Copper Stock and Inventory with Production Tracking in Wire Manufacturing Industry
Cover Letter
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The Problem
In our company, we are working with a Desktop application software developed, which partially meet the management expectation and needs more customization to make the process simpler and easier and more user friendly The existing version of software is developed using traditional Visual Basic version 6 (VB6) and MYSQL as backend While doing the case study in the existing system, it has been discovered that tracking the inventory levels of copper is not straight forward. Every time the resources should calculate the list of copper utilized during a course of time, calculate and analyse the requirements for the future, and place the next order to the vendors that is not accurate and precise. It takes lot of time to track production, sales, past orders, wastage and future orders manually. Not only the above, improper planning results to wasting useful labor in trivial works, and is also prone to human error
Another major drawback on using the existing system is the employees in the production area have to leave the production area, go to a computer, log in to the computers, open the software, provide the required inputs, get information about the input product, and provide the required updates. And the process to do that takes about thirty minutes to an hour To overcome this situation, we plan to build an android mobile app where the employees can bring an android phone or tab into the production area and enter the inputs and get all the information that they need in about one second. That is really the beauty of mobile software. It simplifies some complex tasks that do not need to be complex. Our business model is very simple but the Desktop Software that is being used is complex.
What we need
The best way to simplify complex business processes and make employees’ jobs easier is to customize the existing version of desktop software and to develop home grown mobile applications. Since android version devices are cheap we plan to develop android application that will get the input from the user and synchronize that information into the main server similarly, the same approach will be used for the output.
The Opportunity after the initial discussion with our IT organization with IT heads, the goals / key are derived as below Some of them are the key criteria’s
- Current version of application platform should be customized according to the needs of each So the existing application source code should be altered / modified to meet the requirement. No clear roadmap is laid to follow the requirements.
- Develop an android version of the software that will help the users to use the system in the areas where desktops cannot be used.
Things Considered for Development
Simplify Process Control
- Dynamic estimation of copper consumption (Category wise – RBD, MMH1, MMH2, MMH3, Buncher, Sheeting, Stranding, Insulation)
- Tracking of copper from Purchase Order (PO) to Delivery
- Estimation of all resources, analyze and compare with actual production.
- Process wise raw material usage and comparison with estimation.
- Purchase history to avoid peak pricing and reduce procurement costs.
Simplify Purchase Operation
- Create PO and track the purchase depending on
Ist Fortnight (From 1st to 15th of Every Month)
2nd Fortnight (From 16th to 31st of Every Month)
CSP (End of Day)
M-1 (1 -31 of Previous Month)
M+1 (1-31 of Next Month)
Spot Boiling (Any Time) - Maintain Re-order level
- Purchase Management with purchase price variance and review depending upon Provisional Price and Finance Price
- Ability to view the previous Booking
- Track Booking
- Report based on duration booking
- Excise Returns
- Price Arrival is made on either Domestic or International which depends upon London Metal Exchange, Premium / Metric Ton, Dollar RateTherefore Price per Metric Ton = LME + Premium / Metric Ton + $rate x Metric Factor+ Freight
- Production Planning
- Tentative Sales
- Considering Stock
Sales
- Customer Tentative
- Against Purchase Order (PO)
Better Production Control & Inventory
- Complete Production Control for both situations i.e. make to order and make to stock.
- Production Scheduling and actual raw material usage while reducing wastage and improving effectiveness.
- Detailed Stock in, Stock Out and Stock issue with all dynamic situations
Improve in Sales Management
- Auto reminders that you do not miss out any enquiry.
- History of all quotations with pricing.
- Achieve greater sales and customer satisfaction with support, warranty tracking and after-sales-service.
Better Manpower Control
- Manpower control with task assignments and track productivity.
Excellent Finance Support
- Managing all transactions and inputs in terms of payment.
- Approvals and Reminders to make your most important department dynamic.
Other Benefits
- Identify dead products and eliminate loss-making products from the inventory.
- Improved decision-making and better ROI.
- Interactive dashboards with graphical interface.
- Customizable reports for better decision making.
- Smooth and systematic structure to work in the organization.
- Tracking of Baskets either through RFID or QRCode
- Tracking of Finished Goods (Wooden Wire Coils) with the help of RFID or QRCode
- Complete Product Tracking, anywhere, anytime using QRCode or RFID
Proposed Architecture
Our proposed project is a real time implementation using recommend latest technologies and Internet of Things (IOT) to meet our demand reducing the investment as low as possible which and also by utilizing the existing systems. For example the price of an android tablet is only Rs.5,000 where as the price of an computer is roughly around 20,000. In the place of investment in one computer we can have 4 android tablets. The benefit of android tablet over desktop computers is given in table below.
| Topic | Computer | Tablets / Smartphones |
| Power | Requires More Power and is dependent on electricity | Can operate from 12 to 24 hours if charged for less than an hour. Don’t want to depend on Electricity 24/7 |
| Cost | Prices for a computer (desktop or laptop) can vary widely, depending on its capabilities, storage, and other features Prices can range from Rs.20,000 to Rs 25000. | Tablets price are cheap starts from as low as from Rs.3,500 |
| Portability | Desktop computers are not portable. Laptop computers are portable, lightweight, and easy to place in a backpack, but laptops can become bulky and more difficult to carry around, weighing several pounds. | Tablets are more portable than any computer or laptop. They are designed to be taken everywhere with you, thus the very definition of portable. |
| Operating System | We need to ensure that all computers are using Original Operating systems. | Tablets come with a more slimmed down operating system because of the limited computing power and memory. The Operating systems in tablet doesn’t need to be purchased and is easily upgradable |
| Boot time | The latest computers running the latest operating systems have improved a lot on their boot time. However, are still slower than a tablet. | Generally speaking, most tablets are much faster at booting than most computers. |
| Data entry and user input | A computer uses a keyboard for data entry that most users are familiar with and comfortable using. The mouse is also available for easy scrolling and right-clicking. | Tablets use an on-screen keyboard that is smaller than a standard computer keyboard, takes time to learn, and users with bigger fingers may have a hard time typing. We can also Scan and take screenshot |
| Touchscreen | Although most laptops and desktops still have no touch screen support and it is not as easy as tablets. | All tablets support a touchscreen, which can be easier for new computer users. |
Table 1 – Computer and Tablets / Smartphones Comparison
Figure 1 – Proposed Architecture
Application Development Maintenance (ADM) & Hosting
The following are the requirements for ADM
Hardware
Basic requirement for running Apache Webserver or equivalent
Application
PHP above version 5.6
Database
Mysql
Support (hardware)
Not applicable
Support (software)
mysqli and pdo drivers
Mobile App Requirements
Any android Mobile that supports Wi-Fi
Deployment and testing
No separate server is required
Information assurance
Comply with standard firewalls, Automated Backups
Integration/interoperability
No Middleware is used. Excel / CSV import export or custom module will be developed
Performance
Lightweight Application, Lightweight server, Faster Page Loading with AJAX, Faster Query processing.
Standards
Industry recommended coding standards with proper code commenting and naming conventions.
Defect tracking applications like Bugzilla or mantis or similar applications will be used for monitoring the status on the reported bugs
Proposed Modules
Goods Receivable
At a very high level, the goods receivable will be more or less similar to shown below.
Figure 2 – Receivable of Goods
As soon as we receive the goods, the security will take the screenshot of the vehicle, scan the invoice using the tablet or mobile and save it. This will help the application to indirectly capture the GPS location, the date on which the goods is arrived and the PO against which the order is received, the vendor from whom the goods is received, Date of purchase order, Date of goods received, Vehicle information etc. This will help the system to generate the first QRCode with all the above information and this code will serve as a unique tracking code from start to finish of the process. Another advantage of this QRCode is that it will help on tracking the age of the goods.
Security Scans the Incoming Goods, Generates QRCode and Vehicle is sent to store for despatch
Figure 3 – Receiving Goods and updating Information by Security
Goods inwarded in store is validated and assigned unique QRCode against the invoice scanned by security and physical invoice copy
Figure 4– Receiving Goods and updating information in stores
Goods are unloaded from vehicle and moved to store
Store Maintenance
Figure 5 – Store Maintenance
Goods received from vendor is validated and the various process are tracked using the unique QRCode
Production Tracking
Production in Cables industry is a huge process. It has various steps to be processed to achieve the required product.
