Index of Report i) Title Sheet ii) Certificate iii) Acknowledgement iv) Synopsis v) List of Figures vi) List of Photographs/

Plates vii) List of Tables viii) Table of Contents 1. Introduction 2. Literature Survey/ Theory 3. Design/ Experimentation/ Fabrication/ Production/ Actual work carried out for the same. 4. Observation Results 5. Discussion on Result and Conclusion

S. M. Auto Stamping Pvt. Ltd is an TS-16949:2009 Certified (certifying agency TUV NORD) Group of companies engaged in manufacture of metal stamping and deep draw components (press parts, weld assemblies & press tools) required for automobile, engineering sector since 1995. From a very tiny unit it has grown to multifold within a short span of less than a decade. Now we have 3 units working day in & day out to meet the ever -growing demands of our esteemed customers. Competitive pricing and timely delivery is our strength. We love to tackle critical components where eagles fear to trade. As far as production is concerned, we have maintained the tight schedule & just in time concept. or SM Auto Stamping Pvt. Ltd. (SM) is an ISO/TS-16949:2009 certified group (by TUV NORD) company engaged in manufacture of sheet metal stamping and deep draw components (press parts, weld assemblies & press tools) required for automobile, engineering sector since 1995. From a very tiny unit it has grown to multifold within a short span of less than a decade. Now we have 3 units working day in & day out to meet the ever -growing demands of our esteemed customers. Due to sincere efforts & dedication towards perfection we enjoy excellent vendor rating from well renowned customers. List of some of our customers is attached hereto. At SM , we work hard to meet the expectations of our customers by focusing on quality in every product, on-time delivery to every customer (JIT), and competitive pricing to provide value in every service. We love to tackle critical components where eagles fear to trade. We pride ourselves on providing outstanding customer service, competitive prices, priority response and we are heading towards world-class problem solving capabilities. As far as production is concerned, we have maintained the tight schedule & just in time concept. Maintaining zero rejection consistently over a long period shows our dedication & devotion towards perfection. Competitive pricing and timely delivery is our strength. We love to tackle critical components where eagles fear to trade. Needless to mention about the range of machineries and tool room facilities. List is enclosed along with other technical details.

As far as production is concerned, we have maintained the tight schedule & just in time concept. Maintaining zero rejection consistently over a long period shows our dedication & devotion towards perfection.

The Vision "To be a global business partner in sheet metal stamping, weld assemblies tool design & development."

Quick Facts

Started in 1995. A private limited company in SSI sector situated in Nashik - About 170 Km. North east of Mumbai ( the financial capital of India) Having four group companies. Quality system is TS-16494:2009 certified by TUV NORD. Bagged the prestigious 'UDYOGBHARATI AWARD' & UDYOG RATNA AWARD of best industry by Indian Achievers & AIAFBD. Dec.'2009 awarded as BEST DELIVERY PERFORMANCE AWARD for 2009 ( 1.2 million components annually) & "SELF CERTIFIED COMPANY" award from HALDEX INDIA LTD (ANAND GROUP). Total built-up area of 3 locations is 35000 sq.ft. (3500 sq.mtrs.) & proposed builtup on new location 10,000 sq.ft. (1000 sq.mtrs.) Growth rate 55-60% since last 3 years.

Founder Directors 1. Mr.M.N.Kulkarni One of the founder Director, being mechanical engineer, has a solid 28 years experience in the sheet metal stamping field. 2. Mr.S.G.Fegde Other founder Director, Ex. employee of Mahindra & Mahindra Ltd. Having Experience of 25 years in the tool-making field are the two pillars under whose leadership the company has progressed at such a fast pace. PRODUCTS

SM is the organization engaged in manufacture of metal stamping and deep draw components (press pa assemblies & press tools) required for automobile, engineering sector

SM mission, aspires to be a global business partner in sheet metal stamping, weld assemblies ,tool desig

development by 2008. Products Range We offer wide range of automotive components. Some of our key products are as follows:Sheet Metal Pressed Parts Deep Draw Components Chassis Components Welding Assemblies Spring Steel Components Clutch Components Links,Brackets,Bottom Plates,Riser Column etc. Parts for Anti-vibration system for Automotive High Tonnage Components many more ........

