & float the plan on 15th of every month to get the FG stock on 1st day of next month.
This is common process used in most of the organizations. But again it is increasing lead time for execution of material for those orders who received after finalizing monthly plan. For example your lead time of materials is 50 days. Your plan finalized on 15th of the month on total orders in hand as per your machine capacity. If order received on 15th, 16th or
17th which can be consider on next month planning. It means your 50days for material lead + 30 days order kept in pending. If you calculate the entire lead time of materials is almost 80 days.
Weekly planning:- This is most effective process. Where in planning will be based on weekly orders in hand. This will reduce your lead time to manufacture materials and give on time delivery. But again there is few issues wherein your order flow should be constant.
Focus on time delivery
Non Moving Stock
ANIKET [email protected]
12
Events
ACMEE 2016, Chennai Trade Centre, Chennai,
16 th to 20th June 2016
13
Editorial
In an age of VUCA- volatility,
uncertainty, complexity, and
ambiguity, a ‘black swan event’
should not be considered an
aberration. Yet, it is considered as one.
Popularised by Nassim Nicholas Taleb
through his book “The Black Swan: The
Impact Of The Highly Improbable”,
a ‘black swan event’ is a happening
that deviates beyond what is normally
expected of a situation, and extremely
difficult to predict. Although it is used
in context where the repercussions
are felt throughout the world, I believe
that black swan events can be used in
context of an individual as well.
The shock and awe factor is what
separates a black swan event from a
white swan event. Understandably,
Britain’s exit from the European Union
or Donald Trump as President-elect of
the United States of America cannot
be termed as black swan. There was
enough time to decipher the different
scenarios before the event occurred.
An environmental disaster such as
earthquake is a case of black swan
event. Typhoons or Tsunamis cannot
be termed as black swan event
because there is a reasonable warning
BLACK SWAN
given due to advanced technology.
Technology, itself, can be considered
as a black swan. Depends though.
Detection of gravitational waves by
Laser Interferometer Gravitational-
wave Observatory (LIGO) challenges
and asks questions about physics. The
entire paradigm shifts in the thought-
process.
At an individual level, a sudden
loss of job or a loss of a closed family
member can also be considered as
a black swan event. We are often
asked the question “where do you
see yourself 5 years down the line”. It
is an irrelevant question these days.
The world is changing at break-neck
speed. In terms of politics, economics,
social, technological, and environment.
Philosophies of individuals are
changing faster than ever before.
Humans, as a species, are witnessing
a change like never before. We are all
surrounded by black swans. Question
is, how much does it affect you? or
should I say, how do you let it affect
you. The answer, as always, lies in the I.
The editor can be reached on [email protected]
14
Ground Zero
Celebrated Ganpati Festival at Waluj
Tree Plantationat Waluj
Yoga day at Waluj
Traditional Day Celebration at Waluj
15
Kaizen IdeaReplace Deal wood pallets with corrugated Pallets.
Problem / Present StatusDeal wood Pallets are heavy which will increase Air cost.
Counter MeasureBy replacing deal wood pallets with corrugated pallets cost of AIR shipment in export had been reduced.
Kaizen IdeaNeed to protect with filler foam
Problem / Present StatusThere is no additional protection transportation
Counter MeasureApplied Foam sheet Roll in inside of box to improve packing quality.
Kaizen IdeaProvide printed label
Problem / Present StatusThere is no identification of materials on outer box
Counter MeasureMade Printed packing details which contained Party’s Name with address, Invoice details, Box No., Material Code, Description & Qty for Export parties.
Palletisation done for the first time in Chandivali factory
ResultBy replacing corrugated pallets saved cost of ` 30500/- on Material & freight.
ResultBy applying Foam Sheet Roll in corrugated boxes helped us to avoid material rattling inside of box & also increased packing standard
ResultOuter packing label will contained Party’s Name with address, Invoice details, Box No., Material Code, Description & Qty. This will help to the customer to identify materials as per box.
KAIZEN BOARD Idea by: Aniket SanapZone: Dispatch
Before Before Before
After After After
16
ALL MAIL MAY BE ADDRESSED TO:The Editor ‘Forbes Symphony’Forbes & Company LimitedEngineering Division, Saki Powai Road,Chandivali, Andheri East, Mumbai- 72.Tel: 022 2847 1861Email: [email protected]
Editor Milind Patil
Associate editor Sujit Margaj
Metalex 2016, Bangkok,
Hall 98, Stall AA35
from 23 to 26th November 2016
Rajkot Machine Tool Show, Rajkot,
Hall 5, Stall P-4
from 23rd to 26th November 2016
Mahatech Industrial Exhibition 2017,
Agricultural College Ground, Pune, Stall D-43
from 5th to 8th January 2017
This newsletter is for in-house reading for all stakeholders of Forbes & Company Limited. Views expressed in the articles, if any, are exclusively those of the Author and not necessarily that of Forbes and Company Limited or the editorial team.
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