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Summer Internship Prashant Meshram PGP2011-13 Indian Institute of Management Raipur I did my summer internship with Hero MotoCorp, Gurgaon plant. I was assigned the project titled "Projecting accuracy & defining norms in improving the service Prashant Meshram ratio in SPD services", PGP11-13 which was in tandem with the SCM team in the Materials Department. In course of my internship, I worked on the following lines under Spare Parts Division (SPD) i. Learning the key concepts that are being used in forecasting the spare parts demand by HMCL. ii. Projecting the accuracy in the SPD by analyzing the last three years data. iii. Identifying the various factors that are responsible for the demand fluctuations in SPD. iv. Recommendations to minimize the effect of the identified factors. To attain the objectives, the following tasks have to be accomplished: 1.A thorough study on spare parts demand forecasting has to be done to construct a speculative outline of spare part management. 2.Evaluation of the case project documentation to get a clear concept of the case. 3.Interact with project personnel in different roles to understand the current state of the project and to get a holistic picture of the business environment. Unconstrained conversations with anyone related to the subject in order to evaluate everything from the most far-out ideas to detailed improvements of forecasting algorithms. 4.Perform statistical analysis with real demand data to project accuracy of different forecast algorithms. I learnt that various components require significant improvements. The most significant factor that affected the demand variation was found to be the SCHEDULE vs. SUPPLY figures. Any fluctuation where supply is not meeting the schedule leads to the variation in the subsequent months and thus affects the service ratio to a great extent and vice versa. Dealers are trained to understand the benefits associated with the maintenance of the spare parts. Variation at the dealers end gives rise to the random demand which is transferred ultimately to the supplier end thus exhibiting the bullwhip effect. This can be minimized with the help of CFRP (Collaborative Forecasting and Replenishment Program) and proper channel alignment. Internship at HMCL gave me an ample opportunity to relate the theory and practical aspects of business. I got a scrutinized glimpse of various forecasting methods used in manufacturing industries and how supply can be optimized for intermittent demand. It was an unforgettable learning experience to work with the world’s largest manufacturer of two wheelers. 27 NOVEMBER 2012
I did my Summer Internship with Jindal Power Limited (JPL), Tamnar (Chhattisgarh), (officially known as O P Jindal Super Thermal Power Plant) known to be Harish Verma India’s first mega PGP 2011-13 thermal power plant having 1000 MW (4 X 250 MW) installed capacity. The 1000 MW power plant, which is operational for the last few years, requires considerable amount to be invested for the maintenance of inventory, the levels of which are bound to increase with the number of operational years of plant, thereby creating a need to evaluate the inventory and to maintain the same at optimal levels perpetually. My task included analyzing the material management practices followed at JPL and finding out the optimum level of inventory to be maintained in order to ensure the maximum plant availability. Managing large inventory that involves thousands of plant items, is a complex task. In thermal power plant, the procurement is not essentially done on the basis of Economic Order Quantity (EOQ). Generally, long term contracts are signed for the supply of material required. Lead time plays a vital role in calculation of optimal level. The production plan dominates the inventory Summer Internship Harish Verma PGP2011-13 Indian Institute of Management Raipur levels to be maintained. The inventory is classified on ABC and VED. Further, Optimum level of any inventory can be based on its operations, maintenance schedule and history. The optimum level of insurance inventory is mainly based on experience of engineers and managers. There cannot be any optimal level of general spares but efforts are made to keep them close to zero. I targeted the supply chain of power generation, the process of power generation, present and past inventory levels, material procurement practices, and store management practices. I had the opportunity to visit all the concerned departments namely operations, MRP, procurement, stores on weekly basis, which helped me understand the role and working of each of the departments. I could gather major information required for accomplishing the task, by interacting with the concerned officials and through official records and SOP of departments. The internship project helped me attain insight into the efforts made to maintain the inventory at optimal levels. It also helped me in gaining hands-on experience of managerial aspects of power plant operations. My work was applauded by the officials and I hope, my recommendation would help JPL manage their inventory levels and address the existing problem in an efficient way. 28 NOVEMBER 2012
Page 2 and 3: CONTENTS Editorial Director’s Mes
Page 4 and 5: Dinesh Kumar Likhi, Prof. Koilakunt
Page 6 and 7: 10-Step Methodology for Deploying T
Page 8 and 9: human resource management systems d
Page 10 and 11: Operations Strategy Dr. Dinesh Likh
Page 12 and 13: People are assets whose value can b
Page 14 and 15: References [1]. Robert H. Hayes and
Page 16 and 17: environment including energy effici
Page 18 and 19: Dark Ages of Manufacturing Industry
Page 20 and 21: Also the policy makers do not bothe
Page 22 and 23: product to the government at a frac
Page 24 and 25: various public and private sector c
Page 26 and 27: Mr. J L Aggarwal: The steel industr
Page 28 and 29: Q) Sir, the term PMI is very common
Page 30 and 31: DEBATE- Is a Strong Manufacturing B
Page 34 and 35: Summer Internship Abhijeet Srivasta
Page 36 and 37: learnt by observing Toyota over the
Page 38 and 39: Crossword Across 1. Type of manufac
Page 40 and 41: Solution to Crossword Team Strive 3

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