1. Materials Management Summer Training Report by: Anand Swarup Laskar B.Tech - sophomore, IIT Roorkee

2. Objective To study the current material flow in Recon Operation and identify the bottlenecks involved in different processes

3. Recon Operation Flow Chart For enlarged view: click on the image

4. Sections under consideration Dismantling section Engine kit section

5. Dismantling Section Flow chart For enlarged view: click on the image

6. 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

7. Advantages Excessive material handling prevented Duplicate movement of material prevented Manpower can be saved More systematic and organized processes

8. Kit Section Flow-Chart For enlarged view: click on the image

9. Existing layout of engine kit section (ground floor) 12 3 4 5 6 6 7.b7.b 8 9 10 11 12 13 a c 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 E w

10. 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 4 E W 1 2.1 3 5 6 6 6 7 2.3 2.2 Existing layout of engine kit section (first floor)

11. 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 Improvement s

12. Proposed layout of engine kit section (ground floor) 12 3 4 5 5 7 8 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 13 9 10 6 11 12 Gate for security 14 Pallet movement route

13. Advantages Easy pallet movement Secure area for inventory parts Place for emergency storage Sufficient space for men and material handling equipments

14. Analysis of Diesel Engine Second part of the training Objective: To have a basic understanding o f all the basic systems and their sub-parts involved in a diesel engine

15. 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

16. 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

17. 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

18. 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 Analysis of Diesel Engine

19. Thank you