Saraswati plasto DPR August
-
Upload
pathakplastic -
Category
Documents
-
view
230 -
download
0
Transcript of Saraswati plasto DPR August
-
8/22/2019 Saraswati plasto DPR August
1/205
M/c No. Product Name
Order
Quantity
(In pcs)
Total Qty.
Produced
pcs
Balanced
need to
produced
(pcs)
cycle
Time
(Sec)
EBM-1 250ml round bottle TSL yellow 24500 25200 -700 24
EBM-2 1 ltr cobra Bottle Mono 220970 170810 50160 29
EBM-3 50ml FAME bottle 14660 -14660 19
100ml Fame Bottle 14548 -14548 19
250ml Confidor Super Bottle 960 -960 24
EBM-4 3 ltr Jery Can 5000 4680 320 45
EBM-5 1 ltr Triangular Bottle Blue 35000 34008 992 31
EBM-6 1 ltr Anupam coex Bottle 234000 35634 198366 30
ASB1 120ml round PET bottle 300000 220220 79780 12.6
ASB-3 1 ltr Magister Bottle 60000 17700 42300 26.2
IM-1 RD 15 juniar Base 350000 31500 318500 24
IM-2 50mm KR logo white cap 20000 13000 7000 27.2
50mm KR logo blue cap 30000 16000 14000 27.2
IM-3 30ml Raft Measuring cup 90000 100000 -10000 19
30ml Flat measuring cup 50000 42500 7500 19
IM-4 10ml corogon cap pearl white 1000000 138000 862000 24
IM-5 46mm Plain cap 50000 43000 7000 19
25ml Plain measuring cup 100000 12000 88000 19
IM-6 53mm cobra cap 700000 590400 109600 30
IM-7 RD jr Lid 500000 174400 325600 16
IM-8
m easur ng cup w
logo 100000 140000 -40000 16.5
IM-9 53mm Anupam starp 200000 90000 110000 19
IM-11
m corogon easur ng cup
TP violet 1000000 211500 788500 17
IM-12
m easur ng cup w
logo 200000 295700 -95700 19.5
IM-12 53mm Anupam Cap 200000 102000 98000 27
Date: 29/7/2013
-
8/22/2019 Saraswati plasto DPR August
2/205
Wadding M/c-1 28mm confidor cap
Wadding M/c-2 50mm KR logo blue cap
50mm Green Planet Cap
53mm cobra cap
Wadding M/c-3 53mm Anupam cap
Wadding m/c-5 10ml corogon cap
Wadding M/c -6 94mm Anupam cap
Wadding m/c no.7 46mm Plain cap
manual assembly threded plug
53mm anupam cap packing
53mm Anupam cap assembly
50mm Pursuite cap assembly
94mm Anupam Cap assembly
RD jr Lid & Base Assembly
Sr. No. Raw Material Name Grade Qty Kg
HDPE B52A003OtherItems
HDPE B56003
polybag
45*45
HDPE E5201S 7000
shipper
555
MB TSL Yellow 9682 25 Ovensack
MB Blue 29443 25 325 shiper
HDPE 50ma180 200
510
shippers
PP 3530 1500 10 x 1 ltr
ASPET 21c 1150
465
shipper 3
ply
PP H110MA 625
shipper
600 x 430
ASPET 20C 1150
40 x
250ml
PP srm100nc 1075 20 x 500
TotalRaw Material Reconcilation :
-
8/22/2019 Saraswati plasto DPR August
3/205
PA 200
Admer 100
-
8/22/2019 Saraswati plasto DPR August
4/205
weight
(Grams)
No. of
Cavity Grade Color Target
Actual
Production in
Pcs
Producti
on In
Kgs
Opening
RM
Balance
RM
issue
details
37 8 B52A003 tsl yellow 19200 16380 606 63 1150
110 8 B52A003 Natural 23834 18570 2043 32 2500
16 4 B52A003 golden 6063 3572 57
21 4 B52A003 golden 6063 3460 73
42 4 B52A003 white 2400 960 40 165 500
250 2 B52A003 white 1920 1080 270 28 500
110 4 B52A003 blue 11148 6318 695 155 700
100 8 B52A003 tsl yellow 23040 18474 1847 266 2000
13.25 5 20C amber 8571 8008 106 35 1150
65.5 6 ASPET Blue 19786 17700 1159 45 1150
9.6 6 H110MA white 17280 15750 151.2 14 150
10.5 8 MI3530 white 3176 3000 31.5
10.5 8 MI3530 blue 21176 16000 168.0 18 200
7 14 C blue 7958 7500 52.5
7 14 C blue 55705 42500 297.5 15 350
2.56 32 H110MA pearl white 115200 78000 199.7 9 300
8 8 MI3530 white 4547 2800 22.4
3.5 8 MI3530 Natural 13642 12000 42.0 43 200
13.5 16 MI3530 c blue 46080 30600 413.1 10 550
6.66
H110MA blue32400 24000 158.4 9 275
3.6 15 C Natural 78545 56000 201.6 1 275
3.8 8 50mA180 white 36379 20000 76.0 14 100
2 32 C tp violet 162635 141000 282.0 19 300
6.5 8 C trans 35446 30000 195.0 11 300
19 8 MI3530 yellow 25600 18000 342.0 0 400
Daily Production Report bottling pla
-
8/22/2019 Saraswati plasto DPR August
5/205
white 30000
blue 6000
white 18000
white 8100
yellow 10800
Violet 48000
yellow 10000
white 19600
12000
2924
3000
3570
1344
7000
777798 772010 9530 952 13050
Qty
Wad
Receivedin Pcs size QTY issued
100 bayer logo 46.4 20000
600 bayer logo 29.6
2 roll
mayer
plain 46.4 22100
200 dupont 19.2
wad 43.4
500 DX excel 46.4 20000
400
mayer
plain 34.5
20 board 46.4
dupont 19.2 110000
rallis 46.4
% of Wastage
% of wastage whichcan not used
-
8/22/2019 Saraswati plasto DPR August
6/205
-
8/22/2019 Saraswati plasto DPR August
7/205
Total
closing
balance
Regrind
generate
d kg
Regrind
/
reproces
s used
Lumps
(Kg)
Plan
Hour
Mold
change
& Other
BD time
Efficean
cy
1213 601 8.51 8.5 6 16 8 85%
2532 486 20.9 20.9 3.7 24 78%
0 5.44 5.4 8 59%
0 6.3 6.3 8 57%
665 485 37.38 37.4 9.6 4 12 40%
528 253 31.25 31.3 5 12 56%
855 153 25.3 25.3 7.5 24 57%
2266 411 45 45.0 8 24 80%
1185 1078 3.0475 3.0 1 6 93%
1195 36 7.86 7.9 24 89%
164 13 5.376 5.4 16 8 91%
0 2.1 2.1 3 94%
218 13 1.26 1.3 6 20 76%
0 1.61 1.6 3 94%
365 12 2.1 2.1 3 21 76%
309 109 0.8704 0.9 24 68%
0 1.92 1.9 3 62%
243 178 1.575 1.6 9 12 88%
560 147 3.3075 3.3 24 66%
284 126 1.32 1.3 24 74%276 74 2.412 2.4 24 71%
114 38 0.532 0.5 24 55%
319 37 0.48 0.5 24 87%
311 116 1.625 1.6 24 85%
400 58 3.8 3.8 24 70%
t
-
8/22/2019 Saraswati plasto DPR August
8/205
14002 4422 221 221 50
2.8
0.52
-
8/22/2019 Saraswati plasto DPR August
9/205
-
8/22/2019 Saraswati plasto DPR August
10/205
Mold change/Break down
ay s . rs ue o ower s u own, n n g3AM Mold offloaded for Logo insert changeover.
Day shift 4.00 Hrs BD due to Power shutdown,
Day shift 4.00 Hrs BD due to Power shutdown,
Day shift 4.00 Hrs BD due to Power shutdown,
Mold change & color cleaning & production starteday s . rs ue o ower s u own, + c
stopped in Night shiftay s m c s oppe . an s ar e rom .
PM due to cable work 8 hrs BD
M/c stopped due to no space to Keep Finish Goods
color changeover to Bluee ec or cy n er o ro en, rep ace mo oa e m c
started
Cavity insert change
Day shift 4.00 Hrs BD due to Power shutdown,
2 cavity blocked
Day shift 4.00 Hrs BD due to Power shutdown,ay s m c s oppe . an s ar e rom .
PM due to cable work 8 hrs BDay s m c s oppe . an s ar e rom .
PM due to cable work 8 hrs BD
Mold change & startup
Day shift 4.00 Hrs BD due to Power shutdown,
Day shift 4.00 Hrs BD due to Power shutdown,cav y no o so was oc e + ay s . rs
due to Power shutdown,
4 cavity running only
Hot tip cleaning
2 cavity block c# 1, 6
-
8/22/2019 Saraswati plasto DPR August
11/205
-
8/22/2019 Saraswati plasto DPR August
12/205
M/c No. Product Name
Order
Quantity
(In pcs)
Total Qty.