Classification of wire drawing in cable industry
Figure 6– Classification of Wire drawing
Process of wire drawing in cable industry
Figure 7– Process of Wire drawing
Classification of Wire Sizes
Figure 8– Wire Sizes
|
Size (Sq.mm) |
Configuration |
Copper Wt/ Mtr (Gms.) |
PVC Wt/Mtr (Gms.) | Total Wt/Mtr (Gms.) | Copper Content % | PVC Content % |
| FR | ||||||
| 1.00 | 14/0.3 | 8.26 | 7.15 | 15.41 | 54% | 46% |
| 1.50 | 22/0.3 | 11.84 | 8.16 | 20.00 | 59% | 41% |
| 2.50 | 36/0.3 | 19.48 | 11.26 | 30.74 | 63% | 37% |
| 4.00 | 56/0.3 | 30.19 | 13.21 | 43.40 | 70% | 30% |
| 6.00 | 84/0.3 | 45.46 | 15.32 | 60.78 | 75% | 25% |
| 0.75 | 24/0.2 | 6.13 | 5.21 | 11.34 | 54% | 46% |
| 10.00 | 80/0.4 | 79.52 | 26.30 | 105.82 | 75% | 25% |
| 16.00 | 126/0.4 | 124.72 | 35.14 | 159.86 | 78% | 22% |
| 0.00 | 0 | 0.00 | 0.00 | 0 | 0% | 0% |
| Flexible | ||||||
| 0.50 | 16/0.2 | 4.26 | 4.32 | 8.58 | 50% | 50% |
| 0.75 | 24/0.2 | 6.13 | 5.21 | 11.34 | 54% | 46% |
| 1.00 | 32/0.2 | 8.05 | 5.50 | 13.55 | 59% | 41% |
| 1.50 | 30/0.25 | 11.61 | 6.64 | 18.25 | 64% | 36% |
| 1.50 | 48/0.2 | 12.69 | 5.51 | 18.20 | 70% | 30% |
| 2.50 | 50/0.25 | 18.10 | 7.62 | 25.72 | 70% | 30% |
| 2.50 | 80/0.2 | 21.30 | 8.32 | 29.62 | 72% | 28% |
| 4.00 | 53/0.3 | 30.18 | 13.93 | 44.11 | 68% | 32% |
| 6.00 | 84/0.3 | 48.99 | 19.50 | 68.49 | 72% | 28% |
| 10.00 | 80/0.4 | 82.40 | 22.41 | 104.81 | 79% | 21% |
| 16.00 | 126/0.4 | 126.04 | 37.70 | 163.74 | 77% | 23% |
| 25.00 | 196/0.4 | 195.26 | 53.96 | 249.22 | 78% | 22% |
| 35.00 | 276/0.4 | 281.49 | 53.00 | 334.49 | 84% | 16% |
| 50.00 | 396/0.4 | 398.07 | 68.53 | 466.60 | 85% | 15% |
| 95.00 | 484/0.5 | 804.00 | 160.00 | 964.00 | 83% | 17% |
| 70.00 | 360/0.5 | 597.60 | 142.40 | 740.00 | 81% | 19% |
| 185.00 | 925/0.5 | 1540.00 | 325.00 | 1865.00 | 83% | 17% |
| 240.00 | 1210/0.5 | 2025.00 | 248.33 | 2273.33 | 89% | 11% |
| 120.00 | 608/0.5 | 1160.00 | 100.56 | 1260.56 | 92% | 8% |
| 300.00 | 1501/0.5 | 2952.00 | 418.00 | 3370.00 | 88% | 12% |
| 0 | #DIV/0! | #DIV/0! | ||||
| SRK Impex (Power Guide) | ||||||
| 0.50 | 4.25 | 5.06 | 9.31 | 46% | 54% | |
| 0.75 | 6.40 | 5.16 | 11.56 | 55% | 45% | |
| 1.00 | 8.55 | 6.43 | 14.98 | 57% | 43% | |
| 1.50 | 12.23 | 9.27 | 21.50 | 57% | 43% | |
| 2.50 | 20.65 | 11.45 | 32.10 | 64% | 36% | |
| 4.00 | 33.36 | 13.77 | 47.13 | 71% | 29% | |
| 6.00 | 50.40 | 17.28 | 67.68 | 74% | 26% | |
| 10.00 | 85.60 | 26.66 | 112.26 | 76% | 24% | |
| 16.00 | 137.68 | 32.15 | 169.83 | 81% | 19% | |
| 25.00 | 221.82 | 46.27 | 268.09 | 83% | 17% | |
| 0 | #DIV/0! | #DIV/0! | ||||
| FRLS | ||||||
| 1.00 | 14/0.3 | 8.25 | 7.27 | 15.52 | 53% | 47% |
| 1.50 | 22/0.3 | 12.19 | 7.99 | 20.18 | 60% | 40% |
| 1.50 | 30/0.25 | 8.02 | 11.66 | 19.68 | 41% | 59% |
| 2.50 | 36/0.3 | 20.05 | 10.92 | 30.97 | 65% | 35% |
| 2.50 | 50/0.25 | 18.06 | 11.38 | 29.44 | 61% | 39% |
| 4.00 | 56/0.3 | 31.19 | 11.67 | 42.86 | 73% | 27% |
| 6.00 | 84/0.3 | 47.70 | 14.14 | 61.84 | 77% | 23% |
| 10.00 | 80/0.4 | 83.23 | 25.40 | 108.63 | 77% | 23% |
| 16.00 | 126/0.4 | 128.27 | 34.20 | 162.47 | 79% | 21% |
| 95.00 | 484/0.5 | 802.00 | 186.00 | 988.00 | 81% | 19% |
| 150.00 | 750/0.5 | 1250.00 | 214.00 | 1464.00 | 85% | 15% |
| 0 | #DIV/0! | #DIV/0! | ||||
| HR 105DegreeC FR | ||||||
| 0.5 | 16/0.2 | 3.97 | 3.99 | 7.96 | 50% | 50% |
| 0.75 | 24/0.2 | 6.03 | 4.78 | 10.81 | 56% | 44% |
| 1 | 32/0.2 | 8.10 | 4.94 | 13.04 | 62% | 38% |
| 1.5 | 30/0.25 | 11.75 | 5.98 | 17.73 | 66% | 34% |
| 1.5 | 48/0.2 | 12.04 | 7.88 | 19.92 | 60% | 40% |
| 2.5 | 50/0.25 | 19.01 | 8.21 | 27.22 | 70% | 30% |
| 4 | 56/0.3 | 31.43 | 11.88 | 43.31 | 73% | 27% |
| 6 | 84/0.3 | 47.78 | 14.27 | 62.05 | 77% | 23% |
| 0 | #DIV/0! | #DIV/0! | ||||
| Welding Cable- Rubber Cable | ||||||
| 16 | 336/0.25 | 139.35 | 44.3 | 183.65 | 76% | 24% |
| 35 | 276/0.4 | 294.31 | 45.21 | 339.52 | 87% | 13% |
| 35 | 259/0.4 | 294.76 | 66.53 | 361.29 | 82% | 18% |
| 20 | 408/0.25 | 169.57 | 46.29 | 215.86 | 79% | 21% |
| 0 | #DIV/0! | #DIV/0! | ||||
| ZHFR | ||||||
| 1.5 | 22/0.3 | 12.82 | 8.29 | 21.11 | 61% | 39% |
| 2.5 | 36/0.3 | 20.64 | 10.46 | 31.10 | 66% | 34% |
| 4 | 56/0.3 | 30.97 | 11.10 | 42.07 | 74% | 26% |
| 0 | #DIV/0! | #DIV/0! | ||||
| Lapp-ZHFR | ||||||
| 1 | 32/0.2 | 8.28 | 5.80 | 14.08 | 59% | 41% |
| 1.5 | 30/0.25 | 12.95 | 7.95 | 20.90 | 62% | 38% |
| 2.5 | 50/0.25 | 20.28 | 11.24 | 31.52 | 64% | 36% |
| 4 | 56/0.3 | 32.20 | 13.73 | 45.93 | 70% | 30% |
| 6 | 84/0.3 | 49.18 | 17.05 | 66.23 | 74% | 26% |
| 0 | #DIV/0! | #DIV/0! | ||||
