SOS MAY 2024

Value Stream- Total No. of

Safety members %ge
Department Hazards raised

SOS YEAR July 2024

TOTAL OPEN CLOSE

OPEN SOS STATUS

CAPA Responsible number
Admin
M.E
Maintenance
Dispatch
IT
EHS
Safety Performance – Safety Triangle

Fatal

Lost Time Injuries (LTI)

-
Medical Treatment Injury
Identified (MTI) Closed
- - Total Injury Ra
IdentifiedFirst Aid Incidents Closed
- -
Identified Near miss Incidents Closed

Identified Unsafe Act / Behaviour Closed

Identified Unsafe condition Closed

 YTD- 2024

Total Injury Rate (TIR)– 0.0

Closed
Reactive
Closed

Proactive
 Jul-20

Plan Act
Week 1 1,590,006
Week 2 9,478,152
Week 3 26,661,640
Week 4 48,880,438
Week 5 20,067,966
Total 106,678,201
 Owner

Remarks

BV Pla
60000000

50000000

40000000

30000000

20000000
9478152.3158534
8
10000000 1590005.5858657
3 924605.91
0
Week 1 Week 2
 Arvind/Mohan

BV Plan Vs Actual-Jul'20
48880438.096378
4

26661639.566285
5 20067965.726611
8
9478152.3158534
8
58657
24605.91
ek 1 Week 2 Week 3 Week 4 Week 5

Plan Act
 Date Planned Qty Actual Qty Diff
1 22 19 3
2 20 14 6
3 24 20 4
4 20 13 7
5 15 11 4
6 18 17 1
8 30 27 3 35
Plan vs Ac
9 20 22 -2 30
10 23 22 1
25
11 20 25 -5
12 20 16 4 20
13 18 23 -5 15
15 18 23 -5
10
16 16 6 10
17 24 22 2 5
18 25 21 4 0
1 2 3 4 5 6 7 8 9 10 11 12 13 1
19 24 18 6
-5
20 10 14 -4
22 12 17 -5 -10
23 22 18 4 Plan Qty Ac
24 25 23 2
25 21 24 -3
26 21 17 4
27 17 17 0
28 18 14 4
29 20 23 -3
30 20 16 4
week 1 119 94 25
week 2 131 135 -4
week 3 117 104 13
week 4 176 169 7 Plan Adherence
Total 543 502 41
 Plan vs Actual

2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27

Plan Qty Actual Qty Diff

92.45%
 Tray Report for May-2024
week 1 (01 to 10 July) week 2 (11 to 18) week 3(20 to 25)
Planned 190 263 329
Actual 190 223 79
Missed 0 -40 -250
Machining
Remarks. components & Pick Machining components & Pick
list list
24
week 4(27 to 31)
180
139
-41

Machining components & Pick list

 Gate Entry Pending for GRN May 2024
Remarks Week 1 (01 to 10 July) Week 2 (upto 18 July)
Issues Opening Closing Opening Closing
32 6 6 8

Rate Diff/GST/P&F 4 5
NO PO 2
Wrong Gate Entry correcte
material Unboxing
Inventory Control
Material not received/With 1
Lot numbering Method 1
supplier issue 1

Aging Aging
Rate Diff/GST/P&F 02-15 Days, 02-03 Days 02-5days, 1-3days, 02-2days
NO PO 01-10days, 1-2days
Wrong Gate Entry correcte
material Unboxing
Inventory Control
Material not received/With 01-5days
Lot numbering Method 01-03 Days
supplier issue 01-03 Days
for GRN May 2024
Week 3 (upto 24 July) Week 4 (upto 31 July) Week 5
Opening Closing Opening Closing Opening Closing
8 9 9 4