Produced
pcs
Balanced
need to
produced
(pcs)
cycle
Time
(Sec)
EBM-1
250ml Round Natural Bottle
(AB Chem) 10000 10590 -590 24
250ml round Coex PA bottle
white 12000 9000 3000 24
EBM-2 1 ltr cobra Bottle Mono 220970 194390 26580 29
EBM-3 250ml Confidor Super Bottle 75000 11520 63480 24
100ml Confidor super bottle 70000 8820 61180 24
EBM-4 5 Ltr BASF can 15000 1105 13895 45
EBM-5 1 ltr Triangular Bottle Blue 35000 37050 -2050 40
1 ltr Square Bottle pearl
white 12000 280 11720 38
EBM-6 1 ltr Anupam coex Bottle 234000 37788 196212 30
100ml Cobra Bottle Mono 500000 16632 483368 17
IBM-1 10/30ml Corogon Bottle 500000 0 500000 15
ASB-3 1 ltr Magister Bottle 60000 34800 25200 26.2
IM-1 RD 15 juniar Base 350000 49000 301000 24
IM-2 50mm KR logo blue cap 30000 41000 -11000 27.2
IM-3 30ml Flat measuring cup 50000 55000 -5000 19
50mm Pursuite ring 35000 12000 23000 20
IM-4 10ml corogon cap pearl white 1000000 252000 748000 22
IM-5 25ml Plain measuring cup 100000 66000 34000 12.5
IM-6 53mm cobra cap 700000 629100 70900 30
IM-7 RD jr Lid 500000 204150 295850 16
IM-8
logo 100000 170000 -70000 16.5
50mm BASf cap 25000 3250 21750 20
IM-9 53mm Anupam starp 200000 112000 88000 19
IM-11
cup TP violet 1000000 338400 661600 17
Date: 30/7/2013
-
8/22/2019 Saraswati plasto DPR August
13/205
IM-12
logo 200000 304700 -104700 19.5
Red (SAC Derabasi) 60000 15000 45000 19.5
IM-12 53mm Anupam Cap 200000 120600 79400 26
Wadding M/c-1 28mm confidor cap
28mm folicure cap
Wadding M/c-2 50mm KR logo blue cap
50mm Pursuite cap
53mm cobra cap
Wadding M/c-3 53mm Anupam cap
Wadding m/c-5 10ml corogon cap
Wadding m/c no.7 46mm Plain cap
manual assembly threded plug
53mm anupam cap packing
assembly
50mm Blue cap assembly
RD jr Lid & Base Assembly
Sr. No. Raw Material Name Grade Qty Kg
HDPE B52A003
Other
Items
HDPE B56003
polybag
45*45
HDPE E5201S 7000
shipper
555
MB WHITE 10055 25
shipper
465
MB TSL Yellow 9682 25 Ovensack
MB Blue 29443 25 325 shiper
HDPE 50ma180 100
510
shippers
PP 3530 750 10 x 1 ltr
ASPET 21c 1150
465
shipper 3
ply
Total
Raw Material Reconcilation :
-
8/22/2019 Saraswati plasto DPR August
14/205
PP H110MA 500
shipper
600 x 430
ASPET 20C
40 x
250ml
PP srm100nc 1000 20 x 500
green 13965
silver grey 88901
c blue 80505 25
-
8/22/2019 Saraswati plasto DPR August
15/205
weight
(Grams)
No. of
Cavity Grade Color Target
Actual
Production in
Pcs
Production In
Kgs
Opening
RM
Balance
40 8 B52A003 Natural 12000 10590 424
40 8 B52A003 white 12000 9000 360 601
110 8 B52A003 Natural 23834 23580 2594 486
42 4 B52A003 white 14400 10560 444
23 4 B52A003 white 14400 8820 203 485
300 2 B52A003 tsl yellow 1920 1105 332 253
110 4 B52A003 blue 3600 3042 335
100 2 B52A003
Pearl
white 568 280 28 153
100 8 B52A003 tsl yellow 2880 2154 215
21 8 B52A003 Natural 20329 16632 349 411
8 14 B52A003 pearl white 0 0
65.5 6 ASPET Blue 19786 17100 1120 36
9.6 6 H110MA white 21600 17500 168.0 13
10.5 8 MI3530 blue 25412 25000 262.5 13
7 14 SRM100NC blue 13263 12500 87.5
1.8 8 SRM100NC Natural 15840 12000 21.6 12
2.56 32 H110MA pearl white 125673 114000 291.8 109
3.5 8 MI3530 Natural 55296 54000 189.0 178
13.5 16 MI3530 c blue 46080 38700 522.5 147
6.6 6 H110MA blue 32400 29750 196.4 126
3.6 15 SRM100NC Natural 32727 30000 108.0
12.5 4 MI3530 yellow 4320 3250 40.6 74
3.8 8 50mA180 white 36379 22000 83.6 38
2 32 SRM100NC tp violet 162635 126900 253.8 37
Daily Production Report bottling
-
8/22/2019 Saraswati plasto DPR August
16/205
6.5 8 SRM100NC trans 10338 9000 58.5
6.5 8 SRM100NC red 16246 15000 97.5 116
19 8 MI3530 yellow 26585 18600 353.4 58
white 40000
green 5000
blue 9000
yellow 5950
white 52200
yellow 23400
Violet 54000
white 33600
5831
4200
9100
12250
750513 885594 9137 3344
Qty
a
Received
in Pcs size QTY issued
bayer logo 46.4 40000
220 bayer logo 29.6
plain 19.8
mayerplain 46.4 22100
150 dupont 19.2
wad 43.4
1000 DX excel 46.4
200
mayer
plain 34.5
% of wastage
not used
% of Wastage
-
8/22/2019 Saraswati plasto DPR August
17/205
board 46.4
dupont 19.2 110000
rallis 46.4
bayer logo 26.4 63000
bayer logo 19.8 110000
-
8/22/2019 Saraswati plasto DPR August
18/205
RM
issue
details Total
closing
balance
Regrind
generate
d kg
Regrind
/
reproces
s used
Lumps
(Kg)
Plan
Hour
Mold
change
& Other
BD time Efficeancy
0 0 22.4 22.4 10 88%
1575 2176 1379 29.2 29.2 13 10 4 75%
3000 3486 890 19.8 19.8 2 24 99%
0 0 15.96 16.0 7 24 73%
700 1185 532 48.3 48.3 24 61%
400 653 305 90 90.0 17 12 12 58%
0 30.8 30.8 7 10 85%
700 853 478 18 18.0 5 3 11 49%
0 37.9 37.9 6 3 75%
700 1111 534 16.38 16.4 6 12 9 82%
0 0 0.0 0 #DIV/0!
1150 1186 65 19.65 19.7 1 24 86%
175 188 20 2.304 2.3 24 81%
250 263 0 3.57 3.6 24 98%
0 1.4 1.4 5 94%
125 137 25 1.008 1.0 3 11 8 76%
200 309 17 0.8704 0.9 24 91%
50 228 39 0.805 0.8 24 98%
500 647 124 3.375 3.4 24 84%
150 276 79 1.32 1.3 24 92%
0 0.504 0.5 10 92%
100 174 23 2.5 2.5 3 6 8 75%
50 88 4 0.532 0.5 24 60%
250 287 33 1.12 1.1 24 78%
plant
-
8/22/2019 Saraswati plasto DPR August
19/205
0 1.56 1.6 7 87%
75 191 33 2.34 2.3 2 11 6 92%
450 508 155 4.75 4.8 24 70%
10600 13944 4735 376 376 72
which can
0.79
4.9
-
8/22/2019 Saraswati plasto DPR August
20/205
-
8/22/2019 Saraswati plasto DPR August
21/205
Mold change/Break down
Material Logo insert change & Production startup in night
shift
1 cavity Not coming OK due to Moog problem
Mold change & PDN startup
Mold change & color cleaning of barrel & startup
Mold change & Production startup & color cleaning
Mold change + 1 cavity having mjor flash
1 cavity not ok so it was blocked
Mold change & PDN startup
4 cavity running only
-
8/22/2019 Saraswati plasto DPR August
22/205
Cavity Plate offloaded & insert change & M/c startup
2 cavity block c# 1, 6
m/c bearing broken
-
8/22/2019 Saraswati plasto DPR August
23/205
M/c No. Product Name
Order
Quantity
(In pcs)
Total Qty.
