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Materials Management
Summer Training Report by:
Anand Swarup Laskar
B.Tech - sophomore, IIT Roorkee
Objective

To study the current material flow in Recon
Operation and identify the bottlenecks
involved in different processes
Recon Operation – current state
Engine sent
by
customer
Customer contacting
marketing division
Back to
customer
Dispatch
Marketing division passing info.
to production control
Recon Operation
Engine
stored at
Yard
Parts
mounting
Warehouse
Monthly schedule
formed
Parts sent
to different
vendors
Flow Chart
Parts
brought to
kit section
Engine dismantled as
per plan
Test
bed
Crank sec
Block sec
In-house
parts sent to
cleaning
section
Conn. rod
Assembly
Head sec
Info. Flow
Cam sec
Verbal
comm..
For enlarged view: click on the image
Sections under consideration


Dismantling section
Engine kit section
Engine brought at
yard
Dismantling
section as per plan
Engine
dismantled
Parts classification
Al parts
Cast Iron
Sub Ass.
In-house
Al parts
BER parts
Temp. storage in
CC cart
Weekly taken by
vendor (chemiclean)
Old parts
Dismantling Section
CI parts
Flow chart
Temp. storage at
SM cart
Daily taken by
vendor (Sri Metal)
Sub. Assemblies
BR parts
Old / mounting
parts
For enlarged view: click on the image
In-house parts
Directly taken by
vendor (Sri Metal)
Temp. Storage for Scrap
(Cummins prop.)
Temporary storage in colored
parts box
Cleaning
Temp. stored at
store
Improvements Possible



Eliminating intra-section transport of
materials to be taken by vendors
Direct movement of material by technicians to
respective bins/crates based on suppliers
Optimum utilisation of crate space. A proper
method should be designed to fill the crates
Advantages




Excessive material handling prevented
Duplicate movement of material prevented
Manpower can be saved
More systematic and organized processes
MS formed by Prod. Cnt
Al parts from
CC
Kit Section
Flow-Chart
Al storage
(Upstairs)
CI parts
From SM
Temporary
storage
New Mat.
From WH
Pallets
Racks (inventory
section)
Minimax /
Cleaned old
hardware
New Mat. from
inhouse store
RX parts/ass.
From SM
KIT
SECTION
Eng. Kit,
organized
in pallets,
and
daywise
Reqm.
Movable
racks
Temporary
storage
Movable
racks
For enlarged view: click on the image
To
assembly
as per plan
13
4
3
1
Existing layout of engine
kit section (ground floor)
5
2
6
11
10
6
8
12
a
7
.
cb
9
1. Movable rack – RX assemblies/parts
2. Pallets ready for dispatch
3. Office / control (kit section)
4. Stairs
5. unwanted material storage
6. Racks – Inventory
7. Racks – (a) unmovable parts, (b) scavenged pistons, (c) warranty parts
8. Empty Pallets
9. Racks – pending job materials,
10. Racks - casting parts tubes and connections ( KV model),
11. Racks – aftercoolers, Misc.
12. Crates – Cast Iron parts (from SM)
13. Gates
13
E
w
4
2.3
3 2.1
2.2
1
6
6
6
7
5
Existing layout of engine kit section (first floor)
1. Storage - Aluminium parts
2. Storage – MP kit section
2.1 – Minimax area
2.2 – MP kit (NH,NT)
2.3 – MP kit (KV)
3. Office
4. Stairs
5. Gate
6. Racks
7.Unorganised Area
E
W
Improvements

Classification of materials



Slow consumption material: Those material
which are consumed at a very slow rate.
They should be placed such that they don’t
interfere in the working other materials
Fast consumption material: Those material
which are consumed at a very fast rate.
Placed in matter such that they are easy to
identify and issue.
Change in layout of the kit section
Proposed layout of engine kit
section (ground floor)
4
3
1
1.Movable rack – RX assemblies/parts
2.Pallets ready for dispatch
3. Office / control (kit section)
4.Stairs
5.Store
6.Racks – Inventory
7.Racks – Old parts
8.Empty Pallets
9.Racks – Casting parts tube and
10.Crates – Cast Iron parts (from SM)
11.aftercoolers
12.Misc
13.Materials requiring security
14. Emergency storing
Pallet movement route
2
5
5
8
13
12
14
6
Gate for
security
10
9
11
7
Advantages




Easy pallet movement
Secure area for inventory parts
Place for emergency storage
Sufficient space for men and material
handling equipments
Analysis of Diesel Engine


Second part of the training
Objective: To have a basic understanding of
all the basic systems and their sub-parts
involved in a diesel engine
Analysis of Diesel Engine

Basic Systems and Components








Lub System
Fuel System
Air intake/exhaust
Cooling systems
External components and accessories
Components of cylinder block
Valve injector train
Mountings and adaptors
Analysis of Diesel Engine



Lub System: Oil pump, pressure regulators,
filters, oil coolers
Fuel System: High pressure, low pressure
fuel
systems, Engine
and injection timing
Air Intake & Exhaust system: Air cleaner,
supercharger, turbocharger,
cylinder
scavenging, exhaust
manifolds, restriction
limits
Analysis of Diesel Engine

Cooling system: water pump, water manifold,
thermostat, water pump, fan drive pulley,
heat exchanger

External components and accessories: Drive
assemblies, crank, cam, idler, flanges, hub,
cover housings, manifolds, flywheel, vibration
damper
Analysis of Diesel Engine

Components of Cylinder Block: liners, pistons,
rings, connecting rods, crankshaft,
camshaft, bushing, bearing

Valve & injector train: cam, cam follower,
tappets, rocker type cam follower

Mountings and Adaptors: Vibration damper,
flywheel housing, hood frames, generator
DC, generator AC
Thank you