WEEK 9:

On Monday I completedthe final report i had started on Saturday.

On tuesday i made my final presentation and got it approved from my mentor.

On wednesday we presented our final reports.

Today i got mail from Mech Head, Hazira that i had to present the presentation in the mechanincal Mangerss' monthly meeting. I was theonly one to havegiven the opportunity. my presentation was freatly appreciated by the all the top managers of hazira plant and mech. head himself.

Action Plan was made to implement all my recommendations. My report and presentrations was forwarded to all departments from purchase to all plants.
mr. P.k. jain termed thepresentation as "beacon" and a path forward.

WEEK 8:

This week I completed my questionnaire collection work.
along with questionnaire collection on-floor work was observed in. Doubts were cleared with Trchinican and Engineer of the areas.
Areas visited were
CP10 (CP area)
CP 10 Spinning
POY Spinning (for Connector--specific consumable)

Secondly, I worked on SAP to obtain Vendor information regarding the consumables used in Patalganga Plant of Reliance.
Post orders were checked and cost differences were analysed.
This search also provided information about the substitutes of various consumables used in hazira that were used in PG plant.

Thirdly. I contacted the vendors of all consumables under study to enquire about their recommendations on storage and application of those consumables.

"Vendor Opportunity Questionnaire" was prepared.


Mentor declared project completion and I started making my project report.

WEEK 7:

Monday was our mid-term presentation.Our progress till date was seen by various senior officials and suggestions were given to contnue and improve our work.

Later this week, I had to collect all the questionnaires i had ditributed in the shopfloor.
This week i visited all the sections where the 10 consumables were used.
I completed the questionnaire for the engineers and technicians.
I also observed the work going on in the shopfloor.

Information from both sources, my observation as well as from the questionnaires were documented.
The product profiles were updated with the informations and inferences were drawn on the base of the study.
The various sections visited weree:
1. Utility
2.Spinning 10m
3.Mech. worskhop 18m
4. Winder workshop 6m
5. Lag area

This week I also visted the CP 10 (Latest plant for POY in RIL,hazira). I observed the work there and drew infrerences based on that.

The week was a successful one as I observed various opportunities for improvement and subsequent optimisation in consumables consumption.

WEEK 6:

The Main Target this week was to distribute the questionaaires prepared to get information from the shopfloor, inventory levels screening and vendor change evaluation.

• Proper sets of questionaire were prepared for each section. Inall there were 15 sets of 52 questionaaires.
• I distributed them to the 15 sections and explained them about the questionnaires. alongwith the ditribution i also took notes about the working style of various workshops and nature of work there.

• Besides this, I was looking on the defined inventory levels of various consumables. I looked through list of 439 Mechanical consumables. A list of 15 consumables was prepared whose defined inventory values didnt match the consumptions. The list was then forwarded to inventory section for proper action.

• I prepared the vendor lists of the 10 consumables i was studying. I analysed the vendor changes over the time. Several iNferences were drawn from the study, enquired and documented.Study revealed much of the savings could be done through proper vendor selection.

At the end of week I prepared my presentation for the mid-term evaluation which was scheduled on Monday.

WEEK 5:

This week my mentor Sh. R.B. Kohli arrived. He reviwed mt progress in the project.
He told me to change my approach to the project.
he told me that he expected from the project a general strategy to handle the consumables which anyone can follow and hence may induce cost reductions. and then I must move with a few high value consumables to show the effectiveness of the strategy.

This week I made the strategy to work upon the 5 major factors that affected the cost of any consumable:
1. vendors
2. shopfloor usage
3. alternate products
4.Inventory handling
5. consumption Trends.

To look at all the 5 factors at the same time I prepared a product profile.
For filling up the product profile structured shopfloor information was also required along with what was already there in ERP(Sap). So i also prepared a questionnaire to get the shopfloor information.

then i doistributed the questionnaires in the shopfloor by making suitable folders for each department.
and i worked upon SAP to obtaina ll possible information that was requires for the product profile. Part B specially.

WEEK 4:

This week I continued on the my work on pack and winding consumables.
main highlights for this week were:

Follow up with Winder workshop and pack room about my reports and recommendations.

I went to the spinning section. Observed the important consumables.

spinning uses the most costly consumable(in terms of cost incurred in 1 yr.) : Aeron silicon spray. there were also other consumables like stick wipe. both the items were used in spinnnerette cleaning which is done every two days on every machines.

I observed the proactive maintenance being carried on and reported my observations to spinning Head.

I also worked on SAP to get valuable information about these consumables.this was also included in the report.

I also prepare the mid term report for the institute.

I also visited the Effluent tratment plant for the same.A day was spend on the induction of tankfarm and ETP

WEEK 3

This week i strated off my project.
As per the plan worked out with my working mentor Sh. V.K. Jain, i had to study the pack room and winding consumbales this week.

So this week i visited spinning, studied 6 consumables there : 3 kinds of bearings, 2 types of grease and cotton rags.

using the system (SAP) i took out the consumption of these consumables over the past 5 years. i also analysed them and compared with shopfloor realities. Improper tendancies were confirmed for.

after spending 3 days in winding shop and preparing the report on winding consumables , i was transferred to pack assembly room.
there were 5 main consumbles used: meshes,S.S.Powders and various tools.
even after closely studying the process for 3 days I could not found any space for opinising consumption of these consumbales. i prepared there trends too but the were totally demand driven trends.

at the end of 3 days i prepared my report.

my next week target will be spinning consumables.