OCTOBER 19-20, 2012 - YMCA University of Science & Technology

Proceedings of the National Conference on
Trends and Advances in Mechanical Engineering,
YMCA University of Science & Technology, Faridabad, Haryana, Oct 19-20, 2012
5. Suggested Implementation Plan
It was then decided to formulate a phase wise implementation approach by picking up the provisions which had
higher weighted scores in the above seven major areas. For deciding the number of provisions taken up for
implementation in a phase, out of the total provisions under a major area, the proximity or differences of scores
around the cutoff were considered i.e. there should be a considerable differences between the score of the last
provision in the phase 1 and the first provision has been divided into three phases as an order of priority for
implementation in any diesel locomotive industry. The three phases of the suggested approach are presented in
table V
The provision or controls suggested to be implemented in phase 1 will in general be less costly, easy to
implement and would have positive or complementary effect on many other areas in the organization.
Phase 2 includes measures which are slightly more difficult to implement, involves reasonably higher cost,
which may require some kind of budgetary provisions and approvals.
Phase 3 includes provisions, which are more related with hardcore technical changes, machinery, equipment and
tooling. Implementation of these provisions will involve substantial capital investment and may require a
number of iterations and trials for implementation.
6. Results of the study
The following results were drawn from the study,
• Average monthly rejection of part before the conduct of the study was 3.6%
• The raw material usage is only 26% of the available inventory each month.
• The company has a high WIP inventory which is 86% of what is actually required.
• The finished goods stock inventory is as per requirement.
• In the existing layout material movement is very high and will be reduced by at least 75% by changing
to the new layout. In the new layout, the material movement distance has been reduced to 131.5 metres
compared to 537.45 metres in the existing layout.
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