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Contents

PROJECT UNDERTAKEN ........................................................................................................................... 2

AIM .......................................................................................................................................................... 2

IMPORTANCE OF THE PROJECT............................................................................................................... 2

TASKS TO BE COMPLETED ....................................................................................................................... 3

TASKS COMPLETED AND STEPS INVOLVED ............................................................................................. 4

MAJOR CHALLENGES FACED .................................................................................................................10

LEARNING OUTCOMES ..........................................................................................................................11

GANTT CHART .......................................................................................................................................12

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PROJECT UNDERTAKEN

To setup a new central warehouse for the TATA MOTORS Pantnagar plant in which the
outstation material can be kept and easily be supplied to different TCF shops kitting areas as
per the requirement by the shops.

Standardisation of the material kept in the central warehouse according to the material handling
and the safety norms of industry guidelines and also reducing the obsolescence present for the
different outstation materials.

AIM

We need to setup a new central warehouse of all the outstation material that come into different
Assembly shops and try to reduce the congestion, chaos and also improve the standardisation
for the material flow in different shops.

IMPORTANCE OF THE PROJECT

In the current process all the material from different vendors are directly feeded in the TCF
shops in the plant. Some of these materials go through the standardisation process while some
of them are kept in the store location. Materials are of two types local and outstation material,
since outstation material needs to have more inventory due to a large TACT time and limited
amount of storage in the TCF shops which causes lot of congestion and chaos inside the shops.

In TCF shops limited amount of docks are available and the time for one vehicle unloading
takes a while due to which vehicles needs to be holded which causes shortage of material and
stoppage of line. In case of material coming from more than 300km also called as outstation
material standard feeding of material is difficult since inventory is large, therefore leads to
violation of FIFO (First In First Out) as well as inventory variance also occurs due to it.

All of these leads to other different problems like:

1) Improper material handling

2) Violation of safety norms (due to more stacking of material)

3) Less movement for material for feeding

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4) Rejection of material due to expiration

Thus all of these factors had a common solution that is the setup of a central warehouse.

TASKS TO BE COMPLETED

For the setup of central warehouse tasks that needed to be completed are:

1) Finalisation of the area for the setup of the new central warehouse estimating the area that
is required for storage of all the outstation material of different TCF shops.

2) Completition of the master file for the creation of list of all the outstation material of
different TCF shops. The list must include:

a) Part number.

b) Part Description.

c) Supplier of the particular part.

d) Location through which the material is coming.

e) Models corresponding to different parts.

f) Shops corresponding

g) Lot size and standard packaging quantity

h) Packaging details

i) Usage location for the part in shop.

j) Validity of the part in shop.

k) Location in the central warehouse.

l) Supply frequency

3) Physical verification of the part need to be done so as to see with how much frequency and
variance is the material inwarded or whether the material is on shortage basis or it has
become in any case obsolete.

4) Area finalised needs to be checked and a layout corresponding to different parts need to
be created for the central warehouse. Estimation of the area required and the number of
heavy duty racks to be placed, high rise racks and multi-tier storage consumption all of
these things constituted for this estimation.
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5) Docks needed for the SUMO shop because of the presence of only one working dock under
warehouse. These docks are to be shifted from different non-working shops including their
maintenance and to be build according to the size of warehouse requirement.

6) Shifting of materials to be done starting from TCF1B shop because of the presence of less
number of outstation parts thereby giving us the idea and the consequences faced while
setting up the new central warehouse.

7) Space creation for Overflow and slow moving materials is also needed, since some of the
parts have very high numbers of inventory and more locations cannot be given to such
materials also in case of slow moving materials a separate location needed to be given to
prevent chaos and a proper sequential system can be implemented.

8) Trollies to be made for easy movement of material to different TCF shops. This would lead
to decrease in TAT time and material handling would become easy and fast.

9) Analysis of min max in kitting areas is to be done. Basis on this analysis we would decide
the Kanban min max quantity and also the frequency of material movement and its demand
in every hour, since direct kitting and line feeding will be done after the implementation of
this project.

10) Kanban implementation for TCF1B shop. We are using a 2-bin Kanban quantity system
for this project. Also use of a barcode for Kanban cards also needs to be implemented for
easy material request generation.

11) Maintenance activities including racks and floor painting, dismantling of the high rise racks
and emptying of the cages, proper light and water system implementation according to the
safety norms of the industry.

12) WIS for material handling and SOP creation for trolley count mechanism and vehicle
unloading, Trolley movement and feeding.