CLIENTS Due to sincere efforts & dedication towards perfection we enjoy excellent vendor rating from well renowned customers. Maintaining zero rejection consistently over a long period shows our dedication & devotion towards perfection. This makes us different indeed ! We take pleasure in extending our services to the following prestigious clients out of many :Mahindra Sona Ltd.- Nashik Exedy India Ltd. (Formerly Ceekay Daikin Ltd.) Innova Rubbers Pvt.Ltd. Reliable Group of Industries ( 2 plants) ABB Ltd. , Nashik SKF India Ltd.

QUALITY SYSTEM An ISO 9001:2000 Certified Organization manufacturing & supply of various press parts & weld assemblies . SM continues to strengthen its position as more customer insight on the high quality & reliability of our produce. Ultimately our measure of quality is your satisfaction that is why quality is built in to every step of Products,

every facility, from raw material to delivery of finished products. Our ISO 9001:2000 driven quality programs ensure that product you get from SM are best available. Quality Policy We, at SM Auto Stamping Pvt.Ltd. are committed to manufacture of Precision Sheet Metal Pressed Components, Press Tools and Assemblies to exceed customer expectations in terms of Quality, We shall achieve this through Enhancing Quality Culture Culture throughout the organisation. Continual Improvement in all areas of operations. Employee Empowerment through enhancing training activities. Establishing Performance Measurable for all processes. Innovating New Techniques.

Our efforts shall focus on Protection of Environment, Health and Safety. Quality Objectives

Improve Safety Index. Improve Supplier Performance To reduce Customer Complaints To improve Customer Satisfaction Index To Reduce Internal Rejection Enhance Training Activity To Increase Continual Improvement Project. To maintain On-time Delivery to Customer (100%) To Reduce Customer Returns To Reduce Inventory Levels (RM,FG &WIP) To reduce Cost of Poor Quality To reduce Lead Time for Tool Development. To Increase Productivity To Increase Overall Equipment Efficiency To reduce electrical consumption w.r.t sales.

Problem Identification:We had discussion with the company management about the problems they are facing in their industry. They told us about the various problems arising in their daily routine. The biggest problem they are facing is related to material handling and inventory management. The cost of material handling is much higher also there is large distance travelling between successive operations for various products. This leads to long cycle time and costly material handling. This badly affects the profit of company. Hence, they suggested working on the material handling to increase the effectiveness of plant and reduce the material handling cost. Problem Statement: SM Auto stamping is planning to increase the profit by reducing the material handling cost in the facility in the next few years. They are looking to improve the efficiency and effectiveness of their existing plant in terms of space utilization, material handling cost and efficiency. The proposed layout must be robust, able to meet future needs without additional equipment or re-design. Our project team identified the following problems in the industry: Complicated plant layout The machines are randomly arranged. Machines are not arranged sequentially according to their uses. Available space is not used properly. High material handling cost Random arrangement of the machines causes large distance to be travelled between successive operations. This leads to the high cost wasting on the material handling. Long cycle time Due to the large distance travelled between machine to machine in a successive operation, time required for the completing the product is also increased. Low machine efficiency Manual material handling It leads to long cycle time. It may causes accidents during material handling. It causes damage of materials during movements. The efficiency of production system is reduces. It may not deliver right quantity of material or parts at right time at right place. Possible solution:1. Automation 2. Re-Design plant layout 3. Use of special purpose machine (SPM)

4. Optimize material flow 5. Deploy equipments

Finalizing solution:1. Automation:Some simple automation can help reduce both labor and handling of product. Automation leads to improve efficiency of a production system by ensuring the right quantity of materials delivered at the right place at the right time most economically. It cut down indirect labor cost. It reduces the damage of materials during storage and movement. It maximizes space utilization by proper storage of materials and thereby reduces storage and handling cost. It minimizes accident during materials handling. It reduces overall cost by improving materials handling. It improves customer services by supplying materials in a manner convenient for handlings. It increases efficiency and sale ability of plant and equipment with integral materials handling features. However, additional capital cost involved in any materials handling system. Once a materials handling system get implemented, flexibility for further changes gets greatly reduced. With an integrated materials handling system installed, failure/stoppage in any portion of it leads to increased downtime of the production system. Automated handling system needs maintenance, hence any addition to materials handling means additional maintenance facilities and costs. The above limitations or drawbacks of implementing automated system are highly expensive and need high capital investment. 2. Use of special purpose machine (SPM) To reduce the material handling cost and large distance travelled we can use SPM. Instead of using separate machine for each operation we can directly go for SPM. SPM can done all operations required to complete the job with lowest material handling. However, use of SPM needs high capital investment and maintenance cost. Skilled manpower required for controlling SPM. 3. Deploy equipments Material-handling costs can be reduced by deploying the right equipment in the right places. Take advantage of gravity-fed movement before adding power-driven equipment, by installing gravity conveyors and slide lines. Using capital equipment like a forklift can be reviewed in combination with alternatives such as pallet jacks to determine. Each piece of machinery can be evaluated to calculate its return on investment before