Produced
pcs
Balanced
need to
produced
(pcs)
EBM-1 500ml Coex Bottle Natural 20000 17024 2976
EBM-2 1 ltr cobra Bottle Mono 220970 216930 4040
EBM-3 250ml Confidor Super Bottle 75000 23280 51720
100ml Confidor super bottle 70000 18900 51100
EBM-4 5 Ltr BASF can 15000 3681 11319
EBM-5 1 ltr Square Bottle pearl white 12000 4798 7202
EBM-6 100ml Cobra Bottle Mono 500000 56438 443562
ASB-3 1 ltr Magister Bottle 60000 39960 20040
500ml PET Bottle 30000 9360 20640
IM-1 RD 15 juniar Base 350000 65000 285000
IM-2 50mm KR logo blue cap 30000 42000 -12000
50mm Suzumida cap 30000 17000 13000
IM-3 50mm Pursuite ring 35000 33000 2000
IM-4 10ml corogon cap pearl white 1000000 366000 634000
IM-5 25ml Plain measuring cup 100000 123000 -23000
IM-6 53mm cobra cap 700000 652500 47500
53mm obran cap 50000 21600 28400
IM-7 RD jr Lid 500000 232150 267850
IM-8 50mm BASf cap 25000 16900 8100
IM-9 53mm Anupam starp 200000 134000 66000
IM-11
10ml corogon Measuring cup TP
violet 1000000 488800 511200
Date: 31/7/2013
-
8/22/2019 Saraswati plasto DPR August
24/205
IM-12
50ml Plain measuring cup Red
(SAC Derabasi) 60000 48000 12000
IM-12 53mm Anupam Cap 200000 139200 60800
Wadding M/c-1 28mm confidor cap
Wadding M/c-2 50mm plain cap white
50mm Pursuite cap
50mm KR logo blue cap
53mm cobra cap
Wadding M/c-3 53mm Anupam cap
38mm cobra cap white
Wadding m/c-5 10ml corogon cap
Wadding M/c -6 94mm Anupam cap
Wadding m/c no.7 46mm Plain cap
manual assembly threded plug
53mm anupam cap packing
53mm Anupam cap assembly
50mm Pursuite cap assembly
94mm Anupam cap
22mm Fame cap
RD jr Lid & Base Assembly
Sr. No. Raw Material Name Grade Qty Kg
HDPE B52A003
HDPE B56003
HDPE E5201S 6000
TotalRaw Material Reconcilation :
-
8/22/2019 Saraswati plasto DPR August
25/205
MB WHITE 10055 25
MB TSL Yellow 9682 25
MB Blue 29443
HDPE 50ma180 100
PP 3530 1000
PP H110MA 750
ASPET 20C 1150
PP srm100nc 1000
pearl white 20051 25
yellow 12184 25
o blue 14275 25
PA 150
Admer 50
-
8/22/2019 Saraswati plasto DPR August
26/205
cycle
Time
(Sec)
weight
(Grams)
No. of
Cavity Grade Color Target
Actual
Production in
Pcs
Production
In Kgs
24 65 8 B52A003 Natural 19200 17024 1107
30 110 8 B52A003 Natural 23040 22540 2479
24 42 4 B52A003 white 14400 11760 494
24 23 4 B52A003 white 14400 10080 232
45 300 2 B52A003 tsl yellow 3840 2576 773
34 100 2 B52A003
Pearl
white 5082 4518 452
17 21 8 B52A003 Natural 40659 39806 836
26.2 65.5 6 ASPET D blue 5771 5160 338
23 46.2 6 ASPET D Blue 10330 9360 432
24 9.6 6 H110MA white 21600 16000 153.6
27.2 10.5 8 MI3530 blue 1059 1000 10.5
27.2 10.5 8 MI3530 white 18000 17000 178.5
19 1.8 8
SRM100N
C Natural 36379 21000 37.8
22 2.56 32 H110MA pearl white 125673 114000 291.8
12 3.5 8 MI3530 Natural 57600 57000 199.5
29.5 13.5 16 MI3530 c blue 23431 23400 315.9
29.5 13.5 16 MI3530 obran 23431 21600 291.6
14 6.6 6 H110MA blue 37029 28000 184.8
24.8 12.5 4 MI3530 yellow 13935 13650 170.6
16 3.8 8 50mA180 white 43200 22000 83.6
17.5 2 32
SRM100N
C tp violet 157989 150400 300.8
Daily Production Report bo
-
8/22/2019 Saraswati plasto DPR August
27/205
19.5 6.5 8
SRM100N
C red 35446 33000 214.5
27.8 19 8 MI3530 yellow 24863 18600 353.4
blue 45000
white 14000
yellow 6500
blue 4000
white 17100
yellow 18000
4000
Violet 18000
yellow 7500
white 4200
27000
2210
2210
8941
5600
18430
22750
756356 884915 9930
Other
Items Qty
Wad
Received
in Pcs size QTY issued
polybag
45*45 75 bayer logo 46.4 40000
shipper
555 bayer logo 29.6
-
8/22/2019 Saraswati plasto DPR August
28/205
shipper
465 300 plain 19.8
Ovensack 2 roll
mayer
plain 46.4 44200
325 shiper 150 dupont 19.2
50 x
100ml 500 wad 43.4 21300
10 x 1 ltr 2000 DX excel 46.4
shipper
600 x 430 board 46.4
40 x
250ml dupont 19.2 90500
20 x 500 rallis 46.4
-
8/22/2019 Saraswati plasto DPR August
29/205
Opening
RM
Balance
RM
issue
details Total
closing
balance
Regrind
generate
d kg
Regrind
/
reproces
s used
Lumps
(Kg)
Plan
Hour
Mold
change
& Other
BD time
1379 1000 2379 1259 80.6 80.6 13.5 16 8
890 2400 3290 808 5.5 5.5 2.6 24
0 0 0 9.24 9.2 4.9 24
532 700 1232 497 50.14 50.1 4 24
305 700 1005 212 66 66.0 20 24
478 650 1128 669 19.5 19.5 7 24
534 800 1334 493 7.35 7.4 4.9 24
0 19.65 19.7 7
65 1150 1215 442 11.55 11.6 3 11 6
20 150 170 16 2.88 2.9 24
0 0 3.57 3.6 1
0 200 200 6 2.1 2.1 5 17 6
25 50 75 37 1.404 1.4 24
17 300 317 26 1.152 1.2 24
39 200 239 40 0.42 0.4 24
0 4.59 4.6 12
124 600 724 110 2.16 2.2 7 12
79 200 279 94 1.782 1.8 24
23 200 223 52 1.5 1.5 24
4 100 104 21 0.532 0.5 24
33 300 333 32 1.12 1.1 24
tling plant
-
8/22/2019 Saraswati plasto DPR August
30/205
33 200 233 19 2.34 2.3 24
155 425 580 226 4.75 4.8 24
4735 10325 15060 5059 300 300 72
% of Wastage 3.7
% of wastage which
can not used 0.72
-
8/22/2019 Saraswati plasto DPR August
31/205
-
8/22/2019 Saraswati plasto DPR August
32/205
Efficeancy Mold change/Break down
89% Mold change & Production startup & color cleaning
98%
82% M/c stopped for 1 hrs for loader connection
70% 1 cavity Not coming OK due to Moog problem
67% Frequent stopage of m/c
89%
98%
89%
91%Mold change & PDN startup + Night shift Chiller flange
open corrected & started
74%
94%
94% Cavity insert change & Barrel color cleaning & startup
58% 1 cavity having mjor flash
91%
99%
100%
92% color change
76%
98% Mold change & PDN startup
51% 4 cavity running only
95%
-
8/22/2019 Saraswati plasto DPR August
33/205
93% Cavity Plate offloaded & insert change & M/c startup
75% 2 cavity block c# 1, 6
-
8/22/2019 Saraswati plasto DPR August
34/205
M/c No. Product Name
Order
Quantity
(In pcs)
Total Qty.
Produced
pcs
Balanced
need to
produced
(pcs)
cycle
Time
(Sec)
weight
(Grams)
EBM-1
500ml Coex Bottle
Natural 20000 18240 1760 24 65
1 ltr Round Coex Bottle 20000 7254 12746 32 115
EBM-2 1 ltr cobra Bottle Mono 220970 237700 -16730 30 110
EBM-3
250ml Confidor Super
Bottle 75000 36000 39000 24 42
100ml Confidor super
bottle 70000 28980 41020 24 23
EBM-4 5 Ltr BASF can 15000 6962 8038 45 305
EBM-5
1 ltr Square Bottle
pearl white 12000 9790 2210 34 100
EBM-6
100ml Cobra Bottle
Mono 500000 102438 397562 15 21
ASB-3 500ml PET Bottle 30000 29160 840 23 46.2
IM-1 RD 15 juniar Base 350000 84250 265750 24 9.6
IM-2 50mm Suzumida cap 30000 39000 -9000 27.2 10.5
IM-3 50mm Pursuite ring 35000 37250 -2250 19 1.8
10ml Camel Cap 100000 -100000 18 1.5
IM-4 10ml corogon cap pearl 1000000 466000 534000 22 2.56
IM-5 25ml Plain measuring c 100000 129000 -29000 12 3.5
IM-6 53mm obran cap 50000 65700 -15700 29.5 13.5
IM-7 RD jr Lid 500000 244400 255600 14 6.6
32ml Confidor super
Measuring cup 25000 7500 17500 14 4.2
IM-8 50mm BASf cap 25000 29900 -4900 24.8 12.5
IM-9 53mm Anupam starp 200000 152000 48000 16 3.8
Date: 1/8/2013
-
8/22/2019 Saraswati plasto DPR August
35/205
IM-11
Measuring cup TP
violet 1000000 611000 389000 17.5 2
IM-12
cup Red (SAC
Derabasi) 60000 76000 -16000 19.5 6.5
50ml Plain Measuring
cup 60000 6000 54000 19.5 6.5
IM-12 53mm Anupam Cap 200000 157200 42800 27.8 19
Wadding M/c-1 28mm confidor cap
Wadding M/c-2 50mm plain cap white
50mm Pursuite cap
50mm KR logo blue cap
53mm cobra cap
Wadding M/c-3 38mm cobra cap white
Wadding M/c-4 10ml camel cap
Wadding m/c-5 10ml corogon cap
Wadding M/c -6 94mm Anupam cap
manual
assembly threded plug
53mm anupam cappacking
53mm Anupam cap
assembly
50mm Pursuite cap
assembly
RD jr Lid & Base
Assembly
Sr. No. Raw Material Name Grade Qty Kg
HDPE B52A003
Other
Items Qty
HDPE B56003
polybag
45*45 100
HDPE E5201S 6000
shipper
555
TotalRaw Material Reconcilation :
-
8/22/2019 Saraswati plasto DPR August
36/205
MB WHITE 10055 25
shipper
465
pearl white t1
Shipper
510 200
MB TSL Yellow 9682 Ovensack
MB Blue 29443 325 shiper
HDPE 50ma180
50 x
100ml 500
PP 3530 625 10 x 1 ltr 1000
ASPET 21c
465
shipper 3
ply 150
PP H110MA 600
shipper
600 x 430
ASPET 20C 1150
