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Thread: Vu final project PRAS Production Rejection Assessment System march spring 2011

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    Icon14 Vu final project PRAS Production Rejection Assessment System march spring 2011

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    PRAS
    Production Rejection Assessment System
















    Objective:

    The main objective of this exercise is to introduce a simple and feasible system for dual targets, i.e. Data Entries & simultaneous On-line Monitoring along with Report Generation right from Set Production Targets Up to Dispatch of Products Side-by-side adequate Measures to Reduce the Reasons of Rejection.
    To provide effective information to factory management for accurate & timely management decisions.
    Salient features of the system are produced hereunder: -

    • Initially it starts from Set Monthly Targets and further elaborates quantity of material from where production starts.
    • To check from the machine’s counter that how much handles have been produced.
    • To ascertain how much material has been consumed by one machine during one target period.
    • To analyze exactly how much quantity has been produced, received by Intermediate Store (IS) & how much runner has been sent to Recycling Section.
    • Describes a detailed report of reasons of rejection machine/product-wise for Molding & Tufting sections after one target period.
    • To maintain proper record for one target period of forwarding & receiving the handles from Molding to IS, from IS to Tufting, from Tufting Section (TS) to Sorting Section (SS), from SS to Blistering Section (BS), from BS to Packing Section (PS) & ultimately from PS to Finish Goods Store (FGS) for final dispatch.
    • To monitor the difference between produced & receiving quantity of Molding/Tufting/Blistering Sections through appropriate check & balance system.
    • To provide adequate information about reasons of rejection & ensure such a Target Plan which minimizes the same in future.

    The main aim of this system is to rectify such human errors that are committed by different levels of employees, either unconsciously or due to sheer negligence or for some trivial advantage (like reducing rate of rejection by mixing rejected handles with runners). It is also observed that in few cases, the blame for such mistakes swings at inter-departmental level, none accepts their fault and the matter is given up in confusion. For example, according to machine counter, production is more than that received by stores, sometimes the difference is even in thousands. Neither the Stores Department nor Production accepts the fault and therefore, tracing the root cause is not possible. However, it maybe noted that in several cases, the person involved is not aware of the grave consequences and errors in calculations that he is going to cause. These things can easily be controlled by simple vigilant inspection or check. Sometimes encouragement of the workers at due time pays a lot.









    Material Calculation


    First of all Factory Management estimates the material required for specific production. For this purpose the material required for each product is calculated by using particular Formulation Sheet of each product. Then management demands the material for this production after checking the material stock in hand. At the time of material calculation, colors are also chosen.

    PRODUCTION DEPARTMENT

    PM prepares Production Plan and the Production starts on the basis of In Process Schedules for molding according to Production Plan. PM further prepares In Process Schedules for Tufting after checking Intermediate Store’s stock position (for handles/caps). It is recommended that PM also prepare Process Schedules for Blistering after checking Sorting Store’s stock position, (for brushes/caps) & packing material stock position report (for Blistering Card).
    Material is received from Raw and Packing Material Store (RPMS) through Requisition.
    OP packs the produced items in bags or containers, as instructed, and labels them with Product Label. After physical inspection Shift Incharge (SI) maintains record of production & material consumption in the Product Log Book & transfers the products to its relevant section. It is recommended that Material Calculation Form will place near on every machine so Operator can easily write down the injected quantity of material. SI also prepares Machine Down-Time Report.

    Raw Material Store


    Store Officer receives imported/local material. He prepares and maintains records of Received Goods Intimation Slip for imported materials and Goods Receipt Note (GRN) for both imported & local materials and the material is taken in the stock ledger. Record is maintained on the Raw Material Registers.
    Material is issued against Requisition Slip as and when required.
    Store Officer receives recycled material from Recycling Section through Transfer Slip and maintains records in the Recycling Material Register.