| Lapp- Uniplus | ||||||
| 1 | 32/0.2 | 8.63 | 5.57 | 14.2 | 61% | 39% |
| 1.5 | 30/0.25 | 11.84 | 7.89 | 19.73 | 60% | 40% |
| 2.5 | 50/0.25 | 20.2 | 10.63 | 30.83 | 66% | 34% |
| 4 | 56/0.3 | 32.67 | 12.88 | 45.55 | 72% | 28% |
| 6 | 84/0.3 | 48.99 | 15.06 | 64.05 | 76% | 24% |
| 25 | 196/.4 | 224.68 | 55.61 | 280.29 | 80% | 20% |
| 35 | 259/0.4 | 299.47 | 64.24 | 363.71 | 82% | 18% |
| 50 | 364/0.4 | 414.7 | 70.38 | 485.08 | 85% | 15% |
| 70 | 358/.5 | 634 | 88 | 722 | 88% | 12% |
| Molex | ||||||
| 4 | 65/.254 | 29.8 | 10.8 | 40.6 | 73% | 27% |
| 0 | #DIV/0! | #DIV/0! | ||||
| ESBEE | ||||||
| 0.5 | 20/0.18 | 4.66 | 4.66 | 9.32 | 50% | 50% |
Table 2- Different Wire Configurations – 1
| Size (Sq.mm) | No of Cores | Configuration | Copper Wt/ Mtr (Gms.) | PVC Wt/Mtr (Gms.) | Sheath Wt (Gms.) | Total Wt/Mtr (Gms.) | Copper Content % | PVC Content % | Sheath Content |
| Flat-Thick | |||||||||
| 1.5 | 3 | 22/0.3 | 35.58 | 26.5 | 67.08 | 129.16 | 28% | 21% | 52% |
| 2.5 | 3 | 36/0.3 | 57.84 | 38.51 | 73.8 | 170.15 | 34% | 23% | 43% |
| 4 | 3 | 56/0.3 | 91.1 | 49.35 | 78.6 | 219.05 | 42% | 23% | 36% |
| Flat-Thin | |||||||||
| 1.5 | 3 | 22/0.3 | 37.88 | 17.21 | 41.18 | 96.27 | 39% | 18% | 43% |
| 2.5 | 3 | 36/0.3 | 58.31 | 27.98 | 61.96 | 148.25 | 39% | 19% | 42% |
| 4 | 3 | 56/0.3 | 91.3 | 39.64 | 73.91 | 204.85 | 45% | 19% | 36% |
| 6 | 3 | 84/0.3 | 137.55 | 59.37 | 89.68 | 286.6 | 48% | 21% | 31% |
| 10 | 3 | 80/0.4 | 249.39 | 71.84 | 122.77 | 444 | 56% | 16% | 28% |
| 16 | 3 | 126/0.4 | 381.79 | 91.2 | 142.78 | 615.77 | 62% | 15% | 23% |
| 1 | 3 | 14/0.3 | 24.36 | 20.35 | 39.58 | 84.29 | 29% | 24% | 47% |
| Flat-Thin-XLPE | |||||||||
| 1.5 | 3 | 22/0.3 | 38.66 | 10.31 | 48.4 | 97.37 | 40% | 11% | 50% |
| 2.5 | 3 | 36/0.3 | 62.82 | 15.31 | 61.4 | 139.53 | 45% | 11% | 44% |
| 4 | 3 | 56/0.3 | 95.27 | 23.38 | 75.07 | 193.72 | 49% | 12% | 39% |
| 0 | #DIV/0! | #DIV/0! | #DIV/0! | ||||||
| Multicore | |||||||||
| 0.5 | 2 | 16/0.2 | 8.11 | 8.92 | 29.87 | 46.9 | 17% | 19% | 64% |
| 0.75 | 2 | 24/0.2 | 12.31 | 10.2 | 33.38 | 55.89 | 22% | 18% | 60% |
| 1 | 2 | 32/0.2 | 16.5 | 10.69 | 36.82 | 64.01 | 26% | 17% | 58% |
| 1.5 | 2 | 30/.25 | 23.38 | 12.14 | 41.95 | 77.47 | 30% | 16% | 54% |
| 2.5 | 2 | 50/0.25 | 38.35 | 17.31 | 61.93 | 117.59 | 33% | 15% | 53% |
| 4 | 2 | 56/0.3 | 62.17 | 24.88 | 83.73 | 170.78 | 36% | 15% | 49% |
| 6 | 2 | 84/0.3 | 95.43 | 29.38 | 107.39 | 232.2 | 41% | 13% | 46% |
| 10 | 2 | 80/0.4 | 166.14 | 49.64 | 170.88 | 386.66 | 43% | 13% | 44% |
| 0.5 | 3 | 16/0.2 | 12.3 | 13.11 | 32.45 | 57.86 | 21% | 23% | 56% |
| 0.75 | 3 | 24/0.2 | 18.45 | 15.33 | 34.63 | 68.41 | 27% | 22% | 51% |
| 1 | 3 | 32/0.2 | 24.81 | 15.8 | 38.19 | 78.8 | 31% | 20% | 48% |
| 1.5 | 3 | 30/.25 | 35.16 | 17.72 | 45.2 | 98.08 | 36% | 18% | 46% |
| 2.5 | 3 | 50/0.25 | 58.44 | 28.13 | 58.88 | 145.45 | 40% | 19% | 40% |
| 4 | 3 | 56/0.3 | 93.4 | 37.83 | 75.09 | 206.32 | 45% | 18% | 36% |
| 6 | 3 | 84/0.3 | 141.16 | 41.34 | 93.86 | 276.36 | 51% | 15% | 34% |
| 10 | 3 | 80/0.4 | 221.24 | 71.79 | 150.15 | 443.18 | 50% | 16% | 34% |
| 16 | 3 | 126/0.4 | 384.17 | 94.44 | 244.17 | 722.78 | 53% | 13% | 34% |
| 0.5 | 4 | 16/0.2 | 16.26 | 17.7 | 32.33 | 66.29 | 25% | 27% | 49% |
| 0.75 | 4 | 24/0.2 | 24.19 | 19.92 | 37.04 | 81.15 | 30% | 25% | 46% |
| 1 | 4 | 32/0.2 | 33 | 21.35 | 40.1 | 94.45 | 35% | 23% | 42% |
| 1.5 | 4 | 30/.25 | 46.1 | 23.14 | 52.05 | 121.29 | 38% | 19% | 43% |
| 2.5 | 4 | 50/0.25 | 80.89 | 36.51 | 62.42 | 179.82 | 45% | 20% | 35% |
| 4 | 4 | 56/0.3 | 124.83 | 49.55 | 85.07 | 259.45 | 48% | 19% | 33% |
| 6 | 4 | 84/0.3 | 188.2 | 57.1 | 127.86 | 373.16 | 50% | 15% | 34% |
| 10 | 4 | 80/0.4 | 329 | 93.65 | 208.74 | 631.39 | 52% | 15% | 33% |
| 16 | 4 | 126/0.4 | 516.05 | 167.09 | 270 | 953.14 | 54% | 18% | 28% |
Table 3 – Different Wire Configurations – 2
Since many process is involved in production, and using devices like computer in production area for our requirement is practically difficult. Therefore, we would suggest using the tablets / hand held devices inside the production area. Process like RBD, MMH1, MMH2, Buncher, Sheating are taken place only inside the production area. Since the output of a process is input of another process, tracking of the copper coils (Baskets) becomes mandatory. In MMH different types of wires of various sizes are use. Hence we need to track the copper used, copper joined, remaining copper, source copper etc., The proposed production area may look as shown below.