40 x
250ml
PP srm100nc 500 20 x 500
green 13965
silver grey 88901
PA 75
Admer 50
red 6213 25
-
8/22/2019 Saraswati plasto DPR August
37/205
No. of
Cavity Grade Color Target
Actual
Production
in Pcs
Production
In Kgs
Opening
RM
Balance
RM
issue
details Total
8 B52A003 Natural 2400 1216 79
8 B52A003 white 12600 7254 834 1259 350 1609
8 B52A003 Natural 23040 20770 2285 808 2500 3308
4 B52A003 white 14400 12720 534 0 0
4 B52A003 white 14400 10080 232 497 800 1297
2 B52A003 tsl yellow 3840 3281 1001 212 1000 1212
2 B52A003
Pearl
white 5082 4992 499 669 500 1169
8 B52A003 Natural 46080 46000 966 493 1000 1493
6 ASPET D Blue 22539 19800 915 442 1150 1592
6 H110MA white 21600 19250 184.8 16 175 191
8 MI3530 white 25412 22000 231.0 6 225 231
8
SRM100N
C Natural 4547 4250 7.7 0 0
32 H110MA red 108800 100000 150.0 37 150 187
32 H110MA pearl white 125673 100000 256.0 26 250 276
8 MI3530 Natural 7200 6000 21.0 40 0 40
16 MI3530 obran 46861 44100 595.4 110 500 610
6 H110MA blue 15429 12250 80.9 0 0
6
SRM100N
C blue 9257 7500 31.5 94 25 119
4 MI3530 yellow 13935 13000 162.5 52 125 177
8 50mA180 white 43200 18000 68.4 21 50 71
Daily Production Report bottling plant
-
8/22/2019 Saraswati plasto DPR August
38/205
32
SRM100N
C tp violet 157989 122200 244.4 32 225 257
8
SRM100N
C red 28062 28000 182.0 0 0
8
SRM100N
C red 7385 6000 39.0 19 25 44
8 MI3530 yellow 24863 18000 342.0 226 0 226
blue 45000
white 17000
yellow 9750
blue 11000
ob blue 9900
46000
Po red 70000
Violet 12000
yellow 11500
24000
2261
2261
7497
15750
784594 930582 9941 5059 9050 14109
a
Received
in Pcs size QTY issued
bayer logo 46.4
bayer logo 29.6
% of Wastage
% of wastage which
can not used
-
8/22/2019 Saraswati plasto DPR August
39/205
plain 19.8
46.4
mayer
plain 46.4
dupont 19.2
wad 43.4
DX excel 46.4
mayer
plain 34.5
board 46.4
dupont 19.2
rallis 46.4
bayer logo 26.4 126000
bayer logo 29.6 100000
-
8/22/2019 Saraswati plasto DPR August
40/205
closing
balance
Regrind
generated
kg
Regrind /
reprocess
used
Lumps
(Kg)
Plan
Hour
Mold
change
& Other
BD time Efficeancy
36.4 36.4 2 51%
684 126.5 126.5 11.8 14 8 58%
1019 26.4 26.4 4.5 24 90%
0 16.38 16.4 6.5 24 88%
522 25.3 25.3 3 24 70%
196 38.735 38.7 14.5 24 85%
667 34 34.0 2.6 24 98%
525 4.62 4.6 2.5 24 100%
673 15.246 15.2 4 24 88%
6 2.112 2.1 24 89%
0 1.365 1.4 24 87%
0 0.612 0.6 3 93%
24 0.66 0.7 5.7 17 4 92%
20 0.8448 0.8 24 80%
19 0.42 0.4 3 83%
15 3.105 3.1 24 94%
0 1.32 1.3 10 79%
0 1.428 1.4 6.8 6 8 81%
15 2.75 2.8 24 93%
2 0.532 0.5 24 42%
-
8/22/2019 Saraswati plasto DPR August
41/205
13 0.6 0.6 24 77%
0 1.56 1.6 19 100%
0 1.95 182.0 3 5 81%
0 3.99 120.0 24 72%
4399 347 643 65
4.1
0.65
-
8/22/2019 Saraswati plasto DPR August
42/205
-
8/22/2019 Saraswati plasto DPR August
43/205
Mold change/Break down
mold change & PDN startup + left side blow
pin get bend in night shift 4 hrs BD
M/c stopped for 1 hrs for loader connection
1 cavity Not coming OK due to Moog problem
Cavity insert change & Barrel color cleaning &
startup
1 cavity having major flash
mold change & PDN startup
M/c stopped
Mold change & PDn started
4 cavity running only
-
8/22/2019 Saraswati plasto DPR August
44/205
Frequent cavity blockage
color change
2 cavity block c# 1, 6
m/c bearing broken
-
8/22/2019 Saraswati plasto DPR August
45/205
M/c No. Product Name
Order
Quantity
(In pcs)
Total
Qty.
Produce
d pcs
Balance
d need
to
produce
d (pcs)
cycle
Time
(Sec)
weight
(Grams)
EBM-1 1 ltr Round Coex Bottle 20000 20982 -982 32 115
250ml Cobra Bottle Monolayer 200000 560 199440 24 37
EBM-2 1 ltr cobra Bottle Mono 220970 240240 -19270 30 110
500ml Cobra Bottle 200000 19980 180020 24 57
EBM-3 250ml Confidor Super Bottle 75000 48960 26040 24 42
100ml Confidor super bottle 70000 39690 30310 24 23
EBM-4 5 Ltr BASF can 15000 10362 4638 45 305
EBM-5 1 ltr Square Bottle pearl white 12000 15484 -3484 30 100
EBM-6 100ml Cobra Bottle Mono 500000 147762 352238 15 21
ASB-3 500ml PET opaqe green bottle 30000 15600 14400 23.5 46.2
IM-1 RD 15 juniar Base 350000 105250 244750 24 9.6
IM-2 50mm Suzumida cap 30000 60000 -30000 27.2 10.5
IM-3 10ml Camel Cap 300000 250000 50000 16 1.5
IM-4 10ml corogon cap pearl white 1000000 576000 424000 22 2.56
IM-5 25ml Plain measuring cup 100000 0 100000 12 3.5
IM-6 53mm obran cap 50000 111600 -61600 29.5 13.5
IM-7
Measuring cup 25000 32500 -7500 18 4.2
IM-8 50mm BASf cap 25000 42250 -17250 24.8 12.5
IM-9 53mm Anupam starp 200000 0 200000 16 3.8
IM-11
TP violet 1000000 690900 309100 17.5 2
IM-12 50ml Plain Measuring cup 60000 76500 -16500 19.5 6.5
IM-12 53mm Anupam Cap 200000 160800 39200 27.8 19
Wadding M/c-1 28mm confidor cap
Wadding M/c-2 50mm plain cap white
53mm cobra cap
Wadding M/c-3 38mm cobra cap white
Date: 2/8/2013
-
8/22/2019 Saraswati plasto DPR August
46/205
Wadding M/c-4 10ml camel cap
Wadding m/c-5 10ml corogon cap
Wadding m/c no.7 46mm plain cap
37mm white cap
manual assembly threded plug
53mm anupam cap packing
53mm Anupam cap assembly
50mm Pursuite cap assembly
Almix cap wadding
RD jr Lid & Base Assembly
Sr. No. Raw Material Name Grade Qty Kg
HDPE B52A003 6250
Other
Items Qty
HDPE B56003
polybag
45*45 75
MB WHITE 10055 100
shipper
465
orange 9.18E+08
shipper
590 50
pearl white t1Shipper510
MB TSL Yellow 9682 Ovensack
MB Blue 29443 325 shiper 150
HDPE 50ma180
20 x 500
shipper 1000
PP 3530 1000 10 x 1 ltr 100
ASPET 21c 1150
465
shipper 3
ply
PP H110MA 750
shipper
600 x 430
ASPET 20C
40 x
250ml
PP srm100nc 710 20 x 500
silver grey 88901
white t5 25
PA 75
TotalRaw Material Reconcilation :
-
8/22/2019 Saraswati plasto DPR August
47/205
Admer 50
-
8/22/2019 Saraswati plasto DPR August
48/205
No. of
Cavity Grade Color Target
Actual
Production
in Pcs
Producti
on In
Kgs
Opening
RM
Balance
RM
issue
details Total
8 B52A003 white 15300 13728 1579 0 0
8 B52A003 Natural 1200 560 21 684 2000 2684
8 B52A003 Natural 2880 2540 279 0 0
8 B52A003 Natural 21600 19980 1139 1019 1500 2519
4 B52A003 white 14400 12960 544 0 0
4 B52A003 white 14400 10710 246 522 400 922
2 B52A003 tsl yellow 3840 3400 1037 196 1000 1196
2 B52A003
white 5760 5694 569 667 500 1167
8 B52A003 Natural 46080 45324 952 525 1075 1600
6 ASPET op green 16545 15600 721 673 1150 1823
6 H110MA white 21600 21000 201.6 6 200 206
8 MI3530 white 25412 21000 220.5 0 225 225
32 H110MA red 172800 150000 225.0 24 225 249
32 H110MA pearl white 125673 110000 281.6 20 300 320
8 MI3530 Natural 0 0 0.0 19 19
16 MI3530 obran 46861 45900 619.7 15 625 640
6 C blue 28800 25000 105.0 0 125 125
4 MI3530 yellow 13935 12350 154.4 15 150 165
8 50mA180 white 0 0 0.0 2 0 2
32 C tp violet 157989 130000 260.0 13 250 263
8 C red 35446 35400 230.1 0 250 250
8 MI3530 yellow 4144 3600 68.4 0 135 135
blue 30000
white 18000
ob blue 28800
68000
Daily Production Report bottling plant
-
8/22/2019 Saraswati plasto DPR August
49/205
Po red 175000
Violet 36000
white 2800
6000
30000
4590
5600
5200
6000
14000
774664 1114736 9453 4399 10110 14509
a
Received
in Pcs size QTY issued
bayer logo 46.4 40000
plain 19.8
camel 22.6
ep wad 22.6 220000
mayer
plain 46.4 44200
dupont 19.2
wad 43.4
DX excel 46.4
mayer
plain 34.5
board 46.4
dupont 19.2 41000
rallis 46.4
bayer logo 29.6 50000
% of Wastage
% of wastage which
can not used
-
8/22/2019 Saraswati plasto DPR August
50/205
-
8/22/2019 Saraswati plasto DPR August
51/205
closing
balance
Regrind
generate
d kg
Regrind
/
reproces
s used
Lumps
(Kg)
Plan
Hour
Mold
change
& Other
BD time
Efficean
cy
0 87.4 87.4 8.5 17 90%
1070 32.19 32.2 6.5 1 6 47%
0 61.6 61.6 5.5 3 88%
1087 22.8 22.8 7.8 18 3 93%
0 15.12 15.1 3.6 24 90%
123 6.9 6.9 4.5 24 74%
145 79.3 79.3 14.6 24 89%
593 34 34.0 5 24 99%
644 8.4 8.4 3.7 24 98%
1096 15.708 15.7 6.5 18 6 94%
5 2.208 2.2 24 97%
5 2.31 2.3 24 83%
24 0.36 0.4 24 87%
38 0.768 0.8 24 88%
19 0 0.0 0 #DIV/0!
