job card --productivity

8/7/2019 job card --productivity

1/18

PLANT

.

JOBCARDS + PRODUCTIVITY

Dec,2010


2/18

Plant : 13/6

Presented By : Mr. Deepak Mallik

Date : 10/01/2011

Frm /

Plant Productivity Presentation

for the Month of DEC. 10


3/18

Frm /

Monthly Sales ( In Lacs )

Plant : 13/6

Presented By : Mr. Deepak Malik

Date : 10/01/2011

665

454

541

630

528

702651

578521

0

100

200

300

400

500

600

700

800

Apr'10 May'10 Jun'10 Jul'10 Aug'10 Sep'10 Oct'10 Nov'10 Dec'10


4/18

Frm /

Sales/Manhours (in Rs/Manhr)

Plant : 13/6


Date : 10/01/2011

685627

697 675

583

724 732687 672

0

100

200

300

400

500

600

700

800



5/18

Frm /

Sales in Rs. / Rupees Wage

Plant : 13/6


Date : 10/01/2011

33

23

29 30

24

3230

2624

0

5

10

15

20

25

30

35



6/18


7/18

JOB CARDS


8/18

STEP-1

Check Physical Inventory on Shop Floor

( All areas , net off Rejections/Scrap

which must be returned to Stores before

physical inventory or else be considered

part of inventory).


9/18

STEP2 Balance this Physical Inventory as per Bill of

Materials in Sets.

(Keep only what is fast moving and required

for current month and return excess inventory

or Ask stores to issue components required to

balance your inventory in sets)


10/18

STEP3

Issue Job Cards week wise ,every

Wednesday for next weeks requirement.

(must consider work in progress WIP).


11/18

STEP

4 Max. Two Job Cards in WIP

Any Job Cards Qty/Value for that productshould normally be equivalent to max one

weeks requirement during that month.


12/18

STEP

5

Total Value of WIP at any stage should notbe more than one weeks Sale value.


13/18

STEP 6 MIS to be sent latest by 7th each month on

status of Job Cards & WIP as on last date of

previous month.

Rejection observed during process be

recorded & returned to stores by RRRN

(Material Rejection Return Replacementnote) for getting replacements.


14/18

STEP 6 Production HODs must ensure that material

returned as above be recovered through reworking

& if not possible then these materials be Scrapped

by using STN (Scrap Transfer Note) to Stores.

.Stores to ensure that all materials which were rejected dueto inputs from Suppliers be returned to concerned Supplier ,

debit note for such return be obtained from A/Cs andenclosed with such returns (Please follow Excise & Other

formalities as required)


15/18

STEP 7 Prod Head/Stores to send monthly MIS for :

(i) Material returned to Suppliers giving

item code/description/qty/value/reason for

rejection/Future desired action.(ii) Total Job Cards pending as on last

working day:

(iii) Total STNs (Scrap Transfer notes) Latest by 7th ofEach month for previous

month.


16/18

Present Status:

1. We are already using job card & no production can take place on linewithout a job card.

2. Process sequence of printing & using a job card is as shown inseparate slide.

Advantages ofusing Job Cards:

a) Lot size is defined & store issues exact Quantity as per bill of materials.

b) Every lot size has a unique batch code & incase of any customer problem, we can trace back the

date, line No., operators on each operations & various dimensional readings taken as per ControlPlan.

c) Job cards are stored for 3 years.

d) There is no ambiguity about process sequence & Quality Plan & are followed strictly includingcritical parameters/ Special Characteristics.

e) MaterialaTracebility/ accountability of issued material to the line.

JOB CARD:


17/18

Discipline needed inuse of job card:

a) Full material must be available in store & on ERP stock.

b) BOM has to be correct 100%.

c) ERP must run.

d) In no case line be allowed to run without job card.

e) Process sequence followed on line must be same as shown on job cardas per control plan.

f) job cards have to be stored in Record Room for 3 years with properindexing & traceability.

g) Without Job Card CCDC/PDIR will not accept material.

23rd Oct,2009


18/18

job card --productivity

Documents