Figure 9 – Production Tracking
Every information updated in production area will be available to other departments immediately helping them to either raise PO or keep track on the utilized copper etc.,
Rod Break Down (RBD)
Figure 10 – Rod Break Down (RBD) Machine
RBD Manual Production Entry Format
| sl.no | date | shift | basket no | size | production in kgs |
| 1 | 01-Nov | day | b06 | 2.9 | 1027 |
| night | b36,b02 | 2.9 | 1515 | ||
| 2 | 02-Nov | day | b49,b28,b31,b11,b29 | 2.9 | 4790 |
| night | b03,b24,b21,b35,b50 | 2.9 | 4682 | ||
| 3 | 03-Nov | day | 0 | 0 | |
| night | 0 | 0 | |||
| 4 | 04-Nov | day | b38,b08 | 1.63 | 382 |
| night | b22,b35,b52,b54,b16,b17,b23,b47,b30,b01,b15,b05,b40,b43,b27 | 1.63 | 4594 | ||
| 5 | 05-Nov | day | 0 | 0 | |
| night | 0 | 0 | |||
| 6 | 06-Nov | day | 0 | 0 | |
| night | 0 | 0 | |||
| 7 | 07-Nov | day | 0 | 0 | |
| night | 0 | 0 | |||
| 8 | 08-Nov | day | 0 | 0 | |
| night | b10,b54,b41 | 1.63 | 1502 | ||
| 9 | 09-Nov | day | 0 | 0 | |
| night | b22,b59,b13,b37 | 2.9 | 3051.5 | ||
| 10 | 10-Nov | day | 0 | 0 | |
| night | b41,b28,b35,b21,b20 | 1.63 | 956 | ||
| 11 | 11-Nov | day | 0 | 0 | |
| night | 0 | 0 | |||
| 12 | 12-Nov | day | b44 | 1.63 | 192 |
| night | b30,b21,b20, | 1.62 | 1508 | ||
| night | b44,b31 | 2.9 | 1040 | ||
| 13 | 13-Nov | night | b36,b14,b24,b18 | 1.63 | 1230 |
| night | b55 | 1.62 | 228 | ||
| night | b11,b26,b35 | 1.62 | 1508 | ||
| night | b28,b27 | 3.26 | 2057 | ||
| 14 | 14-Nov | day | b01 | 3.26 | 835 |
| night | b09,b05,b34,b19,b47,b38 | 1.63 | 985 | ||
| 15 | 15-Nov | day | b06,b55,b19,b40,b59,b08,b43,b25,b29,b04,b05,b23,b17 | 1.63 | 3609 |
| night | 0 | 0 | |||
| 16 | 16-Nov | day | 0 | 0 | |
| night | 0 | 0 | |||
| 17 | 17-Nov | day | 0 | 0 | |
| night | 0 | 0 | |||
| 18 | 18-Nov | night | 0 | 0 | |
| night | 0 | 0 | |||
| 19 | 19-Nov | day | b24,b30,b09,b17,b36,b05,b10,b14,b41,b55,b52,b33,b06,b12,b47,b03,b15 | 1.63 | 3204 |
| night | 0 | 0 | |||
| 20 | 20-Nov | day | b2,b41,b55,b19, b59,b43,b4,b14,b60,b18, b13,b36,b12,b25,b6,b33 | 1.63 | 3064 |
| night | b05,b08,b47,b49,b03,b16,b44 | 1.63 | 1145 | ||
| night | b35,b38 | 2.9 | 1615 | ||
| 21 | 21-Nov | day | b6,b40,b1 | 2.9 | 2071 |
| night | 1,2,3 | 1.38 | 810 | ||
| night | b15,b08,b4,b14,b19,b2,b5,b26 | 1.63 | 1098 | ||
| 22 | 22-Nov | day | b17,b29,b30,b24,b36,b6,b16,b13,b18,b10,b20,b47,b9,b23,b44,b57,,b47,b34,b31,b12,b03,b25,b43 | 1.63 | 4394 |
| night | b08,b5,b14,b50,b19,b41,b55,b59,b4,b2,b33,b52,b15,b51,b39 | 1.63 | 2865 | ||
| 23 | 23-Nov | day | 0 | 0 | |
| night | 0 | 0 | |||
| 24 | 24-Nov | day | b26 | 1.63 | 145 |
| night | b06 | 2.9 | 732 | ||
| night | b30,b10,b18,b36,b13,b20,b16,b49,b09 | 1.63 | 897 | ||
| night | box4,box5 | 1.38 | 1037 | ||
| 25 | 25-Nov | day | b05,b06,b44,b41,b17,b59,b30,b36,b43,b15,b33,b26,b57 | 1.63 | 3721 |
| night | b26,b3,b19,b2,b4,b29,b24,b47,b13,b10,b31,b23,b09,b39,b25,b50,b11,b16,b18,b52,b49,b51,b55 | 1.63 | 8205.5 | ||
| 26 | 26-Nov | day | b14,b8,b17,b57,b26,b43,b06,b34,b30,b05,b41 | 1.63 | 2520 |
| night | b36,b26,b59,b44,b04,b02,b20,b33,b03,b06,b17,b41,b24,b15,b19,b29,b57,b11 | 1.63 | 5533 | ||
| 27 | 27-Nov | day | b43,b36,b30,b10,b47,b9 | 1.63 | 1665 |
| night | b05,b16,b49,b02,b39,b50,b26,b13,b25,b59 | 1.63 | 3067.5 | ||
| 28 | 28-Nov | day | b23,b47,b55,b18,b33,b24,b57,b4,b59,b20 | 1.63 | 2101 |
| night | b29,b05,b41,b26,b39,b52,b02,b59,b12,b31,b57,b20,b55,b24,b19,b33,b50,b25 | 1.63 | 6457.5 | ||
| 29 | 29-Nov | day | b51,b8,b52,b20,b14,b34 | 1.63 | 2762 |
| night | b54,b47,b44,b29,b41,b05,b57,b49,b13b09 | 1.63 | 4783 | ||
| 30 | 30-Nov | day | b15,b14,b10,b06,b55 | 1.63 | 2495 |
| night | 0 | 0 | |||
| Total | 102079 |
Table 4 – RBD Manual Production Entry Screen
The RBD Screen will have the below given fields. During Each Entry of the Reel No (Basket No), the available quantity will be displayed to the user. In the below screen it is showed in the Red Font. The Reel No (basket number) will be Alphanumeric. There will be a separate module to Add, Edit and remove baskets. Additional fields may be added, Existing fields may be removed based on the company representative feedback in the below given screen.
Figure 11– RBD Screen
Figure 12 – RBD Input Types
MMH
Figure 13– Multiwire Drawing (MMH)
In our company, we have 8 lines and 16 lines multiwire drawing. The input and output sizes is defined in the below given image.
Figure 14 – MMH Input & Output
Figure 15-MMH Die Sequences
MM30 Manual Production Entry Format
| sl.no | date | size | production in kgs | Scrap |
| 1 | 01-Nov | 1.63 | 412 | 1 |
| 0 | 0 | |||
| 2 | 02-Nov | 0 | 0 | |
| 0 | 0 | |||
| 3 | 03-Nov | 0 | 0 | |
| 0 | 0 | |||
| 4 | 04-Nov | 0 | 0 | |
| 0 | 0 | |||
| 5 | 05-Nov | 0.6 | 113.5 | 0 |
| 0 | 0 | |||
| 6 | 06-Nov | 0 | 0 | |
| 0 | 0 | |||
| 7 | 07-Nov | 0 | 0 | |
| 0 | 0 | |||
| 8 | 08-Nov | 0 | 0 | |
| 0 | 0 | |||
| 9 | 09-Nov | 0 | 0 | |
| 0 | 0 | |||
| 10 | 10-Nov | 0 | 0 | |
| 0 | 0 | |||
| 11 | 11-Nov | 0 | 0 | |
| 0 | 0 | |||
| 12 | 12-Nov | 0 | 0 | |
| 0 | 0 | |||
| 13 | 13-Nov | 1.3 | 182.5 | 0 |
| 0 | 0 | |||
| 14 | 14-Nov | 0.8 | 33.5 | 0 |
| 0.552 | 203.72 | 0 | ||
| 15 | 15-Nov | 0 | 0 | |
| 0 | 0 | |||
| 16 | 16-Nov | 0 | 0 | |
| 0 | 0 | |||
| 17 | 17-Nov | 0 | 0 | |
| 0 | 0 | |||
| 18 | 18-Nov | 0 | 0 | |
| 0 | 0 | |||
| 19 | 19-Nov | 0 | 0 | |
| 0 | 0 | |||
| 20 | 20-Nov | 0 | 0 | |
| 0 | 0 | |||
| 21 | 21-Nov | 0 | 0 | |
| 0 | 0 | |||
| 22 | 22-Nov | 49 | 2 | |
| 0 | 0 | |||
| 23 | 23-Nov | 0 | 0 | |
| 0 | 0 | |||
| 24 | 24-Nov | 0 | 0 | |
| 0 | 0 | |||
| 25 | 25-Nov | 0 | 0 | |
