Shop floor study of entire manufacturing cycle of 5 batches.
Physical weighment of all raw materials & intermediates as per the BOM of the production order.
Variance observed between actual consumption with BOM, deviation reported to technical team for assessing the impact.
In Correct raw material consumption observed.
Time & Motion study done for the men and machine.
Rejection reasons analysed and cost for reworking of the batches done.
Benefits
Critical analysis report submitted for variance in material consumption
3% raw material saving in the material cost achieved by correcting the material consumption discipline.
Cost of reworking the rejected batches submitted to plant management. On an average batch cost increases by 5-8% and necessary awareness program conducted for cost consciousness
Reward and recognition recommended for improvement in the productivity.