8 1

2
1

Aging Aging
01-4days, 07-3days 01-4days

01-2days

02-3days
01-3days
 Month - July 2024 WORK CENTER UTILIZATION Value Stream - BV

Week work center Name Run time Utilisation Capacity

week 1 ASMTS_BS Assembly & testing- BV- 15-100 FB MS 10 31% 32
week 2 ASMTS_BS Assembly & testing- BV- 15-100 FB MS 5 8% 53
week 3 ASMTS_BS Assembly & testing- BV- 15-100 FB MS 26 50% 53
week 4 ASMTS_BS Assembly & testing- BV- 15-100 FB MS 89 168% 53
week 5 ASMTS_BS Assembly & testing- BV- 15-100 FB MS 198 375% 53
week 1 ASMTS_BM Assembly & testing- BV-125RB-200FB 6 9% 64
week 2 ASMTS_BM Assembly & testing- BV-125RB-200FB 100 95% 106
week 3 ASMTS_BM Assembly & testing- BV-125RB-200FB 70 66% 106
week 4 ASMTS_BM Assembly & testing- BV-125RB-200FB 42 40% 106
week 5 ASMTS_BM Assembly & testing- BV-125RB-200FB 64 301% 106
week 1 ASMTS_BL Assembly & testing- BV-TMBV 250-600 34 53% 64
week 2 ASMTS_BL Assembly & testing- BV-TMBV 250-600 23 22% 106
week 3 ASMTS_BL Assembly & testing- BV-TMBV 250-600 42 40% 106
week 4 ASMTS_BL Assembly & testing- BV-TMBV 250-600 0 0% 106
week 5 ASMTS_BL Assembly & testing- BV-TMBV 250-600 39 37% 106
TOTAL 748 86% 1220

work center Name Run time Utilisation Capacity

ASMTS_BS Assembly & testing- BV- 15-100 FB MS 328 126% 222
ASMTS_BM Assembly & testing- BV-125RB-200FB 282 102% 444
ASMTS_BL Assembly & testing- BV-TMBV 250-600 138 30% 444
Total Assembly & testing 748 86% 1110
OTD July

Estimated OTD
Owner
 REWORK Utilization
SL Transaction Date MO Number Manufactured Qty labor run time Actual Cost
1 30,000
Rewo
11-Jul-2020 321558 2 4 24,188
2 11-Jul-2020 321781 3 3 1,081
25,000
3 11-Jul-2020 321882 5 7 25,269
4 11-Jul-2020 321924 16 8 6,038 20,000
5 11-Jul-2020 321941 10 10 0
15,000
6 21-Jul-2020 322316 32 8 6,038
7 21-Jul-2020 322693 14 14 17,842 10,000
8 24-Jul-2020 322819 36 3.6 2,717
5,000
9 24-Jul-2020 322901 6 1.2 906
10 0
1 2 3 4

Manufactured Qty Used labor ruActual Cost

124 59 84,079
30,000
Rework Cost
25,000

20,000

15,000

10,000

5,000

0
1 2 3 4 5 6 7 8 9 10
 INVENTORY LIQUIDATION-JUNE'20
Date: 1/6/20
Value Stream: BV Plan--May'20
Beginning inventory of 1st May'20 32.6
Purchase value for May'20 1.2
Sale Value X Material cost % 2.4
Liquidation of unallocated inventory 0.60
Beginning inventory of 1st Jun'20 (Forecast) value in Crore INR 30.75

Liquidation of unallocated inventory-July'20 Plan 16.0

Liquidation of unallocated inventory-july'20 Actual

Liquidation of unallocated inventory July'20 Actual Value-INR-Cr

Parts selling to Sonic & SRC 1000000

Unallocated valve 600000

 Owner Venkatesh

UNE'20
Act--May'20 1/6/2020 1/7/2020
32.6 31.0 28.1
1.27 2.3 2.2
2.8 4.9 6.4
0.76 0.3 0.3
31.00 28.1 23.5

Target Responsible Remarks

July VV 5.5 -week2 -SRC done

July VV
 Owner

Week From To Total Released Not releas

1st 1-Jul-20 4-Jul-20 900 200 700

2nd 6-Jul-20 11-Jul-20 700 140 560

Reason Ageing line more than 3 days
401- castings POP lines are reflecting against B7 MO 4
117- Subcon POP lines are reflecting against B7 MO 9
80-Captive POP lines are reflecting against without CO link Not required 2
102-Bought out lines are reflecting against not required to BV 1
16

401- castings POP lines are reflecting against B7 MO 1

117- Subcon POP lines are reflecting against B7 MO 9
80-Captive POP lines are reflecting against without CO link Not required 1
102-Bought out lines are reflecting against ------ 1
33 lines are not required to BV & 30 no’s BOM error & balance B7 MO demand
12
Resp
Maharaja
Siddarth
Anthon
Karunakar