| 0 | 0 | |||
| 26 | 26-Nov | 0 | 0 | |
| 0 | 0 | |||
| 27 | 27-Nov | 119 | 2.5 | |
| 0 | 0 | |||
| 28 | 28-Nov | 350.88 | 0 | |
| 0 | 0 | |||
| 29 | 29-Nov | 508 | 0 | |
| 494 | 2.5 | |||
| 30 | 30-Nov | 420.5 | 0 | |
| 0 | 0 | |||
| Total | 2886.6 | 8 |
Table 5 – MM30 Manual Production Entry Format
MWD-MMH Manual Production Entry Format
| sl.no | date | shift | reel no | Configuration | production in kgs | Scrap |
| 1 | 01-Nov | day | m55,m191,m156,m197,m87,m136,m74 | 8/0.275 | 1492 | 1 |
| night | m167,m12,m124,m73,m184 | 10/0.175 | 235.5 | 6 | ||
| 2 | 02-Nov | day | m161,m205,m92 | 10/0.175 | 1040 | 0 |
| night | 0 | 0 | 0 | |||
| 3 | 03-Nov | day | m193,m91,m114 | 8/0.275 | 644 | 9 |
| night | m53,m98,m209,m184,m187 | 8/0.290 | 1431 | 3.5 | ||
| night | m157,m215 | 8/0.275 | 485.5 | 0 | ||
| night | m146 | 10/0.175 | 417 | 0 | ||
| 4 | 04-Nov | day | m222,m77,m14 | 8/0.278 | 1355.5 | 4.5 |
| day | m147 | 8/0.275 | 428 | 0 | ||
| day | m78,m224 | 10/0.175 | 636 | 0 | ||
| night | m156 | 6/0.290 | 365.5 | 0 | ||
| night | m209,m51,m200,m79 | 8/0.275 | 1717 | 1 | ||
| night | m198,m65,m187,m74 | 10/0.175 | 1225 | 0 | ||
| 5 | 05-Nov | day | m25 | 6/0.275 | 66.5 | 0 |
| day | m42,m55,m98 | 8/0.275 | 1253.5 | 1.5 | ||
| day | m91 | 8/0.278 | 214 | 0 | ||
| day | m45,m208,m193,m30,m191 | 10/0.175 | 1965 | 0 | ||
| night | m53,m13 | 14/0.290 | 993 | 0 | ||
| night | m201,m127 | 10/0.175 | 725 | 0 | ||
| 6 | 06-Nov | day | m285,m136,m151,m14 | 16/0.378 | 1557.5 | 3.5 |
| night | m25,m35,m189,m110 | 14/0.278 | 1580 | 2 | ||
| 7 | 07-Nov | day | m91,m14 | 8/0.275 | 648.5 | 0 |
| day | m203,m197 | 14/0.278 | 789 | 1 | ||
| night | m215,m217 | 14/0.278 | 787 | 0 | ||
| night | m189,m147 | 15/0.478 | 479.5 | 0 | ||
| night | m140 | 11/0.478 | 139.5 | 0 | ||
| night | m136 | 9/0.478 | 24.5 | 0 | ||
| night | m215 | 7/0.478 | 4.5 | 1.5 | ||
| night | m29,m25,m55 | 8/0.275 | 1293 | 1.5 | ||
| 8 | 08-Nov | day | m42,m91,m136 | 8/0.275 | 1294 | 1 |
| day | m175 | 14/0.278 | 393 | 1 | ||
| night | m142,m184 | 8/0.232 | 640.5 | 0 | ||
| night | m217 | 7/0.232 | 281 | 0 | ||
| 9 | 09-Nov | day | 0 | 0 | 0 | |
| night | 0 | 0 | 0 | |||
| 10 | 10-Nov | day | m213,m151,m87,m247 | 7/0.232 | 841.5 | 0 |
| day | m285 | 10/0.175 | 416.5 | 0 | ||
| night | m120,m53,m131 | 7/0.232 | 421 | 2 | ||
| night | m197 | 8/0.232 | 321 | 0 | ||
| night | m109,m215 | 10/0.175 | 832.5 | 0 | ||
| 11 | 11-Nov | day | m156,m142,m110,m60,m189 | 7/0.232 | 702 | 2 |
| day | m200,m184,m186 | 10/0.175 | 1110 | 1.5 | ||
| night | m148 | 10/0.175 | 415.5 | 0 | ||
| night | m247,m34,m53,m212,m87 | 10/0.175 | 770 | 2 | ||
| 12 | 12-Nov | night | m247,m277 | 6/0.278 | 71 | 2 |
| night | m168,m98 | 8/0.275 | 428.5 | 0 | ||
| night | m09,m113,m122,m73 | 10/0.175 | 1536.5 | 2.5 | ||
| 13 | 13-Nov | day | m125,m143 | 8/0.275 | 428 | 1 |
| day | m172,m97,m230 | 10/0.175 | 732.5 | 0 | ||
| night | m230,m64,m6,m36,m199,m47 | 10/0.175 | 2489 | 0 | ||
| 14 | 14-Nov | day | m8 | 10/0.175 | 260.5 | 0 |
| day | m132,m125, | 14/0.290 | 985.5 | 3 | ||
| night | m110, | 14/0.290 | 496.5 | 0 | ||
| night | m129,m212,m53,m156,m50,m86 | 12/0.277 | 1963 | 1 | ||
| 15 | 15-Nov | day | m53,m85 | 14/0.275 | 747 | 1 |
| night | m82 | 8/0.278 | 139 | 0 | ||
| night | m01,m68 | 6/0.202 | 89 | 0 | ||
| night | m247,m50 | 6/0.278 | 341.5 | 0 | ||
| night | m149,m170 | 8/0.278 | 454.5 | 2 | ||
| night | m132,m143,m168,m42,m59,m91,m197,m85 | 14/0.275 | 2988.5 | 2 | ||
| 16 | 16-Nov | day | 0 | 0 | 0 | |
| night | 0 | 0 | 0 | |||
| 17 | 17-Nov | day | m196,m1,m42,m82 | 8/0.278 | 861 | 3.5 |
| day | m83,m68,m98 | 14/0.275 | 1121.5 | 3 | ||
| night | m175,m83,m33,m42,m98,m187 | 14/0.275 | 1649.5 | 0 | ||
| 18 | 18-Nov | day | m91 | 7/0.298 | 415 | 4.5 |
| night | m197 | 14/0.275 | 137 | 0 | ||
| night | m214 | 8/0.278 | 429 | 1 | ||
| night | m132 | 7/0.298 | 433.5 | 0 | ||
| night | m59,m85 | 6/0.278 | 426 | 0.5 | ||
| 19 | 19-Nov | day | m143 | 8/0.275 | 214 | 0 |
| day | m168,m247,m01,m50,m59,m187 | 14/0.275 | 1588 | 1 | ||
| night | m150,m81,m89,m175,m49,m125 | 14/0.275 | 2029 | 1 | ||
| night | m175,m121,m68 | 6/0.278 | 429.5 | 0 | ||
| night | m68,m83,m49,m196,m110,m42,m59 | 8/0.278 | 1539 | 1 | ||
| night | m55 | 7/0.190 | 139.5 | 1 | ||
| 20 | 20-Nov | day | m190,m59,m01 | 7/0.190 | 421 | 1.5 |
| day | m110,m196,m85 | 7/0.256 | 483 | 0 | ||
| day | m143,m82 | 14/0.275 | 828 | 1.5 | ||
| day | m12,m170,m25,m50 | 14/0.275 | 1509.5 | 0 | ||
| night | m83,m156,m34,m157,m217,m05,m125,m167,m189 | 7/0.256 | 1450.5 | 0 | ||
| 21 | 21-Nov | day | m83,m143,m50 | 14/0.275 | 981.5 | 1 |
| day | m128 | 8/0.278 | 100 | 0 | ||
| day | m196,m13 | 7/0.232 | 13 | 0.5 | ||
| night | m82,m207,m83,m170,m82,m121 | 7/0.232 | 428 | 0 | ||
| night | m85,m124,m12 | 14/0.275 | 912.5 | 1 | ||
| 22 | 22-Nov | day | m156,m25, | 7/0.232 | 150.5 | 0 |
| day | m13,m121 | 7/0.378 | 421.5 | 0.5 | ||
| day | m58,m83,m196 | 14/0.275 | 892 | 1 | ||
| night | m53,m33,m121 | 7/0.378 | 646.5 | 1 | ||
| night | m170 | 8/0.280 | 248 | 0 | ||
| night | m207,m233 | 14/0.275 | 575 | 0 | ||
| night | m184 | 10/0.175 | 184 | 2.5 | ||
| 23 | 23-Nov | day | m83,m41,m42 | 10/0.175 | 1244 | 4.5 |
| night | m185,m189 | 10/0.175 | 648 | 0 | ||
| 24 | 24-Nov | day | m81,m12 | 6/0.378 | 444 | 0.5 |
| day | m208 | 4/0.278 | 113 | 0 | ||
| day | m167, | 14/0.290 | 496 | 2 | ||
| day | m198,m193,m146 | 16/0.278 | 665 | 0 | ||
| night | m161 | 4/0.275 | 279 | 1 | ||
| night | m191,m156,m13,m205,m30 | 14/0.278 | 946 | 1 | ||
| night | m230,m129 | 10/0.175 | 833.5 | |||