purchase. This will help a company determine the point when the machine will pay for itself by decreasing material-handling costs. 4. Re-Design plant layout When materials move through production, it's important for this path to be as short as possible. Time spent transporting materials to and from different operations on the assembly floor is time not spent in production. Set up a straight line for materials to travel from inventory receipt through kitting, assembly, test and shipping with little or no backtracking. This can greatly reduce manufacturing time and increase earnings. Re-Design of plant layout can be done in two ways. 1) By changing the arrangement and order/sequence of machines to obtain optimize material flow. 2) By completely changing the current plant layout without considering any constraints and rearranging in various manner.

Hence by studying various available solutions we decided to go for Re-Design plant layout by using various analysis & optimization techniques.
CHAPTER 2 Literature Review 2.1 Plant Layout Design Plant Layout is the organization of the physical facilities of a company to promote the efficient use of equipment, material, people and energy. The goals of a Plant layout design are to minimize unit costs, optimize quality, promote effective use of people, equipment, space and energy, provide for employee convenience, safety and comfort, control project costs, and achieve production deadlines. (Frazelle, 2002, p.189-200) The procedure followed in Plant Layout Design consist in 4 phases, starting with gathering data and information, continuing with production and flow analysis, ongoing with identifying and supporting services, and ending with the implementation and a follow up evaluation. 2.2 Flow Analysis The flow analysis considers the operations, transportations, inspections, delays, and storages required as a part moves from receiving to shipping in a plant. The purposes of this kind of analysis are to minimize distance traveled to minimize backtracking, to minimize cross-traffic, to eliminate unnecessary steps in the process, to combine steps in the process, and to minimize production costs. (Meyers, 1993, p.45-70) The most commons flow analysis techniques used in a plant are flow process charts, flow diagrams and operation charts. Flow Diagram

A flow diagram is a graphical diagram which shows the path traveled by each part from receiving to stores to fabrication of each part to final assembly to packout to warehousing to shipping. Operations Charts An operation chart graphically shows the raw material, the buyouts, the fabrication sequence, the assembly sequence, the equipment needs, the time standards, and an indication of plant layout. 2.4 Inventory Inventories are tangible assets that incur costs, tie up working capital, consume space, and must be managed in and out. Most operations, capacity planning and scheduling and depend on inventory. Inventory are held for sale in the normal core of business, or used in producing goods and services for sale. Stocks fill the timing gaps in the rates of supply and demand. Inventory offers insurance and good planning/ control can minimize the associated costs and satisfy efficiency/effectiveness requirements. Basic inventory decisions involve how much to order (replacement quantities), when to order (timing), and how to control the stock system security (issues, safety levels, issues from stock etc). (Sule,1994, p.385-400) Types of inventory The inventory depends on the nature of the company. The different types of inventory are: Merchandise inventory: goods held for sale, ready for sale without further processing. Raw materials inventory: materials stored that are used in production. Work-in-process inventory: partially completed goods. Finished goods inventory: manufactured goods, ready for sale. There are two common ways on how to use the purchased goods after they are stacked up in piles, and the oldest items are at the bottom of the pile. LIFO (last infirst out) take from top of the pile, and FIFO (first in-first out) take from the bottom of the pile. The types of inventories are commonly recognized by their SKU. SKU stands for Stocking Keeping Unit and is a number associated with a product for inventory purposes. Most of the companies use this number to identify an individual product. Because of this, each product must have a SKU, and each SKU must be unique.