    MOLDING SECTION


    PM prepares In Process Schedule for Molding Section. It describes that which product is in production process on each machine. A shot counter displays on every machine which shows the number of shots manufactured. When production starts, the initial and final reading of shot counter is entered in the Log Book & production is calculated by multiplying difference of initial and final counter reading (or in other words, number of shots) by number of cavities in respective molds. No Shift In charge can enter wrong figures in Log book because next shift verifies Counter reading & further writes its own initial counter reading. In the software one shift must enter its production updates, prepared qty. of specific products & shows details of pending targets of the Molding Section.
    There is actually no special change in current system of Molding Section except that all entries shall now be entered in new Computer Software. In present software this system is available but some additional changes are necessary which requires incorporation.
    SI prepares Requisition Slip to collect the material from Raw Material Store based on completed production on Process Schedule for Molding, Formulation Sheets and enters the balance material in the Logbook.
    OP mixes material as per instructions keeping in view the Production shown on Process Schedule for Molding and feeds the same to relevant machine. It is recommended that he would write down the fed quantity on Material Consumption Form which will place in front of the machine.
    After physical inspection of the product SI prepares the Daily Molding Production & Sorting Report and OP/Helper transfers product to the Intermediate Store. Recyclable and purged material is transferred to Recycling Section through Transfer slip.
    SI maintains the record of production and material consumption in the Product Logbook. He also prepares Machine Down-Time Report.

    Intermediate Store


    ASO receives items (handles, caps and brush stands) from Molding Section through Daily Molding Production & Sorting Report. SO writes down the received quantity in Daily Molding Production & Sorting Report after doing physical weight of receiving product. He arranges them accordingly at marked places and maintains records in Stock Record Register and enters data in computer software. These items are sorted out and then stored at specified places. Supervisor prepares Daily Sorting Report and Daily Molding Production & Sorting Report. ASO transfers the rejected material to Recycling Section through Transfer Slip and maintains records in stock record register and updates record in computer software. Daily Molding Production & Sorting Report is reviewed by MS/QI & its copy is sent to PM. It is sent to MS/PM/GM only on demand but they can see these reports on their system.
    ASO issues required items to relevant sections (Blistering, Tufting, Packing, and Printing) against Requisition Slip by following FIFO rule as far as possible. Unused handles from tufting section and caps from blister section are returned back to IS through Transfer Slip. He maintains records in the Stock Record Register, prepares Daily Stock Position Report and provides to MS/PM/GM on demand.

    TUFTING SECTION

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    SI prepares Requisition Slip to collect the material from Raw and Packing Material Store based on Process Schedule for Tufting, Formulation Sheets and material balance in the Logbook. Similarly handles are collected from Intermediate Store. Handles which are received from Intermediate store will be added in Tufting stock position. After production the quantity which is received by Sorting section is reduced from Tufting stock position.
    SI prepares Daily Tufting Production & Sorting Report in order to transfer tufted handles (brushes), whereas Helper/OP transfers them to Sorting Section. SI maintains record of production and material consumption in the Product Logbook. SI also prepares Machine Down-Time Report.

    Sorting Section


    Supervisor receives brushes from Tufting section through Daily Tufting Production & Sorting Report & defective brushes from packing section through transfer slip. Supervisor writes down the received quantity in Daily Tufting Production & Sorting Report after checking physical weight of receiving product.
    SGs carry out sorting of brushes & rejects the brushes on the basis of work instruction & formulation sheet. Supervisor prepares Daily Tufting Production & Sorting Report and forwards the same to QI/MS/PM for reviewing. Supervisor also prepares Daily Sorting Report & forwards to MS.
    Supervisor prepares transfer slip for transfer of sorted brushes to Blistering section and rejected brushes to Recycling section. Some of the brushes are transferred to Tufting section through Transfer slip for re-finishing (TC) if required.
    Supervisor also maintains all relevant record in sorting record register.