| 25 | 25-Nov | day | m78,m1 | 8/0.278 | 453.5 | 1 |
| day | m45,m124,m201 | 14/0.278 | 665 | 2 | ||
| day | m74,m92,m45 | 14/0.278 | 699.5 | |||
| night | m30,m224,m193,m196,m207,m92,m124,m13,m198m18,m224, | 14/0.278 | 2553.5 | 1.5 | ||
| night | m45,m25 | 16/0.278 | 880 | |||
| night | m5,m128,m201,m193,m146,m59 | 8/0.278 | 1323 | 0.5 | ||
| 26 | 26-Nov | day | m147,m12,m191,m1,m13,m205 | 16/0.278 | 2634.5 | 0 |
| day | m143, | 8/0.278 | 435.5 | 0 | ||
| day | m196 | 4/0.278 | 281 | 1.5 | ||
| day | m92 | 6/0.278 | 333 | 0 | ||
| day | m198 | 5/0.378 | 249 | 0 | ||
| day | m53,m224,m102 | 7/0.378 | 1050 | 0 | ||
| night | m12,m87,m205,m34,m102,m197 | 16/0.278 | 2633.5 | 0 | ||
| night | m25,m191,m128,m212,m13 | 7/0.378 | 2754 | 0 | ||
| 27 | 27-Nov | day | m18,m128,m213,m247 | 16/0.278 | 1285 | 0 |
| day | m161,m233,m01 | 8/0.478 | 707 | 0 | ||
| day | m50 | 8/0.378 | 152 | 3 | ||
| day | m154 | 6/0.478 | 176.5 | 2.5 | ||
| night | m124,m34 | 4/0.278 | 473 | 1 | ||
| night | m196 | 6/0.278 | 514 | 0.5 | ||
| night | m12,m191,m30,m82 | 16/0.378 | 1978 | 1.5 | ||
| 28 | 28-Nov | day | m198,m102,m33 | 16/0.277 | 1304 | 0 |
| day | m161,m59,m175,m87,m87,m197,m50 | 6/0.378 | 2521.5 | 0 | ||
| night | m147,m175,m50 | 6/0.378 | 51 | 0 | ||
| night | m59,m30,m191,m45,m8,m146,m25 | 8/0.232 | 1576 | 0 | ||
| 29 | 29-Nov | day | m198 | 7/0.232 | 140.5 | 0 |
| day | m143,m98, | 6/0.202 | 172.5 | 0 | ||
| day | m142 | 6/0.211 | 97.5 | 0 | ||
| night | m212,m30,m13,m8 | 6/0.278 | 852 | 0 | ||
| night | m224 | 8/0.278 | 219.5 | 0 | ||
| night | m5 8 | 16/0.277 | 435 | 0 | ||
| night | m05 | 14/0.270 | 379.5 | 0 | ||
| 30 | 30-Nov | night | 0 | 0 | 0 | |
| total | 103885 | 111 | ||||
| valeo | 23097 | |||||
| balance to buncher | 80788 |
Table 6 – MWD-MMH Manual Production Entry Format
Buncher
Figure 16– Buncher
Bunchers, stranders and cablers take individual strands or cables and form them into desired geometric configurations. These machines support processing requirements in bare wire, building wire, power cable and data communications cables.
Buncher Manual Production Entry Format
| sl.no | date | Shift | Size | reel no | Configuration | production in kgs | Scrap |
| 1 | 01-Nov | day | 0 | 0 | |||
| night | 0 | 0 | |||||
| 2 | 02-Nov | day | 2.5 | m35 | 36/0.3 | 243 | |
| night | 0 | 0 | |||||
| 3 | 03-Nov | day | 6.0 | m013 | 84/0.9 | 350 | |
| day | 1.5 | m113 | 22/0.3 | 162.5 | |||
| night | 1.5 | m214 | 22/0.3 | 388.5 | |||
| night | 2.5 | m122 | 36/0.3 | 405.5 | |||
| 4 | 04-Nov | day | 2.5 | m143,m125,m73,m62 | 36/0.3 | 1660 | |
| night | 2.5 | m197 | 36/0.3 | 411 | |||
| night | 6 | m191,m136,m157 | 84/0.3 | 1349 | |||
| 5 | 05-Nov | day | 0 | m26 | 32/0.2 | 0 | |
| day | 6.0 | m128,m177 | 84/0.3 | 918 | |||
| day | 4.0 | m25 | 56/0.3 | 358 | |||
| night | 4.0 | m81,m189,m197 | 56/0.3 | 1149 | |||
| night | 1.5 | m142,m164 | 22/0.3 | 601 | |||
| 6 | 06-Nov | day | 0.0 | 0 | 0 | ||
| night | 10.0 | m114,m157,m119,m81,m217 | 80/0.4 | 1944.5 | |||
| night | 2.5 | m285,m131 | 36/0.3 | 749 | |||
| 7 | 07-Nov | day | 4.0 | m55 | 56/0.3 | 445 | |
| day | 2.5 | m151 | 36/0.3 | 258 | |||
| day | 2.5 | m136 | 36/0.3 | 438 | |||
| night | 4.0 | m10,m154,m53,m178,m209,m87,m171 | 56/0.3 | 2890 | |||
| 8 | 08-Nov | day | 4.0 | m150,m130 | 56/0.3 | 708.5 | |
| day | 300.0 | m77 | 37/0.5 | 16 | |||
| day | 300.0 | m215,m35,m121,m134,m62,m98 | 39/0.5 | 108 | |||
| day | 300.0 | m136,m151,m3,m61,m121,m35,m215,m135,m1,m62,m98,m200,m27,m134,m165 | 41/0.5 | 565 | |||
| night | 2.5 | m14,m87 | 36/0.3 | 889 | |||
| 9 | 09-Nov | day | 0 | 0 | |||
| night | 0 | 0 | |||||
| 10 | 10-Nov | day | 1.5 | m102 | 30/0.25 | 358 | |
| day | 2.5 | m110 | 36/0.3 | 399 | |||
| day | 1.5 | m203,m175 | 30/0.25 | 830 | |||
| night | 0 | ||||||
| 11 | 11-Nov | day | 2.5 | m180,m119 | 50/0.25 | 758.5 | |
| night | 6.0 | m156,m16 | 84/0.3 | 396 | |||
| night | 1.5 | m209 | 22/0.3 | 168 | |||
| night | 2.5 | m95,m223,m131 | 50/0.25 | 1232 | |||
| night | 4.0 | m18 | 56/0.3 | 386 | |||
| 12 | 12-Nov | day | 4.0 | m156,m16 | 56/0.3 | 231 | |
| night | 2.5 | m110,m156 | 36/0.3 | 796 | |||
| night | 6.0 | m18 | 84/0.3 | 440 | |||
| 13 | 13-Nov | day | 1.0 | m225,m16,m217,m209 | 32/0.2 | 490.5 | |
| night | 1.5 | m169 | 22/0.3 | 316 | |||
| night | 4.0 | m34,m197 | 56/0.3 | 869.5 | |||
| night | 0.0 | m53,m212 | 24/0.2 | 246 | |||
| 14 | 14-Nov | day | 10.0 | m225 | 7/1.30 | 162 | |
| day | 1.5 | m214 | 22/0.3 | 257 | |||
| night | 2.5 | m55,m142 | 36/0.3 | 674.5 | |||
| night | 4.0 | m59,m121 | 7/0.8 | 22.5 | |||
| 15 | 15-Nov | day | 2.5 | m143,m59,m42 | 36/0.3 | 1280.5 | |
| night | 2.5 | m49,m150 | 36/0.3 | 618.5 | |||
| night | 1.0 | m86,m11 | 32/0.2 | 388 | |||
| night | 4.0 | m1,m175 | 56/0.3 | 882 | |||
| 16 | 16-Nov | day | 0 | 0 | |||
| night | 0 | 0 | |||||
| 17 | 17-Nov | day | 0.5 | m51 | 16/0.2 | 50 | |
| day | 2.5 | m59,m121 | 36/0.3 | 778.5 | |||
| day | 4.0 | m53,m17,m168,m152 | 56/0.3 | 1763 | |||
| night | 1.5 | m50 | 22/0.3 | 242.5 | |||
| night | 4.0 | m53,m187,m132,m196,m53 | 56/0.3 | 2249.5 | |||
| night | 2.5 | m85 | 36/0.3 | 213 | |||
| 18 | 18-Nov | day | 0 | 0 | |||
| night | 4.0 | m18,m196 | 56/0.3 | 806.5 | |||
| night | 2.5 | m42 | 36/0.3 | 391.5 | |||
| 19 | 19-Nov | day | 1.5 | m149 | 22/0.3 | 57 | |
| day | 2.5 | m189 | 36/0.3 | 462 | |||
| day | 2.5 | m110,m42,m13 | 36/0.3 | 1402.5 | |||
| night | 2.5 | m114,m85,m209,m83 | 36/0.3 | 1380 | |||
| 20 | 20-Nov | day | 0.75 | m185 | 24/0.2 | 454 | |
| day | 2.5 | m121 | 36/0.3 | 78.5 | |||