20 3.105 3.1 24 98%
20 0.504 0.5 24 87%
10 2.5 2.5 24 89%
2 0 0.0 0 #DIV/0!
3 0.4 0.4 24 82%
20 0.845 0.8 24 100%
67 3.8 3.8 4 87%
-
8/22/2019 Saraswati plasto DPR August
52/205
4989 380 380 66
4.7
0.70
-
8/22/2019 Saraswati plasto DPR August
53/205
-
8/22/2019 Saraswati plasto DPR August
54/205
Mold change/Break down
Mold change & PDN startup.
mold change & PDN startup.
1 cavity Not coming OK due to Moog problem
day shift color trial & PDN startup from 2PM.
M/c stopped
M/c stopped
M/c stopped
-
8/22/2019 Saraswati plasto DPR August
55/205
m/c bearing broken
-
8/22/2019 Saraswati plasto DPR August
56/205
M/c No. Product Name
Order
Quantity
(In pcs)
Total Qty.
Produced
pcs
Balanced
need to
produced
(pcs)
cycle
Time
(Sec)
EBM-1
Monolayer 200000 30440 169560 21
EBM-2 500ml Cobra Bottle 200000 52410 147590 21
EBM-3
Bottle 75000 60000 15000 24
100ml Confidor super bottle 70000 49770 20230 24
EBM-4 5 Ltr BASF can 15000 11892 3108 45
EBM-5
white 12000 16810 -4810 30
1 ltr Triangular Bottle 20000 2520 17480 32
EBM-6 100ml Cobra Bottle Mono 500000 193346 306654 15
ASB-3
bottle 30000 30240 -240 23.5
500ml Blue Bottle 30000 34320 -4320 23.5
IM-1 RD 15 juniar Base 350000 124500 225500 24
IM-2 50mm Suzumida cap 30000 61000 -31000 27.2
50mm chambal cap 30000 16000 14000 27.2
IM-3 10ml Camel Cap 300000 450000 -150000 13
IM-4 10ml corogon cap pearl whit 1000000 681000 319000 22
IM-6 53mm obran cap 50000 155700 -105700 29.5
IM-7
Measuring cup 25000 62500 -37500 16
IM-8 50mm BASf cap 25000 55900 -30900 24.8
IM-9 38mm cobra cap 200000 14000 186000 30
IM-11
cup TP violet 1000000 813100 186900 17.5
IM-12 50ml Plain Measuring cup 60000 76500 -16500 19.5
IM-12 53mm Anupam Cap 200000 0 200000 27.8
Wadding M/c-1 28mm confidor cap
Wadding M/c-2 50mm plain cap white
50mm Pursuite cap
53mm cobra cap
Date: 3/8/2013
-
8/22/2019 Saraswati plasto DPR August
57/205
53mm cobra cap
Wadding M/c-3 38mm cobra cap white
Wadding M/c-4 10ml camel cap
Wadding m/c-5 10ml corogon cap
37mm white cap
manual assembly threded plug
assembly
Almix cap wadding
RD jr Lid & Base Assembly
Sr. No. Raw Material Name Grade Qty Kg
HDPE B52A003 4000
Other
Items
HDPE B56003
polybag
45*45
HDPE E5201S
shipper
555
MB WHITE 10055 75
shipper
465
orange 9.18E+08
shipper
590
pearl white t1
Shipper
510
MB TSL Yellow 9682 Ovensack
MB Blue 29443 325 shiper
HDPE 50ma180
20 x 500
shipper
PP 3530 750 10 x 1 ltr
ASPET 21c 1150
465
shipper 3
ply
PP H110MA 500
shipper
600 x 430
ASPET 20C
40 x
250ml
PP srm100nc 20 x 500
green 13965
TotalRaw Material Reconcilation :
-
8/22/2019 Saraswati plasto DPR August
58/205
silver grey 88901
red 29020
golden t3 25
white t5
pearl white 20051
crimson 13315yellow 12184
c blue 80505
o blue 14275
pearl blue 133101
blue 24577
yellow 1786
PA
Admer
red 6213
pearl blue 28760
p blue 41954034
yellow 12180
HDPE b5500
red 11155
orange 30444
green 15404
-
8/22/2019 Saraswati plasto DPR August
59/205
weight
(Grams)
No. of
Cavity Grade Color Target
Actual
Production in
Pcs
Production In
Kgs
Opening
RM Balance
37 8 B52A003 Natural 32914 29880 1106 1070
58 8 B52A003 Natural 32914 32430 1881 1087
42 4 B52A003 white 14400 11040 464 0
23 4 B52A003 white 14400 10080 232 123
305 2 B52A003 tsl yellow 1920 1530 467 145
100 2 B52A003
ear
white 1440 1326 133
110 2 B52A003 white 2700 2520 277 593
21 8 B52A003 Natural 46080 45584 957 644
46.2 6 ASPET op green 16545 14640 676
46.2 6 ASPET blue 5515 5160 238 1096
9.6 6 H110MA white 21600 19250 184.8 5
10.5 8 MI3530 white 2118 1000 10.5
10.5 8 MI3530 white 16941 16000 168.0 5
1.5 32 H110MA red 212677 200000 300.0 24
2.56 32 H110MA pearl white 125673 105000 268.8 38
13.5 16 MI3530 obran 46861 44100 595.4 39
4.2 6 C blue 32400 30000 126.0 20
12.5 4 MI3530 yellow 13935 13650 170.6 10
6.8 32 MI3530 golden 23040 14000 95.2 2
2 32 C tp violet 157989 122200 244.4 3
6.5 8 C red 35446 35100 228.2 20
19 8 MI3530 yellow 0 0 0.0 67
blue 55000
white 15730
yellow 3250
c blue 18900
Daily Production Report bottli
-
8/22/2019 Saraswati plasto DPR August
60/205
ob blue 16200
58000
Po red 155000
Violet 36000
16000
45000
3400
12000
10500
857508 1199470 8822 4990
Qty
Wad
Received
in Pcs size QTY issued
75 bayer logo 46.4 42750
bayer logo 29.6
plain 19.8
camel 22.6
300 ep wad 22.6 220000
mayer
plain 46.4 22100
100 dupont 19.2
1500 wad 43.4
DX excel 46.4
200
mayer
plain 34.5 39600
board 46.4
526 dupont 19.2
rallis 46.4
bayer logo 26.4
% of Wastage
% of wastage
not used
-
8/22/2019 Saraswati plasto DPR August
61/205
bayer logo 29.6 100000
-
8/22/2019 Saraswati plasto DPR August
62/205
RM
issue
details Total
closing
balance
Regrind
generated
kg
Regrind /
reprocess
used
Lumps
(Kg)
Plan
Hour
Mold
change &
Other BD
time
Efficean
cy
500 1570 455 16.65 16.7 8.9 24 91%
900 1987 98 17.4 17.4 7.7 24 99%
0 0 9.66 9.7 12 24 77%
600 723 8 25.3 25.3 8 24 70%
500 645 162 70.15 70.2 16 12 80%
0 0 34 34.0 6 92%
500 1093 675 33 33.0 8 12 693%
1075 1719 759 6.3 6.3 2.6 24 99%
0 10.626 10.6 18 88%
1150 2246 1325 30.954 31.0 6.5 6 94%
200 205 20 2.88 2.9 24 89%
0 1.26 1.3 2 47%
175 180 1 2.1 2.1 16 6 94%
300 324 24 0.45 0.5 24 94%
250 288 19 0.8704 0.9 24 84%
550 589 0 3.105 9.1 24 94%
0 20 0 0.84 107.0 24 93%
0 10 0 1.5 162.0 24 98%
0 2 0 2.04 95.0 6 18 61%
0 3 0 0.4 242.0 24 77%
0 20 0 0.78 209.0 24 99%
0 67 67 0 0.0 0 #DIV/0!
ng plant
-
8/22/2019 Saraswati plasto DPR August
63/205
6700 11690 3613 270 1086 70
3.9
hich can
0.79
-
8/22/2019 Saraswati plasto DPR August
64/205
-
8/22/2019 Saraswati plasto DPR August
65/205
Mold change/Break down
1 cavity Not coming OK due to Moog problem
Night shift M/c stopped due to no place to keep the Finished Goods
mold change & PDN startup.
color change
Cavity insert change & PDN startup
mold change & PDN startup.
M/c stopped
-
8/22/2019 Saraswati plasto DPR August
66/205
m/c bearing broken
-
8/22/2019 Saraswati plasto DPR August
67/205
M/c No. Product Name
Order
Quantity
(In pcs)
Total
Qty.