    BLISTERING SECTION


    SI receives the sorted brushes from Sorting Section through Transfer Slip, brush caps from Intermediate Store and blistering cards from Packing Material Store through Requisition Slip based on Process Schedule for Blistering, and the material balance in the Logbook. Tufted handles which receives from Sorting section are added in Blistering stock position. After production the quantity which is received by Packing section is reduced from Blistering stock position.
    SI prepares the Transfer Slip for transfer of blistered brushes to Packing Section. OP/Helper transfers the stock in containers/bags by trolleys. SI also prepares Machine Down Time Report. SI maintains record of production and material consumption in the Product Logbook.

    PACKING SECTION


    Supervisor receives blistered brushes from Blistering Section through Transfer Slip and maintains records in the Stock Records Register. Packing material is received from Raw and Packing Material Store; brush stands from Intermediate Store through Requisition Slip and record is maintained in the Packing Material Register. Stock is arranged in identifiable manner at marked places.
    PG performs sorting using Formulation Sheets (for caps only), fixes brushes in stands according to Production Plan and finally packs the same in master cartons using 3M-Matic case sealer or manually, duly marked. If stock position does not allow final packing, i.e. required combination of brushes for packing is not available, then the received stock is temporarily packed as a part of stock management.
    Supervisor shifts packed stock to Finished Goods Store and rejected to Sorting Section through Transfer Slips. Some packing is received from Finished Goods Store for repacking or rearrangement, through Transfer Slips. Records of packing are maintained in the Final Packing Register.
    Supervisor prepares Daily Rejection Report and sends it to the Blistering Section. Daily Packing Report is also prepared and submitted to PM/GM if they so desire.

    Finished Goods Store


    AMS/SO/ASO receives packed brushes from Packing Section through Transfer Slip. Brushes are stored at appropriate place and quantities entered in Stock Records Register.
    Order forms are received through MIS, their data is entered in the computer depending upon the available stock and Delivery Order is prepared through the software “Delivery Order”. A copy of Dispatch Statement along with copy of Delivery Order and the documents provided by the transporter are sent to the Head Office. Records of Dispatch Statement and Delivery Orders are maintained. In case of unavailability of stock, Pending Orders List is prepared and handed over to GM and MS on demand.
    AMS/SO/ASO transfers packing that need rearrangement of contents or repacking to Packing Section through Transfer Slip. AMS/SO/ASO prepares Monthly Dispatch Report submit to GM on demand and maintain its record. Pending target report could be viewed in new software.

    Conclusion/ Suggestion:
    Further changes can be incorporated in the same at any stage or with the passage of time. For instance, we may introduce in our system that brushes should not be transferred to SS & instead of this sorting work should be carried out in the Tufting Hall while installing & using conveyor belt which should run, between Molding/Tufting machines to Tufting/Blistering machines. Here workers should place the brushes after accurate and proper sorting. They shall segregate rejected brushes in a placed bin. These rejected handles should be sent to SS for further sorting & for minor repairs if possible as is practice in vogue.
    It is further mentioned that above suggested system would not only reduce the process time, but also reduce manpower and storage requirements. It is also suggested that the layout and design of the new plant premises be adequately designed according to the flow of production process.

    Acronym
    PRAS Production Rejection Assessment System
    MS Molding Section
    TS Tufting Section
    IS Intermediate Store
    BS Blistering Section
    PS Printing Section
    SS Sorting Section
    SS Stationary Store
    PGS Packing Section
    RS Recycling Section
    FGS Finished Goods Store
    RPMS Raw and Packing Material Store
    OP Operator
    SI Shift Incharge
    Attached Files Attached Files

  2. #2
    This project is for sale. If someone wants to purchase please do let us know.

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    Icon14

    SRS date has been expired. Still if someone is looking for this project we have solution for them.

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    A-O-A Sir,
    I need this project. Kindly guide me.

    SHAFQAT ALI ALVI

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    ws, dear please call me on this number 03455242488
    i will guide you

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