PRODUCTION SOP REVIEW

Let’s address the “what” first. What does the Production department at
SP do?
The Production at SP looks after the three main stages namely Erection,
Paint, and Assembly, and hence acts as a linkage between the Store and
Integration, respectively.
IS THE SOP BEING FOLLOWED
EFFECTIVELY?

There are three different SOPS of the Production Department for New Machine Building,
Machine Modification and Machine Dispatch, respectively.

Per my understanding and observations, Mr. Mustakim is the Production Manager who
supervises all the Production activities, including those of the Assembly and Dispatch
supervisor Mudassir and Erection and Paint supervisor Praveen and the workers on the floor
shop and the erection and paint gala.
SOP FOR NEW MACHINE BUILDING

How it works: Start the assembly after 100% crating intimation

Making daily production entries (ERP)

Release JO through ERP Final entries in ERP

Raise stage-wise MRN (Material Request Note) Store inward entries for all sub-assemblies and close the JO

Inform MRN details to store via Mail/Task Issue all the sub-assemblies against the main machine at WIP

Make an assembly /Erection activity sheet and paste it on Main machine production entries
the machine before starting the activity
Self-inspect the machine by the Production Supervisor as per
Update the project module plan Vs the Actual on a daily the checklist (functional checklist)
basis
Raise inspection call to Integration and Design Team (then
inspect the machine as per the BOM and DI)
Update the module weekly basis if any updates for new
machines as well as delays in the schedule (Inform to PPC Clear inspection point if any and inform the Integration
for Kanban update)
Store inward entries
 SOP FOR MACHINE MODIFICATION

• Design sent add/remove list Start the assembly after 100% crating intimation
• Release JO through ERP
Making daily production entries (ERP)
• Raise stage-wise MRN (Material Request Note)
Final entries in ERP
• Inform MRN details to store via Mail/Task
Store inward entries for all sub-assemblies and close the JO
• Make an assembly /Erection activity sheet and paste it on the machine before
starting the activity Issue all the sub-assemblies against the main machine at WIP

• Update the module plan Vs the Actual on a daily basis Main machine production entries
• Production will inform to update the module weekly basis if any updates for new
Self-inspect the machine by the Production Supervisor as per
machines as well as delays in the schedule. the checklist (functional checklist)
• Production dismantle the material as per add remove list and return material to
Raise inspection call to Integration and Design Team (then
store with JO.
inspect the machine as per the BOM and DI)
• Store return the material against JO.
Clear inspection point if any and inform the Integration

Store inward entries

SOP FOR MACHINE DISPATCH

After the machine is ready for dispatch (Checklist to be okayed in all

respects by the Service department), the Commissioning Department
shall intimate the machine’s readiness to the Production department. By
cleaning and dismantling loose parts with extra accessories – Handover
to production for packing.

The production team will take machines for packing purposes and take
them for dismantling. A packing list will be generated and sent by the
Production Department to Commercials for further formalities. (Packing
list to be submitted to Commercials on the same day, if it is domestic
location OR One day in advance, in case of Export location).

Once transport is arranged and all formalities are completed by

Commercials, the Production team will load the machines on suitable
trucks.

The Commercials and Production Department will verify all the materials
concerning the packing list.
PREPARATION OF PRODUCTION SCHEDULE

1. Study of Project Module and accordingly plan for

Production

2. Full kit- 100% criteria based on store input

3. Man Power Availability- assigned work to the worker

as per skill and machine (work) priority

4. Space- machine shifting and optimize maximum

shop floor space
ERP USE OF PRODUCTION
DEPARTMENT
How to release Job Order?

Click the Production tab in the ERP

Under Planning, select Job Orders Waiting for Release

Put the machine no. in the order and item no.

Untick Prefill MRN Qty. and click OK

Next, you can see a list of Job Orders against each sub-assembly and child items/parts

Select all the Job Orders by clicking on top and selecting all

Next, click on Save and Release

HOW TO GENERATE THE MRN?

Go to the Production tab in ERP

Under Planning, select Material Request Note and click Save

Select Single Item only for single consumable/multiple consumable items

If you want to raise the machine stage-wise MRN, then go to Add

Then later select the machine number and the stage

Save and generate the MRN

Later the same MRN is given to the store

PROCEDURE OF ERECTION
1. Once 100% crating is completed, production will start the erection.

