Barrel 1,2,3,4 (6)

MAN - MACHINE CHART- Avtec 4 Bore Block

Process Name

Core Making Cold Box

Item Name

Avtec Block

M/C No

HPCB-1200-05

Activity

Total Cycle Time in sec

No. of blows as per PED study(7.00 Hrs)

Shashi P Mishra

No. of readings (In Sec.)

Machine

S No.

14/04/2014

Actual output per shift

No. of readings (In Sec.)

Man-1

Activity

No. of readings (In Sec.)

Man-2

8:00

10:00

12:00

14:00

16:00

8:00

10:00

12:00

14:00

16:00

8:00

10:00

12:00

14:00

16:00

Unloader moves forward, gasing hood

moves away

Idle

Idle

Ejector pins down, placing core over

unloader

Removing loose pins

Idle

Unloader moves backward

Placing loose pins in the core box

Idle

Idle

Placing loose pins in the core box

Trimming core

Idle

21

25

22

23

20

Cleaning core boxes with air

21

25

22

23

20

Trimming core

21

21

21

21

21

Idle

Press the auto button

Trimming core

Sand blower moves towards upper

core box, lower core box moves up
and aligned with sand blower

17

17

17

17

17

Trimming core

17

17

17

17

17

Trimming core

17

17

17

17

17

Sand blow and exhaust time

12

12

12

12

12

Trimming core

Trimming core

Sand blower moves up and go away

from upper core box ,its place is taken
by gassing hood

12

12

12

12

12

Carrying core box from unloader to trolley

15

11

12

10

Carrying core box from unloader to

trolley

17

15

16

15

14

10

Gassing hood comes down and

aligned with core box

Idle

10

10

10

10

10

Idle

11

Gassing and curing

60

60

60

60

60

Idle

60

60

60

60

60

Idle

60

60

60

60

60

12

Gassing hood moves up, core box

moves down

10

10

10

10

10

Idle

10

10

12

15

Idle

15

15

15

14

15

Cycle Time Variation on 14/04/2014

TIME

8:00 AM
10:00 AM
12:00 PM
14:00 PM
16:00 PM

MACHINE

MAN-1

MAN-2

CT

159

159

164

164

162

157

159

162

158

151

159

159

161

155

159

161

159

157

160

160

Page 1

Activity

Project Status

Module -1

1.

Timely Gamba Visit .

2. Preparing Work Instruction/SOP for Change

Over/Mounting-Dismounting.
3. Self Development : Taking Initiatives for
Communication Development.

Module -2
1. Preparing CLIT for one Machine and summarizing
changes before and after .
2. Hourly monitoring of Cycle Time of a particular
Item for one month and analyzing trend or fluctuation
in cycle time.
3. Self Development : Taking Initiatives for
Communication Development.

Project Status

Status

Remarks

Completed

Disscussed with Sanjeev Dhawan

Sir. Visit just after morning card
punch.

Time Study Completed

SOP Work Pending.

Completed

Disscussed with Sanjeev Dhawan

Sir.

Status

Remarks

Completed.

Monitoring Changes.

Undergoing

Completed

Pending.

To be reviewed in Next Module.

DATE

14/04/2014

15/04/2014

17/04/2014

25/04/2014

26/04/2014

TIME
8:00 AM
10:00 AM
12:00 PM
14:00 PM
16:00 PM
8:00 AM
10:00 AM
12:00 PM
14:00 PM
16:00 PM
8:00:00 AM
10:00:00 AM
12:00:00 PM
14:00 PM
16:00 PM
8:00:00 AM
10:00:00 AM
12:00:00 PM
14:00 PM
16:00 PM
8:00:00 AM
10:00:00 AM
12:00:00 PM
14:00 PM
16:00 PM