Produce
d pcs
Balanced
need to
produced
(pcs)
cycle
Time
(Sec)
EBM-1 250ml Cobra Bottle Monolayer 200000 66000 134000 19.5
EBM-2 500ml Cobra Bottle 200000 84530 115470 21
EBM-3 250ml Confidor Super Bottle 75000 63120 11880 24
100ml Confidor super bottle 70000 53550 16450 24
50ml confidor super Bottle 45000 4000 41000 24
100ml Round White Bottle 0 0 24
EBM-4 5 Ltr BASF can 15000 0 15000 45
EBM-5 1 ltr Triangular Bottle 20000 10368 9632 36
EBM-6 100ml Cobra Bottle Mono 500000 199360 300640 15
100ml Fame Bottle 260000 36960 223040 15
IBM-1 10/30ml Corogon Bottle 500000 500000 15
ASB-3 500ml Blue Bottle 30000 45000 -15000 23.5
IM-1 RD 15 juniar Base 350000 147250 202750 22
IM-2 50mm Kr Logo white cap 25000 16000 9000 27.2
50mm chambal cap 30000 19000 11000 27.2
IM-3 10ml Camel Cap 300000 470000 -170000 13
10ml Camel Cap 300000 175000 125000 13
IM-4 10ml corogon cap pearl white 1000000 790000 210000 22
IM-5 46mm Plain white cap 50000 26400 23600 18
IM-6 53mm obran cap 50000 159300 -109300 29.5
53mm Cobra Cap 1000000 39600 960400 29.5
IM-7
cup 25000 90000 -65000 16
IM-8 50mm BASf cap 25000 25000 24.8
IM-9 38mm cobra cap 200000 84000 116000 28
IM-11
10ml corogon Measuring cup TP
violet 1000000 827200 172800 17.5
IM-12 50ml Plain Measuring cup 60000 109500 -49500 19.5
IM-12 53mm Anupam Cap 200000 200000 27.8
Date: 4/8/2013
-
8/22/2019 Saraswati plasto DPR August
68/205
Wadding M/c-1 28mm confidor cap
28mm Folicure cap
Wadding M/c-2 50mm chambal cap
50mm white cap Kr logo
50mm KR logo blue cap
53mm cobra cap
53mm cobra cap
Wadding M/c-3 38mm cobra cap
Wadding M/c-4 10ml camel cap
Wadding m/c-5 10ml corogon cap
Wadding M/c -6 94mm Anupam cap
Wadding m/c no.7 46mm plain cap
37mm white cap
manual assembly threded plug
53mm anupam cap packing
53mm Anupam cap assembly
50mm Pursuite cap assembly
Almix cap wadding
22mm Fame cap
RD jr Lid & Base Assembly
Sr. No. Raw Material Name Grade Qty Kg
HDPE B52A003 5000
Other
Items
HDPE B56003
polybag
45*45
HDPE E5201S
shipper
555
MB WHITE 10055 25
shipper
465
orange 9.18E+08
shipper
590
pearl white t1
Shipper
510
MB TSL Yellow 9682 Ovensack
TotalRaw Material Reconcilation :
-
8/22/2019 Saraswati plasto DPR August
69/205
MB Blue 29443 325 shiper
HDPE 50ma180
20 x 500
shipper
PP 3530 1250 10 x 1 ltr
ASPET 21c
465
shipper 3
ply
PP H110MA 625
shipper
600 x 430
ASPET 20C
40 x
250ml
PP srm100nc 500 20 x 500
green 13965
silver grey 88901
red 29020
golden t3 50white t5
pearl white 20051
crimson 13315
yellow 12184
c blue 80505 25
o blue 14275
pearl blue 133101
blue 24577
yellow 1786
PA
Admer
red 6213
pearl blue 28760
p blue 41954034
yellow 12180
HDPE b5500
red 11155
orange 30444
green 15404
-
8/22/2019 Saraswati plasto DPR August
70/205
weight
(Grams)
No. of
Cavity Grade Color Target
Actual
Production
in Pcs
Producti
on In
Kgs
Opening
RM
Balance
RM
issue
details
37 8 B52A003 Natural 35446 35560 1316 455 1300
58 8 B52A003 Natural 32914 32120 1863 98 2275
42 4 B52A003 white 4200 3120 131 0
23 4 B52A003 white 4200 3780 87 0
18 4 B52A003 white 4200 3780 68
21 4 B52A003 white 4200 3780 79 8 500
300 2 B52A003 tsl yellow 1920 0 0 162 0
110 4 B52A003 white 9600 7848 863 675 500
21 8 B52A003 Natural 7680 6014 126
21 8 B52A003 Golden 38400 36960 776 759 500
8 14 B52A003 pearl white 0 0
46.2 6 ASPET blue 11030 10680 493 1325
9.6 6 H110MA white 23564 22750 218.4 20 200
10.5 8 MI3530 white 16941 16000 168.0
10.5 8 MI3530 white 3176 3000 31.5 1 200
1.5 32 H110MA red 26585 20000 30.0
1.5 32 H110MA L yellow 186092 175000 262.5 24 300
2.56 32 H110MA pearl white 125673 109000 279.0 19 300
8.5 8 MI3530 white 28800 26400 224.4 0 225
13.5 16 MI3530 obran 3905 3600 48.6 0
13.5 16 MI3530 obran 42956 39600 534.6 0 600
4.2 6 C blue 32400 27500 115.5 0 125
12.5 4 MI3530 yellow 0 0.0 0
6.8 32 MI3530 golden 98743 70000 476.0 0 450
2 32
SRM100N
C tp violet 19749 14100 28.2 0 0
6.5 8 C red 35446 33000 214.5 0 0
19 8 MI3530 yellow 0 0.0 67 0
Daily Production Report bottling pla
-
8/22/2019 Saraswati plasto DPR August
71/205
blue 40000
green 15000
white 18000
white 12000
blue 7730
c blue
ob blue 15300
blue 68000
Po red 60000
Violet 30000
yellow
white
42000
10500
797820 1022122 8434 3613 7475
Qty
a
Received
in Pcs size QTY issued
25 bayer logo 46.4
bayer logo 29.6
plain 19.8
230 camel 22.6
ep wad 22.6 110000
mayer
plain 46.4 21100
% of Wastage
% of wastage which
can not used
-
8/22/2019 Saraswati plasto DPR August
72/205
100 dupont 19.2
1600 wad 43.4
DX excel 46.4
mayer
plain 34.5
board 46.4
dupont 19.2
rallis 46.4
bayer logo 26.4 126000
bayer logo 29.6 100000
-
8/22/2019 Saraswati plasto DPR August
73/205
Total
closing
balance
Rejectio
n in pcs
Regrind
generate
d kg
Regrind
/
reproces
s used
Lumps
(Kg)
Plan
Hour
Mold
change
& Other
BD time
Efficean
cy
1755 433 90 3.33 3.3 5.9 24 100%
2373 503 120 6.96 7.0 7.6 24 98%
0 0 200 8.4 8.4 8 7 74%
0 0 320 7.36 7.4 6 7 90%
0 0 400 7.2 7.2 4 7 10 90%
508 110 450 9.45 9.5 7 7 90%
162 162 0 0 0.0 12 0%
1175 303 450 49.5 49.5 8.5 24 82%
0 0 600 12.6 12.6 5 4 78%
1259 344 450 9.45 9.5 8 20 96%
0 0 0.0 0 #DIV/0!
1325 828 340 15.708 15.7 3 12 97%
220 2 120 1.152 1.2 24 97%
0 80 0.84 0.8 16 94%
201 2 230 2.415 2.4 3 5 94%
0 0 500 0.75 0.8 3 75%
324 26 780 1.17 1.2 5 21 94%
319 40 230 0.5888 0.6 24 87%
225 1 120 1.02 1.0 18 6 92%
0 0 230 3.105 3.1 2 92%
600 11 400 5.4 5.4 5.5 22 92%
125 10 230 0.966 1.0 24 85%
0 0 0 0.0 0 #DIV/0!
450 0 340 2.312 28.3 24 71%
0 0 220 0.44 28.4 3 71%
0 0 120 0.78 215.3 24 93%
67 67 0 0 0.0 0 #DIV/0!
t
-
8/22/2019 Saraswati plasto DPR August
74/205
11088 2842 7020 151 419 74
2.7
0.87
-
8/22/2019 Saraswati plasto DPR August
75/205
-
8/22/2019 Saraswati plasto DPR August
76/205
Mold change/Break down
open + weight adjustment problem solved
Finished Goods
color change to golden
Night shift M/c stopped
Cavity insert change & PDN startup
Color change to L yellow
PDN startup
Color change
M/c stopped
Hot tip cleaning in day shift
M/c stopped
M/c stopped
-
8/22/2019 Saraswati plasto DPR August
77/205
m/c bearing broken
-
8/22/2019 Saraswati plasto DPR August
78/205
M/c No. Product Name
Order
Quantity
(In pcs)
Total
Qty.