2. Main frame plates erected with tie rods using overhead crane

3. Checking if the main frame matches side frame using tie rod via Pythagoras theorem

4. Machine leveling (especially mandatory for Turret). Bolting from foundation bracket and machine leveling by sprit level
(level bottom)

5. Cabinet attach with main frame plates and weld.

6. Further fabrication using drawing and complete the erection process.

DRAWING STUDY

• The Production team makes use of drawings provided by

the BOM team at various stages like Erection, Paint and
Assembly.
• These line drawings in 2D form provide information about
the various measurements to be kept for welding, bolting,
polishing, drilling, cutting and grinding while working on
the panels, plates, cabinets, doors, tie rods, hood, etc.
EQUIPMENT, MACHINES AND TOOLS USED FOR
ERECTION
1. Air Compressor

2. Hacksaw machine

3. Hand press machine

4. Scissor (hand) cutting machine

5. Overhead Crane (up/down and reverse/forward)

6. Welding machine instrument (welding rod)

7. Right angle

8. Hand tool (cutting wheel, polish wheel, grinding wheel)

9. Hammer
 PROCEDURE OF PAINT

•
After erection as per the plan, the machine then goes to the paint booth

1. Putty filling takes place on the uneven surface and sanding by multiple sanding disc paper
(emery)

2. Cleaning by dry cloth

3. White primer (single layer)

4. Smooth sanding by 380 grade emery paper

• 5. Paint process (single layer)
6. Clean the surface by a Degreaser (powder, dust such
kind of material to clean the surface before final paint)
• 7. Final paint application.
 EQUIPMENT USED FOR PAINT AND PAINT BOOTH

1. Spray gun

2. WFT (Wet Film Thickness) is a gauge that is put on the wet paint Thickness ranging from 40 to 50 mm depending on the
layer

3. DFT (Dry Film Thickness) is a gauge that is put on the dried paint to check the Thickness of the Primer

4. Heater’s function: The heater is used to bond the paint within 3 to 4 hours to minimize the paint drying time and help to
cure paint (number of heaters for one paint booth: 10 and each module capacity is 3 kW, making it a total of 30kW)

5. Inlet and Outlet blower function: to circulate the air (Inlet- to fill fresh air inside the booth) (Outlet- to extract inside air
with paint fumes and dust particles)

6. Viscosity meter- is used to check the viscosity of the paint and if flows out the gauge within 18 to 21 seconds then the
mixture is okay. If the time taken is less, more paint is added to match the viscosity ratio. If the time taken is more than
18 to 21 seconds, thinner is added.
THE ASSEMBLY STAGE
CONTENT
1. Equipment and machines and their functions
2. Pre-fitting process
3. Line Drawings and Assembly Drawings
4. 3D View and Exploded view study
5. Checklist and inspection
6. Drawing Readings (symbols)
EQUIPMENT AND MACHINES USED FOR ASSEMBLY

1. Bench drilling machine (light duty drill work)

2. Lathe machine (for turning or round job)
3. Radial drilling machine (heavy-duty drill work)
4. Shaping machine (flatness or slotting or machining or
groove operations)
5. Milling machine (any kind of keyway operation or slot
operations or groove operations)
 PRE-FITTING PROCESS
• The pre-fitting process involves converting child parts into sub-
assemblies by
• tapping, oiling, greasing, bearing fitting, pneumatic cylinder mounting
with cylinder, eye bolt fitting, cork tape application, BLPC (black powder
coating), razor cutters fitting, idler roll passing with pin and tie rods,---
etc.
MAIN ASSEMBLY, SUB-ASSEMBLY AND CHILD
ITEMS

• The MAIN assembly is the main machine and it has a model

number. For example, PRIMASLIT RL 14053 is the main assembly.
• Sub-assemblies are the list of assemblies that form the main
machine. For example, the Idler Roll Assembly is a sub-assembly.
• Child items are the BOM parts required to form a particular sub-
assembly. For example, the idler pin, bearing, idler roll, Allen bolt,
and cork tape are required to complete the sub-assembly,
namely the Idler Roll Assembly.
LINE DRAWINGS AND ASSEMBLY DRAWINGS

• I studied the line drawings.

