28-08-2014, 04:20 PM
Through my one semester training in Ballkings, I got a comprehensive and in depth detail about manufacturing of various kinds of balls being used in industry, the wide range of applications associated with them and how important is it to deliver a quality product so that it can be used in our everyday products. I got to learn about production, maintenance and quality control in a factory and that what parameters should one keep in mind for an efficient and successful running of an industrial unit. I got knowledge about - wire drawing, ball heading, flashing, grinding, lapping, barrelling, polishing, heat treatment, quality control, etc. – processes, machines involved, problems and their solutions.
All the projects undertaken by me has given positive results after my performance. All my seniors and even employees were really happy to see my performance. After the various projects the results of them are as follows:
PROJECT-1 (QUALITY CONTROL): In this project, a close supervision by me led to really good results for the company. For 1/4” ball, the number of balls per 100 grams weight increased from 75 to 80, thus, boosting up the production. Even the quality of the ball was improved leading to saving in machining costs. Overall, for all the ball sizes, there was a decrease in wastage of 2% per batch on an average. This decrease led to savings for the company. There was a direct saving of 2% of raw material, the current rate of which is Rs. 50 per kg. Furthermore, there was significant saving in flashing costs, which forms a major contributor in machining cost. Also, costs of subsequent machining process, reduced by a good amount.
PROJECT-2 (WASTAGE REDUCTION): In this project, for 1/4” ball, by reducing the wire diameter, I was able to reduce the wastage by approximately 4% per batch. Saving 4% of wastage was equivalent to saving approximately 20 kgs of material. And reduction in wastage meant reduction in raw material. So as per the current raw material rates of Rs. 50 per kg, there was a direct saving of: 20 x Rs. 50 = Rs. 1000 per batch. Also there was a huge amount of saving in flashing costs and the subsequent machining costs.
PROJECT-3 (CENTRALIZED COOLING SYSTEM): The measurements of the tanks taken by me were kept in record of the company and the capacity needed for the centralized cooling system was calculated. The capacity needed came out to be 126600 litres. This project is still under progress as it is a very time consuming process.
PROJECT-4 (HOUSEKEEPING): After my report on factory’s housekeeping, various suggestions given by me were implemented and the rest are under process of implementation. 1. Strict instructions to workers about not using saw dust were given. 2. Die powder falling down was then collected and resused. 3. Floor pits were repaired. 4. Magnets were bought for each department. 5. Separate bins were maintained for wastes. 6. Workers were educated about cleanliness. 7. Purchasing of industrial broom is still under process.
All the projects undertaken by me has given positive results after my performance. All my seniors and even employees were really happy to see my performance. After the various projects the results of them are as follows:
PROJECT-1 (QUALITY CONTROL): In this project, a close supervision by me led to really good results for the company. For 1/4” ball, the number of balls per 100 grams weight increased from 75 to 80, thus, boosting up the production. Even the quality of the ball was improved leading to saving in machining costs. Overall, for all the ball sizes, there was a decrease in wastage of 2% per batch on an average. This decrease led to savings for the company. There was a direct saving of 2% of raw material, the current rate of which is Rs. 50 per kg. Furthermore, there was significant saving in flashing costs, which forms a major contributor in machining cost. Also, costs of subsequent machining process, reduced by a good amount.
PROJECT-2 (WASTAGE REDUCTION): In this project, for 1/4” ball, by reducing the wire diameter, I was able to reduce the wastage by approximately 4% per batch. Saving 4% of wastage was equivalent to saving approximately 20 kgs of material. And reduction in wastage meant reduction in raw material. So as per the current raw material rates of Rs. 50 per kg, there was a direct saving of: 20 x Rs. 50 = Rs. 1000 per batch. Also there was a huge amount of saving in flashing costs and the subsequent machining costs.
PROJECT-3 (CENTRALIZED COOLING SYSTEM): The measurements of the tanks taken by me were kept in record of the company and the capacity needed for the centralized cooling system was calculated. The capacity needed came out to be 126600 litres. This project is still under progress as it is a very time consuming process.
PROJECT-4 (HOUSEKEEPING): After my report on factory’s housekeeping, various suggestions given by me were implemented and the rest are under process of implementation. 1. Strict instructions to workers about not using saw dust were given. 2. Die powder falling down was then collected and resused. 3. Floor pits were repaired. 4. Magnets were bought for each department. 5. Separate bins were maintained for wastes. 6. Workers were educated about cleanliness. 7. Purchasing of industrial broom is still under process.