CT
164
162
159
161
160
160
161
159
162
164
160
164
162
161
162
164
160
161
159
162
164
162
159
161
160

MACHINE
159
162
158
161
159
159
161
158
162
159
159
159
162
161
162
159
159
161
158
162
159
162
158
161
159

MAN-1
159
157
151
155
157
157
155
151
157
159
157
159
157
155
155
159
157
155
151
157
159
155
157
155
157

MAN-2
164
159
159
159
160
160
159
159
159
164
160
164
159
159
159
164
160
159
159
159
164
159
159
159
160

CYCLE TIM
164

164
162

162
161

161
160

159

160

160
159

8:00 AM 10:00 AM 12:00 PM 14:00 PM 16:00 PM 8:00 AM 10:00 AM 12:00 PM 14:00 PM 16:00 PM 8:00:00
AM
14/04/2014

15/04/2014

14/04/2014

15/04/2014

CYCLE TIME VARIAT

164

159

159

159

160

160

159

159

159

164

159

157

151

155

157

157

155

151

157

159

8:00 AM 10:00 AM 12:00 PM 14:00 PM 16:00 PM 8:00 AM 10:00 AM 12:00 PM 14:00 PM 16:00 PM 8:00:00
14/04/2014

15/04/2014

Values
Row Labels
14:00 PM
16:00 PM
8:00:00 AM
10:00:00 AM
12:00:00 PM
Grand Total

Average of CT
161
162
162
162
160
161

Average of MAN-1
155
157
158
157
154
156

Average of MAN-2
159
160
162
160
159
160

CYCLE TIME VARIATION

164

164
162

164

162

162

161
160

162

161
160
159

159

8:00:00 10:00:00 12:00:00 14:00 PM 16:00 PM 8:00:00 10:00:00 12:00:00 14:00 PM 16:00 PM 8:00:00 10:00:00 12:00:00
AM
AM
PM
AM
AM
PM
AM
AM
PM
17/04/2014

25/04/2014

26/04/2014

17/04/2014

25/04/2014

26/04/2014

CYCLE TIME VARIATION MAN-1 & MAN-2

160

164

159

159

159

164

160

159

159

159

164

159

159

157

159

157

155

155

159

157

155

151

157

159

155

157

16:00 PM 8:00:00 10:00:00 12:00:00 14:00 PM 16:00 PM 8:00:00 10:00:00 12:00:00 14:00 PM 16:00 PM 8:00:00 10:00:00 12:00:00
AM
AM
PM
AM
AM
PM
AM
AM
PM
17/04/2014

25/04/2014

26/04/2014

161
160
159

12:00:00 14:00 PM 16:00 PM

PM
26/04/2014

26/04/2014

159

159

160

157

155

157

12:00:00 14:00 PM 16:00 PM

PM
26/04/2014

14-04-14

MAN - MACHINE CHART- Avtec 4 Bore Block

Process Name

Core Making Cold Box

Item Name

Avtec Block

M/C No

HPCB-1200-05

Activity

Total Cycle Time in sec

No. of blows as per PED study(7.00 Hrs)

Shashi P Mishra

No. of readings (In Sec.)

Machine

S No.

14/04/2014

Actual output per shift

No. of readings (In Sec.)

Man-1

Activity

No. of readings (In Sec.)

Man-2

8:00

10:00

12:00

14:00

16:00

8:00

10:00

12:00

14:00

16:00

8:00

10:00

12:00

14:00

16:00

Unloader moves forward, gasing hood

moves away

Idle

Idle

Ejector pins down, placing core over

unloader

Removing loose pins

Idle

Unloader moves backward

Placing loose pins in the core box

Idle

Idle

Placing loose pins in the core box

Trimming core

Idle

21

25

22

23

20

Cleaning core boxes with air

21

25

22

23

20

Trimming core

21

21

21

21

21

Idle

Press the auto button

Trimming core

Sand blower moves towards upper

core box, lower core box moves up
and aligned with sand blower

17

17

17

17

17

Trimming core

17

17

17

17

17

Trimming core

17

17

17

17

17

Sand blow and exhaust time

12

12

12

12

12

Trimming core

Trimming core

Sand blower moves up and go away

from upper core box ,its place is taken
by gassing hood

12

12

12

12

12

Carrying core box from unloader to trolley

15

11

12

10

Carrying core box from unloader to

trolley

17

15

16

15

14

10

Gassing hood comes down and

aligned with core box

Idle

10

10

10

10

10

Idle

11

Gassing and curing

60

60

60

60

60

Idle

60

60

60

60

60

Idle

60

60

60

60

60

12

Gassing hood moves up, core box

moves down

10

10

10

10

10

Idle

10

10

12

15

Idle

15

15

15

14

15

159.8

Cycle Time Variation on 14/04/2014

TIME

8:00 AM
10:00 AM
12:00 PM
14:00 PM
16:00 PM

MACHINE

MAN-1

MAN-2

CT

159

159

164

164

162

157

159

162

158

151

159

159

161

155

159

161

159

157

160

160

Page 10

Activity

15-04-14

MAN - MACHINE CHART- Avtec 4 Bore Block

Process Name

Core Making Cold Box

Item Name

Avtec Block

M/C No

HPCB-1200-05

Activity

Total Cycle Time in sec

No. of blows as per PED study(7.00 Hrs)

Shashi P Mishra

No. of readings (In Sec.)

