Download ABC-MFG-Process Document

MFG – PROCESS DOCUMENT
Ready Mix Division
S. No
1
Process Name
Description
Ready mix Production
In ready mix there are 5 to 6 grades of ready mix (FG) which are fast moving. Sales department will send the
dispatch sheet to the technical department if the requirement of the ready mix/grade is new. Then Technical dept.
will prepare new bill of materials for the new finished good and the batch consumption details are will be send to
production department. If the requirement is not new, then sales/planning dept. will send the dispatch sheet
(production details for the day) to the production dept. Production planning will be done one day before the
production starts.
Production team will create the new BOM in the machine system and starts production and dispatching. This new
code will save in the system and the same code will be used for other customers if the requirement matches with
the existing BOM.
2
Mix Code
Mix code (FG) may vary from customer to customer but the bill of materials remains same. This is due to the price
variance (selling price) from customer to customer and also the mix code will refer the customer identification.
For all the mix codes technical dept will prepare the Batch record sheet.
2
3
4
Delivering rejected Mix
from one customer to
another customer
Degrading the rejected
mix and sending the same
to another customer
Adding Ready Mix in
partial delivered Qty
If one customer rejects the mix because of low/high slump, then the same will be delivered to another customer
from the rejected site. The planning will be handled by the batcher.
If one customer rejects the mix because of low/high slump, then the truck will return to the plant. Based on
production plan, Batcher will consult the technical department and degrades the material (45N-35/20N) and the
same will be delivered to another customer.
During degrading process no overheads should be charged to the assembly.
If there is any partial delivered qty then the truck will return to the plant with the remaining quantity. Then batcher
will add some more material in the same truck and delivers to another customer.
MFG – PROCESS DOCUMENT
Pre-cast Division
S. No
1
Process Name
Description
Pre cast
production
Precast plant is having 5 beds of size 120 Meters long and 1.2 Meter width. Precast plant produces slabs of following
thicknesses 150mm, 200mm, 265mm & 300mm. Different sizes of steel wire being used based on the thickness of the slabs
as following.

12.5 mm for 265 mm & 300 mm slabs

9.3 mm for 150 mm slabs

Mix of 9.3 & 12.5 mm for 200 mm slabs
Number of steel wires used in the slab will also vary depending upon the tech dept design and the numbers of wires that can
be used in the slab are 5, 6, 7 & 9.
Laying of material for each bed takes around 2.30 Hrs and a pre-cleaning time of 1 Hrs. The setting time of each bed will be
around 8-9 Hrs in summer and 12-14 Hrs in winter.
After the setting period is over, the slabs will cut into required sizes as per customer requirement. The cutting time will be
around 1.30-2 Hrs for standard cuts and 4-4.30 Hrs from special cuts.
2
Mix Design
There will be 2 different mix designs, one is for ministry and the other one is standard. Based on the production planning, job
will be created and the bed will be laid.
Any leftover slabs if any produced for ministry will be used for general customers also. In such cases they will deliver the
same slab for standard mix customer in the name of ministry mix.
3
Scrap/Wastage
When a bed is laid there will be minimum wastage of 2sq.mt each on both the sides.
In production process there will be a chance of damage in the slab due to large size aggregates. In this case they will cut the
damage part and uses the beneficiary part for suitable site/customer.
There will be wastage when the bed is cut into standard slabs and for special cuts there will be more wastage.
MFG – PROCESS DOCUMENT
S. No
4
Process Name
Rejections
Description
The total wastage qty need to be tracked in the system and the wastage cost should be charged to product cost.
Rarely, there is a chance of rejecting the slab if there is any difference in the size of the slab or quality of the slab. In case of
difference in size, the slabs will be resized as per new requirement and resend to the same customer or another customer. In
this process there should be some wastage which needs to be tracked.