13) Sequential supply and standardisation.

TASKS COMPLETED AND STEPS INVOLVED

1) The area decided for the central warehouse is SUMO-2B shop. This shop was decided out
of two non-working shops present in TML Pantnagar plant.
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Fig1 MHCV Fig2 SUMO-2B

Sumo shop was decided for the building of central warehouse because of the presence of
an in between line and due to future projects in the MHCV shops. Also SUMO 2B was
setup in a format of a central warehouse with some existing racks and material movement
of some parts.

2) Master file is completed based on the required aspects and the file is corrected each day
basis on the information variance.

Fig3 Part List

3) Layout of the new area is decided with placing of the Heavy duty racks initially in the
SUMO shop. Also free or bin area is also created for very large and heavy material placing.
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Fig4 Layout

The placing of these racks is based on the material handling and material placing norms. A gap
of 130cm is kept between two consecutive racks and no stacking of more than 180cm is placed
for the material. A small gap of 20cm is kept between the wall and the racks and racks are
placed so that FIFO could be maintained.

4) Dock work is started for the central warehouse by transferring it from other non-working
shops.
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Fig5 Work started Fig6 Final dock measure

According to the requirement 2 scissor docks are to be transferred for the central warehouse.
The min height to be kept for these docks must be 130cm so that central warehouse vehicles
can easily be loaded and unloaded on these docks.

5) Overflow material space is created on the downward side of the SUMO shop, here the
existing scrap material is removed and space is created accordingly for the overflow
material.

The material is removed from the existing high rise racks because of absence of the stacker
and also safety norms were violated. Thus an overflow material area with palletised storage
needs to be created.

Fig7 before Fig8 After

6) Trolley was designed on the basis of the size of the material and its turning radius for a
smooth movement in TCF shops.
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Fig9 Trolley

Dimensions of the trolley are as follows:

Length-130cm

Width-90cm

Height-118cm

All of these dimensions were based on the vehicle of the central warehouse.

7) After doing lean assessment Kanban cards is to be introduced. Kanban card will have part
number, part description, quantity to be carried, source location, destination location, type
of container or bin and Kanban quantity. Main purpose of KANBAN card is to ensure
smooth supply strategy with shop floor storage.
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Fig10 Operator’s Movement study

Fig 11 Kanban Card

8) Maintenance activities were completed to start the central warehouse. All of these
activities were performed under proper safety measures and material handling norms.

Other maintenance work included

 Emptying the cages for the lock and key items

 Racks and floor painting as per industry norms

 Dismantling of the high rise racks for material storage area creation.

 Heavy duty racks to be locked with lock nuts and hex screw for safety purpose.

 Lux level light was set for effective working

Fig12 before Fig13 After

9) Sequential data feeding is done by directly supplying all the outstation materials from
central warehouse directly to the TCF 1B shops kitting as well as line areas. Thus JIT
system is implemented and chaos on the line side is reduced.
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Without
JIT

With
JIT

Fig.13 Just In Time

For achieving single piece flow, implementing Just in Time and lean methodology the back
bone is fixing the minimum and maximum standards for materials. For successful
implementation of KANBAN minimum and maximum study is to be done for all parts.
Minimum and maximum study is done on the basis of certain parameters like lead time from
supplier, per day consumption, safety stock, cost of the part, weight and volume of the part
and some environmental characteristics.

MAJOR CHALLENGES FACED

 Transferring the material from an ongoing line in TCF1B shop was very chaotic and
created a lot of problem while feeding.

 Guiding the manpower of the new material movement in TCF2B shop was difficult.

 Unviability of vehicle for material movement lead to line stoppage.

 Managing the database of Kanban card and its maintenance.

 location in the central warehouse as locations were decided dynamically

 Storage to be setup for big parts due to area constraint

 Maintenance of FIFO in central warehouse.

 Change in part location or number lead to location change of all the parts in a row.

 Movement of vehicle was increased which increased the cost of handling of material.
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 Diversification in parts due to new product launch.

LEARNING OUTCOMES

 Layout mapping

 Part planning

 Inventory management

 Reduction of obsolescence

 Material handling norms

 Industry safety norms

 Material feeding and kitting methods

 WIS and SOP creation

 Why why analysis

 Min Max analysis

 Sequencing and standardising

 Kanban system and Pull type material flow

 Importance of supermarket

 Lean manufacturing concepts

 Single piece flow

 Two bins concept

 Short Lead time between production and warehouse

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GANTT CHART