| day | 6.0 | m50,m128,m149, | 84/0.3 | 1765.5 | |||
| night | 4.0 | m50,m13,m189,m167,m49,m13 | 56/0.3 | 2448 | |||
| night | 0.75 | m55 | 24/0.2 | 257 | |||
| night | 1.5 | m187,m23 | 28/0.26 | 605 | |||
| 21 | 21-Nov | day | 0.75 | m55 | 24/0.2 | 137 | |
| day | 1.5 | m110 | 28//0.25 | 271.5 | |||
| day | 4.0 | m158,m143,m12,m124,m82 | 56/0.3 | 1580 | |||
| day | 6.0 | m131 | 84/0.3 | 55 | |||
| night | 4.0 | m143,m207 | 56/0.3 | 883.5 | |||
| 22 | 22-Nov | day | 1.5 | m85,m149 | 28/0.25 | 653 | |
| day | 4.0 | m124 | 56/0.3 | 182 | |||
| day | 1.5 | m4,m110,m185 | 22/0.3 | 639 | |||
| day | 6.0 | m168 | 84/0.3 | 88 | |||
| night | 1.5 | m143,m14 | 22/0.3 | 548 | |||
| night | 1.5 | m131,m82 | 28/0.26 | 590 | |||
| night | 25.0 | m18,m58,m160,m151,m133,m5,m108 | 28/0.4 | 832 | |||
| night | 2.5 | m12 | 36/0.3 | 350.5 | |||
| 23 | 23-Nov | day | 2.5 | m128,m156 | 36/0.3 | 631 | |
| 24 | 24-Nov | day | 0.75 | m29 | 24/0.2 | 58 | |
| day | 2.5 | m33 | 36/0.3 | 417 | |||
| day | 16.0 | m207,m116,m01,m25 | 18/0.4 | 371 | |||
| night | 16.0 | m193,m12 | 126/0.4 | 633 | |||
| night | 2.5 | m13 | 36/0.3 | 78 | |||
| night | 16.0 | m147,m196,m129 | 18/0.4 | 277.5 | |||
| night | 2.5 | m26/0.3 | 36/0.3 | 477 | |||
| 25 | 25-Nov | day | 4.0 | m207,m196,m25 | 56/0.3 | 1209 | |
| night | 4.0 | m205,m59,m204,m30,m74 | 56/0.3 | 2352 | |||
| night | 2.5 | m53, | 36/0.3 | 458 | |||
| 26 | 26-Nov | day | 2.5 | m81,m30,m233,m33 | 36/0.3 | 1840 | |
| day | 4.0 | m205,m207,m5,m18,m124,m157 | 56/0.3 | 2551.5 | |||
| day | 1.5 | m201,m175 | 22/0.3 | 723 | |||
| night | 2.5 | m161,m124,m233,m25 | 36/0.3 | 1697.5 | |||
| night | 1.5 | m175,m01 | 22/0.3 | 490 | |||
| 27 | 27-Nov | day | 50.0 | m201 | 33/0.4 | 236.5 | |
| day | 2.5 | m12,m116 | 36/0.3 | 831 | |||
| day | 50.0 | m191,m40 | 99/0.4 | 608 | |||
| day | 10.0 | m95 | 7/0.13 | 114.5 | |||
| day | 1.5 | m142 | 22/0.1 | 193 | |||
| day | 35.0 | m205,m152,m62,m151 | 39/0.4 | 971 | |||
| day | 35.0 | m13 | 40/0.4 | 244.5 | |||
| night | 2.5 | m114,m45,m127,m197 | 36/0.3 | 1582 | |||
| night | 35.0 | m35,m224 | 40/0.4 | 474 | |||
| night | 70.0 | m187,m171,m14,m53,m139,m81,m209,m160,m220 | 30/0.5 | 886.5 | |||
| 28 | 28-Nov | day | 70.0 | m18 | 90/0.5 | 234.5 | |
| day | 10.0 | m207,m213,m134,m77,m181,m16 | 80/0.4 | 2414.5 | |||
| day | 2.5 | m147,m198 | 36/0.3 | 940 | |||
| day | 1.5 | m01,m45,m40 | 22/0.3 | 1157 | |||
| day | 16.0 | m233,m154,m12,m128 | 18/0.4 | 1252 | |||
| night | 16.0 | m156,m161,m124,m143 | 18/0.4 | 1280 | |||
| night | 16.0 | m28 | 126/0.4 | 766 | |||
| night | 1.5 | m224,m33 | 22/0.3 | 672.5 | |||
| 29 | 29-Nov | day | 1.5 | m193,m161 | 30/0.25 | 716 | |
| day | 1.5 | m196 | 22/0.3 | 235 | |||
| day | 16.0 | b21,b23,b25 | 126/0.4 | 1750.5 | |||
| night | 2.5 | m102,m50,m160 | 50/0.25 | 986.5 | |||
| night | 1.0 | m14 | 32/0.2 | 414 | |||
| night | 4.0 | m180 | 56/0.3 | 473.5 | |||
| 30 | 30-Nov | day | 0.5 | m143 | 16/0.2 | 206.5 | |
| day | 4.0 | m25,m33,m127 | 56/0.3 | 1091 | |||
| Total | 86415.5 | 768.5 |
Table 7 – Buncher Manual Production Entry Format
Stranding
Figure 18 – Stranding
This module will be developed in Phase II
Insulation
Insulation Manual Entry Screen
Table 8 – Insulation Manual Production Entry Format
This module will be developed in Phase II
Sheathing
Sheathing Manual Entry Screen
Table 9– SheathingManual Production Entry Format
This module will be developed in Phase II
Production Planning
This module will be developed in Phase II
Purchase Planning
This module will be developed in Phase II
Accounts Portability
This module will be developed in Phase II
Goods Traceability
As discussed in our earlier meeting, we propose to use QRCodes or Barcodes during the initial stage. Custom reports can be generated from Goods receivable to delivery to track the copper used. The application .
Coil Tracking Report
Figure 19 – Coil Tracking Report
RBD Copper production Report
Figure 20 – RBD Copper production Report
MMH Copper production Report
Figure 21– MMH Copper production Report
Buncher Copper production Report
Figure 22 – Buncher Copper production Report
Copper Ledger
Figure 23 – Copper Ledger
Copper Purchase Report
Figure 24 – Copper Purchase Report
Copper Receipt Details
Figure 25 – Copper Receipt Details
Development Methodology
We propose to break the development as two phases.
Phase I (Six Months)
- Database Design
- Good Receivable
- Store Maintenance
- Production Tracking RBD
- Production Tracking MMH1
- Production Tracking MMH2
- Production Tracking MMH3
- Production Tracking Buncher
- Goods Traceability
- Reports
- Documentation & Training
- System Pilot
- Deployment & Acceptance Training
- System Go Live and Maintenance
Phase II (Not Estimated)
- Database Design
- Production Planning
- Purchase Planning
- Accounts Portability
- Reports
- Documentation & Training
- System Pilot
- Deployment & Acceptance Training
- System Go Live and Maintenance
We can assure you that our time estimates will not vary more than 10% unless there is a vast change in the requirement
Solution Implementation
We are estimating the following major tasks in the implementation phase:
- Getting familiar with development environment
During this phase, we plan to familiarize ourselves with the development methodologies and the various calculations required for the production process, documents to be used, database design etc..
- Coding the Core module
This phase consists of coding the entire Core module using the open source technologies. We suggest using PHP, MYSQL, Apache and Linux environment.