Maharaja
Siddarth
Anthon
Karunakar
[Link] M/C CODES M/C DESCRIPTION Nil
1 3CM 5160 HYUNDAI M/C TURN MILL CENTER Nil
2 3CM 5164 HYUNDAI M/C TURN MILL CENTER Nil
3 3CM 5165 WIDMA VU 850 Nil
4 3CM 5166 WIDMA VU 850 Nil
5 3EM-5205 BFW VMC MACHINE (BV) Nil
6 3EM- 5113 H M T LATHE NH 26 (B.V M/C SHOP) Nil
7 3EM- 5129 KIRLOSKAR LATHE "BOMBAY" (B.V) Nil
8 3EM- 5135 WOTON BORING M/C ( B.V M/C SHOP) Nil
9 3EM- 5136 BALL TURNING LATHE (ACCURATE) Nil
10 3EM- 5137 BALL TURNING LATHE (ACCURATE) Nil
11 3EM-5147 CHINA LATHE CA 6261B (B.V) Nil
12 3EM-5151 BALL TURNING LATHE (ACCURATE) (B.V) Nil
13 3EM-5156 CHINA VTL C 5112 (1 MTR) (BV) Nil
14 3EA-6513 HYDRAULIC PRESS 20 TON FOR BALL Nil
15 3EM-5303 BATLIBOI DRILLING M/C BR - 618 (B.V) Nil
16 3EM-5306 CHINA DRILLING M/C Z3032 x 8/1 (BV) Nil
17 3EM-5420 DIE GRINDER (BALL VALVE) Nil
18 3EM- 5422 DOUBLE ENDED GRINDER (BV) Nil
19 3EL-5428 BALL LAPPING MACHINE (B.V) Nil
20 3EL-5429 BALL LAPPING MACHINE(BDK) (B.V) Nil
21 3EL-5430 BALL LAPPING MACHINE (BDK) (B.V) Nil
22 3EL-5431 BALL LAPPING MACHINE (BDK) (B.V) Nil
23 3W-5438 BALL LAPPING MACHINE (BDK) Nil
24 3W-5439 BALL LAPPING MACHINE (BDK) Nil
25 3W-5440 BALL LAPPING MACHINE (BDK) Nil
26 3CG-5505 ARC WELDING MACHINE (BV) Nil
27 3CA-5815 HYDRO TANK Nil
28 3EA-5913 TEST BED 15 TON (BALL VALVE ) Nil
29 3EA-5915 TEST BED 80 & 175 TON (BALL VALVE ) Nil
30 3EA-5917 TEST BED FOR SCREW END FOR BALL Nil
31 3EA-5918 NON COMPRESSION TEST BED FOR BALL Nil
32 3EA-5919 HYDRAULIC TEST BED 80 TON Nil
33 3EA-5909 HYDRO CLAMPING FOR BALL VALVE 3 TON *D* Nil
34 3W-5942 TEST BED 3 STAGE (BV) Nil
35 3T-5943 TEST BED 170 TON TRIDENT Nil
36 3T-5944 TEST BED 80 TON TRIDENT Nil
37 3EA-6232 EOT CRANE 5000 KGS (BV) Nil
38 3EA 6234 EOT CRANE 2 TON ( BV IMI) Nil
39 3EA-6236 5 TON EOT CRANE , SWIFT MAKE (BALL VALVE) Nil
40 3W-6240 5 TON EOT CRANE (SIGMA) Nil
41 3W-6241 2 TON MONO RAIL CRANE SIGMA Nil
42 3W-6242 3 TON EOT CRANE (BV) Nil
43 3W-6804 STRACKER Nil
44 3EA-5807 AIR COMPRESSOR IR SCREW TYPE UP5 11 C (BV) Nil
45 3CG-5812 AIR COMPRESSOR ELGI 50 HP TYPE E37- 9.5 (BV) Nil
Owner Mohan/Sid

MAY Opening 1011

End 1107

SFG/FG MO 96
Subcon/Inhouse 1011

Target date 20/07 /20

Note: Newly getting added