Machine

S No.

15/04/2014

Actual output per shift

No. of readings (In Sec.)

Man-1

Activity

No. of readings (In Sec.)

Man-2

8:00

10:00

12:00

14:00

16:00

8:00

10:00

12:00

14:00

16:00

8:00

10:00

12:00

14:00

16:00

Unloader moves forward, gasing hood

moves away

Idle

Idle

Ejector pins down, placing core over

unloader

Removing loose pins

Idle

Unloader moves backward

Placing loose pins in the core box

Idle

Idle

Placing loose pins in the core box

Trimming core

Idle

20

23

22

25

21

Cleaning core boxes with air

20

23

22

25

21

Trimming core

21

21

21

21

21

Idle

Press the auto button

Trimming core

Sand blower moves towards upper

core box, lower core box moves up
and aligned with sand blower

17

17

17

17

17

Trimming core

17

17

17

17

17

Trimming core

17

17

17

17

17

Sand blow and exhaust time

12

12

12

12

12

Trimming core

Trimming core

Sand blower moves up and go away

from upper core box ,its place is taken
by gassing hood

12

12

12

12

12

Carrying core box from unloader to trolley

10

12

11

15

Carrying core box from unloader to

trolley

14

15

16

15

17

10

Gassing hood comes down and

aligned with core box

Idle

10

10

10

10

10

Idle

11

Gassing and curing

60

60

60

60

60

Idle

60

60

60

60

60

Idle

60

60

60

60

60

12

Gassing hood moves up, core box

moves down

10

10

10

10

10

Idle

15

12

10

10

Idle

15

14

15

15

15

Cycle Time Variation on 15/04/2014

TIME

8:00 AM
10:00 AM
12:00 PM
14:00 PM
16:00 PM

MACHINE

MAN-1

MAN-2

CT

159

157

160

160

161

155

159

161

158

151

159

159

162

157

159

162

159

159

164

164

Page 11

Activity

17-04-2014

MAN - MACHINE CHART- Avtec 4 Bore Block

Process Name

Core Making Cold Box

Item Name

Avtec Block

M/C No

HPCB-1200-05

Activity

Total Cycle Time in sec

No. of blows as per PED study(7.00 Hrs)

Shashi P Mishra

No. of readings (In Sec.)

Machine

S No.

17/04/2014

Actual output per shift

No. of readings (In Sec.)

Man-1

Activity

No. of readings (In Sec.)

Man-2

8:00

10:00

12:00

14:00

16:00

8:00

10:00

12:00

14:00

16:00

8:00

10:00

12:00

14:00

16:00

Unloader moves forward, gasing hood

moves away

Idle

Idle

Ejector pins down, placing core over

unloader

Removing loose pins

Idle

Unloader moves backward

10

Placing loose pins in the core box

Idle

Idle

11

Placing loose pins in the core box

Trimming core

Idle

20

21

25

23

12

Cleaning core boxes with air

20

21

25

23

23

Trimming core

21

21

21

21

21

Idle

13

Press the auto button

Trimming core

Sand blower moves towards upper

core box, lower core box moves up
and aligned with sand blower

17

17

17

17

14

Trimming core

17

17

17

17

17

Trimming core

17

17

17

17

17

Sand blow and exhaust time

12

12

12

12

15

Trimming core

Trimming core

Sand blower moves up and go away

from upper core box ,its place is taken
by gassing hood

12

12

12

12

16

Carrying core box from unloader to trolley

15

11

10

10

Carrying core box from unloader to

trolley

14

17

15

15

15

10

Gassing hood comes down and

aligned with core box

17

Idle

10

10

10

10

10

Idle

11

Gassing and curing

60

60

60

60

18

Idle

60

60

60

60

60

Idle

60

60

60

60

60

12

Gassing hood moves up, core box

moves down

10

10

10

10

19

Idle

15

10

10

12

12

Idle

15

15

15

14

14

Cycle Time Variation on 17/04/2014

TIME

8:00 AM
10:00 AM
12:00 PM
14:00 PM
16:00 PM

MACHINE

MAN-1

MAN-2

CT

159

157

160

160

159

159

164

164

162

157

159

162

161

155

159

161

162

155

159

162

Page 12

Activity

25-04-2014

MAN - MACHINE CHART- Avtec 4 Bore Block

Process Name

Core Making Cold Box

Item Name

Avtec Block

M/C No

HPCB-1200-05

Activity

Total Cycle Time in sec

No. of blows as per PED study(7.00 Hrs)

Shashi P Mishra

No. of readings (In Sec.)