• The line drawings help the fitter on the shop floor to
identify which machine part to fit and where.
• Line drawing will consist of the entire machine and
assembly drawings will be multiple for one machine,
depending on the various assemblies of that one machine.
 MACHINE-VARIANT WISE ASSEMBLY
SLITTER/ROBO INSPECTION/WIR DRM
Unwind assembly Unwind assembly Unwind assembly

Vacuum splice table (optional) Pendant assembly (rotational Web guide assembly
HMI)
Web guide assembly Web guide assembly Mainframe Idler roll assembly
Dancer assembly Web guide motor (senso motor) Loadcell assembly
Cutter/bottom cutter assembly Auxiliary Splicing Assembly Layon assembly (both in unwind
1. Slitter/ROBO 2. Inspection
(optional) 3.
andDRM
rewind)
Nip assembly Encoder/Nip assembly (optional) Rewind assembly
Mainframe idler roll assembly Mainframe idler roll assembly
Loadcell assembly Loadcell assembly
Layon assembly Layon assembly (both in unwind
and rewind)
Layon splicing assembly (in Backlight box assembly
ROBO)
Static assembly Stroboscope assembly
Rewind assembly (auto core Futec system (optional)
positioning, optional for Robo)
Turret assembly Rewind motor drive assembly
Ejector assembly
Laser light assembly
CHECKLIST AND INSPECTION

•I studied the assembly checklist is a functional checklist on

Excel consisting of the points to be checked, the method, the
instrument used, specification (tolerance), actual observation
and remarks if any.

•Each machine will have its own assembly checklist after which,
upon successful inspection, it will be moved for Commissioning.

•At the end of the assembly checklist, it will be mentioned “Inspected by” and “Checked by”. The
inspection work will be inspected by the Production Supervisor and checked by Mr. Mustakim.
 DRAWING READINGS AND MACHINE SYMBOLS AND TOLERANCES

• The drawing readings are geometric symbols used in the assembly drawings for 3D and exploded
view study.
1. Concentricity symbol ◎

2. Total Runout ⌰

3. Parallelism //

4. Diameter (Ø)
5. Eccentricity
6. Tolerances – (Unidirectional and Bidirectional)
• 8. Counterbore ⌴
• 9. Perpendicularity ⊥
• 10. P.C.D (Pitch Circle Diameter)
• 11. Radius r
GENERAL USE MACHINING GRADES

• One triangle: rough finish

• Two triangles: semi-finish (machining)
• Three triangles: grinding finish
• Four triangles: super finish (through lapping)
GENERAL CONTENT OF DRAWING READING:

1. Item code
2. Item description
3. Raw material details
4. Weight of manufacturing parts
5. Manufacturing procedure of operations
 COMPONENT
IDENTIFICATION
Cir clip Star screw Bearing Motor and its
gearbox
Jack screw

Allen bolt Nut Ball screw Layon lever Pneumatic cylinder

Hex bolt Hex nut Tape dispenser Lead screw Fukuta servo motor
(narrowing unwind
bracket less or
more)

CSK bolt Washer (put under Air conditioner for Roller Induction motor
the bolt) cooling electrical
panels and drives

Push button Reel cone used in Stroboscope (to Backlight box Speedometer and its
(power chuck) in floating to use the inspect poly in a stand
unwind section reel intact WIR)

Futec control panel Drag channels PIRC (Pneumatic

with its HMI (in (used to pass the Individual Rotary
case of WIR but wire channels) Cutter)
optional)
ROLE OF PRODUCTION IN MACHINE
MODIFICATION

1. To Add a revised machine in the project module (Kanban)

2. To release JO for new items: Once the Production team
receives the Add/Remove item list from the Design team,
they raise MRN for the new items through ERP
3. Sending back removed items: The items to be removed
are sent back to the Store
4. To generate MRN: Stage-wise MRN is created for the new
items through the ERP
TYPES OF PACKAGING

• Pellet packing is used for international shipping and the

main machine is packed by Sea Worthy Packing (vacuum
pack)
• For domestic shipping, transport channel
(fabricated/channel frame)
DISPATCH

• The design team provides vehicle accommodation to production

accordingly.
• Over Dimensional Cargo (ODC) Plan view: it is a type of vehicle
accommodation
• 40 FEET And 32 feet
• Full body Eicher
• Trailer (40 feet)
• Finally, load the packed machine as per vehicle accommodation or
experience of the Production team.