- User Acceptance Testing
The application will be available in staging environment for three working days for entire testing.
- Bug Fixing
The bugs discovered during UAT will be fixed and the application will be retested again to ensure that the reported bugs are addressed.
- Delivery
The final product will be available for delivery.
- Possible Extensions
This application can also be possibly extended in many ways based on the future requirement.
Client Responsibilities
Company will provide inexpensivecoders with complete requirement details for the application. Assuming that the above is the finalized requirement and if clarification raises during development it is the responsibility of both the parties to discuss and freeze to change or modify on technology constraints.
Cost & Timeline
Based on the scope in this document, project costs for “Phase I application design and development for Cable Management Requirement” is as follows:
Time for completion: 6 Months from the date of award of the contract.
Considering an average of
8 hrs Per Day
27 days per month
216 hrs per month (27 days x 8 )
1296 Total hrs per resource that is fully utilized.
Structure of the project team
The project requires a team of six (5) key staff persons with professional and Regional/International expertise.
| # | Expert Title | QTY. | Qualification | Relevant Experience(Years) | Expected Time of Engagement |
| 1. | Project Manager | 1 | Bachelor in business administration, management or MIS (Masters degree preferred) | At least 7 years experience in project management and information technology. | 6 months (1296 Hrs) |
| 2. | Software Developer | 2 | Bachelor in Computer Science/IT | At least 5 years’ experience in software/database development and programming | 6 months
(2592 Hrs) |
| 3. | Quality Assurance | 1 | Bachelor in Computer Science/IT | At least 2 years experiences in Softwre Quality Assurance | 1.5 months
(324 Hrs) |
| 4. | Documentation | 1 | Bachelor in Computer Science/IT | At least 2 years experiences in Documentation | 1.5 months
(324 Hrs) |
| 5. | Implementation & Support | 1 | Bachelor in Computer Science/IT | At least 2 years experiences in Implementation & Support | 1.5 months
(324 Hrs) |
Table 10 – Project Team
| Project Phase | Resources |
| Development Initiation | |
| Project Manager | PM |
| Quality Assurance | QA |
| Software Engineer 1 | SE 1 |
| Software Engineer 2 | SE 2 |
| Architecture Design and Decomposition | |
| Project Manager | PM |
| Software Engineer 1 | SE 1 |
| Software Engineer 2 | SE 2 |
| Prototyping | |
| Project Manager | PM |
| Software Engineer 1 | SE 1 |
| Software Engineer 2 | SE 2 |
| Development Plan and Review | |
| Project Manager | PM |
| Software Engineer 1 | SE 1 |
| Software Engineer 2 | SE 2 |
| Coding, Unit Testing/ Code review and Integration | |
| Project Manager | PM |
| Quality Assurance | QA |
| Software Engineer 1 | SE 1 |
| Software Engineer 2 | SE 2 |
| System Integration and User Acceptance testing | |
| Project Manager | PM |
| Quality Assurance | QA |
| Implementation Support | IS |
| Software Engineer 1 | SE 1 |
| Software Engineer 2 | SE 2 |
| Customer Tester | CT |
| System Inventory | |
| Project Manager | PM |
| Quality Assurance | QA |
| Documentation | Doc |
| Software Engineer 1 | SE 1 |
| Software Engineer 2 | SE 2 |
| Packaging, delivery and Project Closure | |
| Project Manager | PM |
| Implementation Support | IS |
| Documentation | Doc |
| Software Engineer 1 | SE 1 |
| Software Engineer 2 | SE 2 |
Table 11– Project Phase
The total hours expected to be spent for this project is 4860 hrs (1296+2592+324+324+324).
One-time development and implementation costs at Rs.xxx /hour is INR X, XX,000 (Indian Rupees XXX lakhs and XXX Thousand Only). This cost is inclusive of statutory taxes and duties. This cost also includes onsite visit for Training, Requirement Gathering, Implementation.
The payment schedule
The payments to the contractor will be made into the following instalments:
| Installment Number | Project Phase | Payment Amt (%) |
| 1 | Advance | 30% |
| 2 | 50% Development completion | 25% |
| 3 | 100% Completion | 20% |
| 3 | System testing by technical team and end-users, installation in staging Environment. | 15% |
| 4 | Submission and Acceptance of final Report on all deliverables | 10% |
Table 12 – Payment Schedule
Contact person from client’s side
The client would designate one of its technical consultant for the contact. This person would be responsible to interact with the inexpensivecoders consultant for administrative and technical matters on day to day basis; comment / approve the deliverables submitted by the consultant within the stipulated time etc.
Incident, Change, and Release Management
A lot of pieces must fit together seamlessly within a computer system (and to other systems) to guarantee success and long-term value. This includes incident management, change management and release management.
Incident Management
During development, the team will track all incidents affecting the development. Incidents may be events that do or have the potential to interrupt or reduce service, or requests for help in processing a transaction or clarifying system functionality. Incidents may be reported to the client or other stakeholders who interact with the development team.
An electronic tracking system similar to email, slack or skype may be used to manage incidents to completion. Incidents are prioritized for resolution, and may be transitioned to Change/Release Management process if they involve a change to the development.
Change Management
System changes can affect multiple users, disrupt services, affect stored data, or involve hardware or software. To reduce risk, all change requests (CRs) are reviewed, prioritized, and tracked to completion. All change processes and workflows will be identified and severity levels will be assigned.
Release Management
Release Management (RM) is the process of planning, creating, testing, and implementing software releases. Developed application will be frequently updated to ensure that it meets the technical and business requirements.
Deployment, testing, documentation and training for the newly integrated systems
Upon successful development and integration of the required application, the contractor shall propose a deployment plan, which includes the rolling out of the new modules and data migration of the production data. It also includes black box testing, proper documentation (technical and functional) and training of related departments on how to use and extend the system.
Quality Assurance and Quality Control
In order to ensure quality of the work, the consultant will ensure to submit the following reports:
- Inception report
- Work progress report before each payment
- Final system report
Project Deliverables
This project encompasses the following major deliverables for Phase I:
- Database Design
- Development of modules that includes Coremodule and Reporting module
- Testing and Deployment
- Documentation and training of the new system
| Activity | M1 | M2 | M3 | M4 | M5 | M6 |
| Database Design | â— | |||||
| Good Receivable | â— | |||||
| Store Maintenance | â— | |||||
| Production Tracking RBD | â— | |||||
| Production Tracking MMH1 | â— | |||||
| Production Tracking MMH2 | â— | |||||
| Production Tracking MMH3 | â— | |||||
| Production Tracking Buncher | â— | |||||
| Goods Traceability | â— | |||||
| Reports | â— | |||||
| Documentation & Training | â— | |||||
| System Pilot | â— | |||||
| Deployment & Acceptance Training | â— | |||||
| System Go Live and Maintenance | â— |
Table 13 – Project Deliverables
Timeframe for Expected Deliverables
The project is expected to be completed over a period of 6 months starting from project kick off date. The indicative timelines for these activities, in number of months, is as shown in the table below. It is very important that project is completed within the proposed time in order to meet the deadline.
Terms & Conditions
- The proposal shall remain valid for acceptance for a period of 30 days from the date of submission
- inexpensivecoders shall start the project within 7 days of receiving the confirmed order
- The required information for project completion on time shall be provided by the company
- The project shall be developed and executed on an offshore model.
- All costs associated with any additional on-site visit required during implementation like Return airfare, accommodation, local travel and food for our consultants will be by the company
- Master Data in pre-defined and agreed format shall be made available as per requirement
- Additional work required beyond the scope will be charged additionally
- Service Tax and all other taxes applicable at the time of billing would be extra at actuals
Force Majeure and Time Delays: inexpensivecoders shall not be liable for any non-performance of this assignment provided such non-performance is occasioned by fire, flood, power failure / UPS breakdown, riots, lockouts, civil disobedience, act of God like floods, cyclone etc. and equipment failure/breakdown. (Unless arising out of improper / erroneous handling of equipment / software by our personnel).
Training
The training will be provided on a two-tier approach with the sole objective of enabling the users with thorough hands on usage of the new software.
- Admin Level training for identified “super users” and
- User Level training for key users
- “Train the Trainer approach” will be deployed to enable the company to conduct further internal trainings.
Exit Methodology
In a bid to thorough hand holding and independent usage of the system, the below given items shall be show caused during the exit
-
- Knowledge Transfer (KT) of the software
- User Documentation for the software
- Source Codes
- Database Scripts
- Help customer to identify and mitigate the risks.