Machine

S No.

25/04/2014

Actual output per shift

No. of readings (In Sec.)

Man-1

Activity

No. of readings (In Sec.)

Man-2

8:00

10:00

12:00

14:00

16:00

8:00

10:00

12:00

14:00

16:00

8:00

10:00

12:00

14:00

16:00

Unloader moves forward, gasing hood

moves away

Idle

Idle

Ejector pins down, placing core over

unloader

Removing loose pins

Idle

Unloader moves backward

Placing loose pins in the core box

Idle

Idle

Placing loose pins in the core box

Trimming core

Idle

21

20

23

22

25

Cleaning core boxes with air

21

20

23

22

25

Trimming core

21

21

21

21

21

Idle

Press the auto button

Trimming core

Sand blower moves towards upper

core box, lower core box moves up
and aligned with sand blower

17

17

17

17

17

Trimming core

17

17

17

17

17

Trimming core

17

17

17

17

17

Sand blow and exhaust time

12

12

12

12

12

Trimming core

Trimming core

Sand blower moves up and go away

from upper core box ,its place is taken
by gassing hood

12

12

12

12

12

Carrying core box from unloader to trolley

15

10

12

11

Carrying core box from unloader to

trolley

17

14

15

16

15

10

Gassing hood comes down and

aligned with core box

Idle

10

10

10

10

10

Idle

11

Gassing and curing

60

60

60

60

60

Idle

60

60

60

60

60

Idle

60

60

60

60

60

12

Gassing hood moves up, core box

moves down

10

10

10

10

10

Idle

10

15

12

10

Idle

15

15

14

15

15

Cycle Time Variation on 25/04/2014

TIME

8:00 AM
10:00 AM
12:00 PM
14:00 PM
16:00 PM

MACHINE

MAN-1

MAN-2

CT

159

159

164

164

159

157

160

160

161

155

159

161

158

151

159

159

162

157

159

162

Page 13

Activity

26-04-2014

MAN - MACHINE CHART- Avtec 4 Bore Block

Process Name

Core Making Cold Box

Item Name

Avtec Block

M/C No

HPCB-1200-05

Activity

Total Cycle Time in sec

No. of blows as per PED study(7.00 Hrs)

Shashi P Mishra

No. of readings (In Sec.)

Machine

S No.

26/04/2014

Actual output per shift

No. of readings (In Sec.)

Man-1

Activity

No. of readings (In Sec.)

Man-2

8:00

10:00

12:00

14:00

16:00

8:00

10:00

12:00

14:00

16:00

8:00

10:00

12:00

14:00

16:00

Unloader moves forward, gasing hood

moves away

Idle

Idle

Ejector pins down, placing core over

unloader

Removing loose pins

Idle

Unloader moves backward

Placing loose pins in the core box

Idle

Idle

Placing loose pins in the core box

Trimming core

Idle

21

25

22

23

20

Cleaning core boxes with air

21

23

25

23

20

Trimming core

21

21

21

21

21

Idle

Press the auto button

Trimming core

Sand blower moves towards upper

core box, lower core box moves up
and aligned with sand blower

17

17

17

17

17

Trimming core

17

17

17

17

17

Trimming core

17

17

17

17

17

Sand blow and exhaust time

12

12

12

12

12

Trimming core

Trimming core

Sand blower moves up and go away

from upper core box ,its place is taken
by gassing hood

12

12

12

12

12

Carrying core box from unloader to trolley

15

10

11

10

Carrying core box from unloader to

trolley

17

15

15

15

14

10

Gassing hood comes down and

aligned with core box

Idle

10

10

10

10

10

Idle

11

Gassing and curing

60

60

60

60

60

Idle

60

60

60

60

60

Idle

60

60

60

60

60

12

Gassing hood moves up, core box

moves down

10

10

10

10

10

Idle

10

12

10

12

15

Idle

15

14

15

14

15

Cycle Time Variation on 26/04/2014

TIME

8:00 AM
10:00 AM
12:00 PM
14:00 PM
16:00 PM

MACHINE

MAN-1

MAN-2

CT

159

159

164

164

162

155

159

162

158

157

159

159

161

155

159

161

159

157

160

160

Page 14

Activity