Produce
d pcs
Balance
d need
to
produce
d (pcs)
cycle
Time
(Sec)
EBM-1 250ml Cobra Bottle Monolayer 200000 102680 97320 18
EBM-2 500ml Cobra Bottle 200000 115918 84082 21
EBM-3 50ml confidor super Bottle 45000 22000 23000 19
100ml Round White Bottle 17248 -17248 19
EBM-4 3 ltr Jery Can 2000 792 1208 45
EBM-5 1 ltr Triangular Bottle 20000 16764 3236 36
EBM-6 100ml Fame Bottle 260000 76294 183706 16
IBM-1 10/30ml Corogon Bottle 500000 0 500000 15
ASB-3 500ml Blue Bottle 30000 0 30000 23.5
IM-1 RD 15 juniar Base 350000 168250 181750 22
IM-2 50mm Kr Logo white cap 25000 40000 -15000 27.2
IM-3 10ml Camel Cap 300000 220000 80000 13
10ml Camel Cap 300000 110000 190000 13
IM-4 10ml corogon cap pearl white 1000000 800000 200000 22
22mm Fame cap 500000 90000 410000 22
IM-5 46mm Plain white cap 50000 41400 8600 18
46mm Plain Yellow cap 15000 18000 -3000 18
IM-6 53mm Cobra Cap 1000000 81000 919000 29.5
IM-7
32ml Confidor super Measuring
cup 25000 100000 -75000 16
30ml Raft Measuring cup 50000 25000 25000 20
IM-8 50mm BASf cap 25000 25000 24.8
IM-9 38mm cobra cap 200000 156000 44000 28
IM-1110ml corogon Measuring cup TPviolet 1000000 0 1000000 17.5
IM-12 50ml Plain Measuring cup 60000 142500 -82500 19.5
IM-12 53mm Anupam Cap 200000 0 200000 27.8
Wadding M/c-1 28mm Folicure cap
Wadding M/c-2 50mm Rallis cap
50mm white cap Kr logo
Date: 5/8/2013
-
8/22/2019 Saraswati plasto DPR August
79/205
50mm KR logo blue cap
53mm cobra cap
53mm cobra cap
Wadding M/c-3 38mm cobra cap
Wadding M/c-4 10ml camel cap
Wadding m/c-5 10ml corogon cap
Wadding M/c -6 94mm Anupam cap
Wadding m/c no.7 46mm plain cap
37mm white cap
manual assembly threded plug
53mm anupam cap packing
53mm Anupam cap assembly
50mm Pursuite cap assemblyAlmix cap wadding
22mm Fame cap
RD jr Lid & Base Assembly
Sr. No. Raw Material Name Grade Qty Kg
HDPE B52A003 4000
Other
Items
HDPE B56003
polybag
45*45
HDPE E5201S
shipper
555
MB WHITE 10055 25
shipper
465
orange 9.18E+08
shipper
590
pearl white t1
Shipper
510
MB TSL Yellow 9682 Ovensack
MB Blue 29443 325 shiper
HDPE 50ma180
20 x 500
shipper
PP 3530 1250 10 x 1 ltr
ASPET 21c
465
shipper 3
ply
TotalRaw Material Reconcilation :
-
8/22/2019 Saraswati plasto DPR August
80/205
PP H110MA 625
shipper
600 x 430
ASPET 20C
40 x
250ml
PP srm100nc 250 20 x 500
green 13965
silver grey 88901
red 29020
golden t3 50
white t5
pearl white 20051
crimson 13315
yellow 12184
c blue 80505
o blue 14275
pearl blue 133101blue 24577
yellow 1786
PA
Admer
red 6213
pearl blue 28760
p blue 41954034
yellow 12180
HDPE b5500
red 11155
orange 30444
green 15404
-
8/22/2019 Saraswati plasto DPR August
81/205
weight
(Grams)
No. of
Cavity Grade Color Target
Actual
Production in
Pcs
Producti
on In
Kgs
Opening
RM
Balance
RM
issue
details
37 8 B52A003 Natural 38400 36680 1357 433 1000
58 8 B52A003 Natural 32914 31388 1821 503 1450
18 4 B52A003 white 18189 18000 324 0
21 4 B52A003 white 18189 14784 310 110 550
255 2 B52A003 white 960 792 202 162 100
110 4 B52A003 white 9600 6396 704 303 450
21 8 B52A003 Golden 43200 39334 826 344 500
8 14 B52A003 pearl white 0 0
46.2 6 ASPET blue 0 0 828
9.6 6 H110MA white 23564 21000 201.6 2 200
10.5 8 MI3530 white 25412 24000 252.0 2 250
1.5 32 H110MA L yellow 53169 45000 67.5 0
1.5 32 H110MA Black 159508 110000 165.0 26 225
2.56 32 H110MA pearl white 10473 10000 25.6
2.56 32 H110MA golden 94255 90000 230.4 40 225
8.5 8 MI3530 white 17600 15000 127.5
8.5 8 MI3530 yellow 20800 18000 153.0 1 275
13.5 16 MI3530 c blue 46861 41400 558.9 11 550
4.2 6
SRM100N
C blue 10800 10000 42.0
7 16 C blue 28800 25000 175.0 10 150
12.5 4 MI3530 yellow 0 0.0 0
6.8 32 MI3530 golden 98743 72000 489.6 0 275
2 32SRM100N
C tp violet 0 0 0.0 0 0
6.5 8 C red 35446 33000 214.5 67 0
19 8 MI3530 yellow 0 0 0.0 0 0
green 50000
red 9000
white 21000
Daily Production Report bottling p
-
8/22/2019 Saraswati plasto DPR August
82/205
blue
c blue 20700
ob blue 1800
blue 60000
black 95000
Violet 24000
yellow
yellow 5600
27000
8400
2100
3500
786883 989874 8246 2842 6200
Qty
a
Received
in Pcs size QTY issued
bayer logo 46.4
300 bayer logo 29.6
plain 19.8
100 camel 22.6
ep wad 22.6
2 rollmayerplain 46.4 44200
dupont 19.2
1500 wad 43.4
200 DX excel 46.4
mayer
plain 34.5
% of Wastage
% of wastage which
can not used
-
8/22/2019 Saraswati plasto DPR August
83/205
board 46.4
dupont 19.2
rallis 46.4
bayer logo 26.4
bayer logo 29.6
-
8/22/2019 Saraswati plasto DPR August
84/205
Total
closing
balance
Rejectio
n in pcs
Regrind
generate
d kg
Regrind
/
reproces
s used
Lumps
(Kg)
Plan
Hour
Mold
change
& Other
BD time Efficeancy
1433 68 450 16.65 16.7 8.7 24 96%
1953 123 340 19.72 19.7 9.8 24 95%
0 0 700 12.6 12.6 7.5 24 99%
660 13 340 7.14 7.1 5.5 24 81%
262 42 340 86.7 86.7 18 6 83%
753 38 780 85.8 85.8 11.5 24 67%
844 12 560 11.76 11.8 5.5 24 91%
0 0 0.0 0 #DIV/0!
828 828 0 0.0 0 #DIV/0!
202 0 270 2.592 2.6 24 89%
252 0 120 1.26 1.3 24 94%
0 0 700 1.05 1.1 6 85%
251 16 2300 3.45 3.5 3 18 69%
0 560 1.4336 1.4 1 2 95%
265 0 760 1.9456 1.9 8 18 4 95%
0 230 1.955 2.0 11 85%
276 0 300 2.55 9.6 2 13 87%
561 2 240 3.24 3.2 24 88%
0 200 0.84 0.8 8 93%
160 -64 540 3.78 3.8 6 10 6 87%
0 0 0 0 0.0 0 #DIV/0!
275 0 430 2.924 218.0 24 73%
0 0 0 0 0.0 0 0 #DIV/0!
67 0 120 0.78 149.0 24 93%
0 0 0 0 0.0 0 #DIV/0!
lant
-
8/22/2019 Saraswati plasto DPR August
85/205
9042 1079 10280 268 639 87
4.3
1.05
-
8/22/2019 Saraswati plasto DPR August
86/205
-
8/22/2019 Saraswati plasto DPR August
87/205
Mold change/Break down
Mold change & PDN startup in night shift
color line problem, uneven flow, weight varation.
M/c stopped
color change & tip cleaning
Mold change & Barrel cleaning and PDN startup
color change & PDN startup
Color change
Mold change & PDn startup
M/c stopped
Hot tip cleaning in day shift
M/c stopped
M/c stopped
-
8/22/2019 Saraswati plasto DPR August
88/205
-
8/22/2019 Saraswati plasto DPR August
89/205
M/c No. Product Name
Order
Quantity
(In pcs)
Total
Qty.
Produce
d pcs
Balance
d need
to
produce
d (pcs)
cycle
Time
(Sec)
weight
(Grams)
EBM-1 250ml Cobra Bottle Monolayer 200000 136280 63720 19 37
EBM-2 500ml Cobra Bottle 200000 131518 68482 21.5 58r oun o e w ec
ring 30000 6396 23604 30 100
EBM-3 50ml confidor super Bottle 45000 40000 5000 19 18
100ml Round White Bottle 35112 -35112 19 18
EBM-4 3 ltr Jery Can 2000 2040 -40 45 255
EBM-5 1 ltr Triangular Bottle 20000 18948 1052 36 100m quare o e w ew
Strip 13000 1560 11440 30 62
EBM-6 100ml Fame Bottle 260000 78758 181242 16 21
400ml Anupam bottle 60000 16300 43700 24 48
IBM-1 10/30ml Corogon Bottle 500000 500000 15 8
ASB-3
m rans reen o e
(Anuproduct) 20000 10200 9800 23.5 46.2
IM-1 RD 15 juniar Base 350000 192750 157250 21 9.6
IM-2 50mm Kr Logo white cap 25000 45000 -20000 26 10.5
50mm Kr Logo cap 25000 19000 6000 26 10.5
IM-3 10ml Camel Cap 300000 265000 35000 13 1.5
IM-4 22mm Fame cap 500000 220000 280000 20 2.56
IM-5 46mm Plain white cap 50000 62400 -12400 18 8.5
46mm plain green cap 10000 12600 -2600 18 8.5
IM-6 53mm Cobra Cap 1000000 94500 905500 29.5 13.5
53mm Cobra Cap 1000000 18900 981100 29.5 13.5
IM-7 30ml Raft Measuring cup 50000 50000 0 20 7
RD Jr Lid Mold 350000 5250 344750 20 6.6
IM-8 50mm BASf cap 25000 0 25000 24.8 12.5
Date: 6/8/2013
-
8/22/2019 Saraswati plasto DPR August
90/205
IM-9 38mm cobra cap 200000 198000 2000 28 6.8
IM-11
m corogon easur ng cup
TP violet 1000000 1000000 17.5 2
IM-12 50ml Plain Measuring cup 60000 175500 -115500 19.5 6.5
IM-12 53mm Anupam Cap 200000 200000 27.8 19
Wadding M/c-1 28mm Folicure cap
22mm Fame cap
Wadding M/c-2 50mm Rallis cap
50mm white cap Kr logo
50mm KR logo blue cap
50mm Plain white cap
50mm Blue cap
53mm cobra cap
Wadding M/c-3 38mm cobra cap
Wadding M/c-4 10ml camel cap
10ml camel cap
Wadding m/c-5 10ml corogon cap
Wadding M/c -6 94mm Anupam cap
Wadding m/c no.7 46mm plain cap
46mm Plain Cap Green
manual assembly threded plug
53mm anupam cap packing
53mm Anupam cap assembly
50mm Blue Cap Assembly
Almix cap wadding
22mm Fame cap
RD jr Lid & Base Assembly
Sr. No. Raw Material Name Grade Qty Kg
TotalRaw Material Reconcilation :
-
8/22/2019 Saraswati plasto DPR August
91/205
HDPE B52A003 5000
Other
Items Qty
HDPE B56003
polybag
45*45 50
HDPE E5201S
shipper
555
MB WHITE 10055 50shipper465
orange 9.18E+08
shipper
590 360
pearl white t1
Shipper
510 200
MB TSL Yellow 9682 Ovensack
MB Blue 29443 325 shiper
HDPE 50ma180
20 x 500
shipper 1500
PP 3530 1250 10 x 1 ltr
RELPET 5841J 1100
465
shipper 3
ply
PP H110MA 500
shipper
600 x 430
ASPET 20C
40 x
250ml
PP srm100nc 475 20 x 500
green 13965
silver grey 88901
red 29020
golden t3
white 10055 25
pearl white 20051
crimson 13315
yellow 12184
c blue 80505
o blue 14275
pearl blue 133101
blue 4183916 13.7
yellow 1786
PA
Admer
red 6213
pearl blue 28760
p blue 41954034
yellow 12180
-
8/22/2019 Saraswati plasto DPR August
92/205
HDPE b5500
red 11155
orange 30444
green 15404
-
8/22/2019 Saraswati plasto DPR August
93/205
No. of
Cavity Grade Color Target
Actual
Production
in Pcs
Producti
on In
Kgs
Opening
RM
Balance
RM
issue
details Total
8 B52A003 Natural 36379 33600 1243 68 1200 1268
8 B52A003 Natural 17414 15600 905 0 0
8 B52A003 Natural 6720 6396 640 123 1450 1573
4 B52A003 white 18189 18000 324 0 0 0
4 B52A003 white 18189 17864 322 13 700 713
2 B52A003 white 1440 1248 318 42 300 342
4 B52A003 white 2400 2184 218 0 0 0
2 B52A003 pearl white 1920 1560 97 38 350 388
8 B52A003 Golden 3600 2464 52 0 0 0
8 B52A003 tsl yellow 19200 16300 782 12 1050 1062
14 B52A003 pearl white 0 0 0
6 ASPET blue 11030 10200 471 828 1100 1928
6 H110MA white 24686 24500 235.2 0 250 250
8 MI3530 white 5538 5000 52.5 0 0
8 MI3530 Blue 19938 19000 199.5 0 275 275
32 H110MA Black 212677 155000 232.5 16 225 241
32 H110MA golden 138240 130000 332.8 0 350 350
8 MI3530 white 24000 21000 178.5 0 0 0
8 MI3530 yellow 14400 12600 107.1 0 300 300
16 MI3530 c blue 17573 13500 182.3 0
16 MI3530 c blue 29288 18900 255.2 2 500 502
16 C blue 28800 25000 175.0 0 0
6 C blue 6480 5250 34.7 0 225 225
4 MI3530 yellow 0 0 0.0 0 0
Daily Production Report bottling pla
-
8/22/2019 Saraswati plasto DPR August
94/205
32 MI3530 golden 98743 42000 285.6 0 300 300
32 C tp violet 0 0.0 0 0
8 C red 35446 33000 214.5 0 88.7 89
8 MI3530 yellow 0 0.0 0 0
green 5000
golden 32062
red 1000
white 7000
blue 18000
white 2000
blue 11050
white 1800
blue 46000
black 80000
L yellow 120000
Violet 48000
yellow
white 19600
green 12600
6000
8636
9000
14000
3500
792291 1075414 7857 1142 8664 9806
% of Wastage
-
8/22/2019 Saraswati plasto DPR August
95/205
Wad
Received
in Pcs size QTY issued
bayer logo 46.4
bayer logo 29.6
plain 19.8
camel 22.6
ep wad 22.6 220000
mayer
plain 46.4
dupont 19.2
wad 43.4 42600
DX excel 46.4
mayer
plain 34.5
board 46.4
dupont 19.2 110000
rallis 46.4
bayer logo 26.4
bayer logo 29.6 100000
% of wastage which
can not used
-
8/22/2019 Saraswati plasto DPR August
96/205
-
8/22/2019 Saraswati plasto DPR August
97/205
closing
balance
Rejectio
n in pcs
Regrind
generate
d kg
Regrind
/
reproces
s used
Lumps
(Kg)
Plan
Hour
Mold
change
& Other
BD time Efficeancy
21 290 10.73 10.7 3.6 24 92%
0 100 5.8 5.8 4.6 13 90%
18 800 80 80.0 6 7 4 95%
0 400 7.2 7.2 24 99%
63 345 6.21 6.2 3.8 24 98%
14 160 40.8 40.8 10 9 87%
0 500 50 50.0 10 6 91%
57 200 12.4 12.4 6 8 10 81%
0 100 2.1 2.1 2.2 2 68%
220 400 19.2 19.2 6 16 6 85%
0 0.0 0 #DIV/0!
1454 190 8.778 8.8 3 12 12 92%
15 80 0.768 0.8 24 99%
130 1.365 1.4 5 90%
20 200 2.1 2.1 3.5 18 1 95%
8 760 1.14 1.1 24 73%
17 450 1.152 1.2 24 94%
200 1.7 1.7 15 88%
9 130 1.105 1.1 5 9 2 88%
200 2.7 2.7 9 77%
57 220 2.97 3.0 7.6 15 65%
0 120 0.84 0.8 10 87%
14 230 1.518 1.5 1 6 8 81%
0 0 0 0.0 0 #DIV/0!
t
-
8/22/2019 Saraswati plasto DPR August
98/205
14 670 4.556 4.6 24 43%
0 0 0.0 0 #DIV/0!
0 220 1.43 127.4 24 93%
0 0 0.0 0 #DIV/0!
2002 7095 267 393 72
4.3
-
8/22/2019 Saraswati plasto DPR August
99/205
0.92
-
8/22/2019 Saraswati plasto DPR August
100/205
-
8/22/2019 Saraswati plasto DPR August
101/205
Mold change/Break down
Air Membrane change in Day shift BD- 1 Hrs.
Mold change & PDN started
comp e e o o oa e or c angeover c
stopped in Night shift
o c ange o or r a ecyc e ex ru er es
cleaning
mold change & PDN startup
Night shift Loader suction problem M/c stopped 1 hrs.
M/c stoppedo oa e s ar e a er comp e ng m c
stopped
Mold insert change & PDN startup
Hot tip cleaning in day shift
color change & PDN startup
Day shift Toshiba Eng is Working 2 hrs BD
Hot tip cleaning in day shift
2 cavity block
Mold change & PDn startup
M/c stopped
-
8/22/2019 Saraswati plasto DPR August
102/205
ay s u r ca on a ram pro em m c s oppe o p
cleaning
M/c stopped
M/c stopped
-
8/22/2019 Saraswati plasto DPR August
103/205
M/c No. Product Name
Order
Quantity
(In pcs)
Total Qty.
Produced
pcs
Balanced
need to
produced
(pcs)
EBM-1 250ml Cobra Bottle Monolayer 200000 141040 58960
250ML Cobra Coex Bottle Blue 81565171
(Himat Nagar) 25000 19320 5680
EBM-2 1 ltr Round Bottle with Neck ring 30000 28470 1530
EBM-3 50ml confidor super Bottle 45000 51000 -6000
100ml Round White Bottle 0 42504 -42504
100Ml confidor Super Bottle 40000 2400 37600
EBM-4 5 ltr BASF jery Can (BASF Panoli) 2500 1105 1395
EBM-5 500ml Square Bottle with View Strip 13000 8160 4840
EBM-6
Bottle, Logo,HDPE, 0,4L, y, IN (Anupam)
67638678 60000 42796 17204
IBM-1 10ml Fame Bottle 500000 37855 462145
ASB-3
500ml White PET Bottle (Modern
Insecticide) 10000 11520 -1520
IM-1 RD 15 juniar Base 350000 219000 131000
IM-2 50mm Kr Logo cap 50000 41000 9000
IM-3 10ml Camel Cap 300000 400000 -100000IM-4 22mm Fame cap 500000 370000 130000
IM-5 46mm Plain white cap 50000 100200 -50200
IM-6 53mm Cobra Cap 50000 36000 14000
35ml cobra Measuring cup 432000 10000 422000
IM-7 RD Jr Lid 350000 36750 313250
IM-8 20ml Rallis measuring cup 100000 42000 58000
IM-9 38mm cobra cap 200000 254000 -54000
IM-11 10ml corogon Measuring cup TP violet 1000000 1000000
IM-12 50ml Plain Measuring cup 60000 207000 -147000
IM-12 53mm Anupam Cap 200000 200000
Wadding M/c-1 22mm Fame cap
Wadding M/c-2 50mm Plain cap
50mm white cap Kr logo
50mm KR logo blue cap
Date: 7/8/2013
-
8/22/2019 Saraswati plasto DPR August
104/205
50mm Green Planet cap
50mm pursuite cap
53mm cobra cap
Wadding M/c-3 38mm cobra cap
Wadding M/c-4 10ml camel cap
10ml camel cap
Wadding m/c-5 10ml corogon cap
Wadding M/c -6 94mm Anupam cap
Wadding m/c no.7 46mm plain cap
manual assembly threded plug
53mm anupam cap packing
53mm Anupam cap assembly
50mm Blue Cap AssemblyAlmix cap wadding
22mm Fame cap
RD jr Lid & Base Assembly
Sr. No. Raw Material Name Grade Qty Kg
HDPE B52A003 5000
HDPE B56003
HDPE E5201S 500
MB WHITE 10055 25
orange 9.18E+08
pearl white t1
MB TSL Yellow 9682 25
MB Blue 29443
HDPE 50ma180
PP 3530 1500
RELPET 5841J
TotalRaw Material Reconcilation :
-
8/22/2019 Saraswati plasto DPR August
105/205
PP H110MA 750
ASPET 20C
PP srm100nc 250
green 13965
silver grey 88901
red 29020
golden t3
white 10055 25
white t5 25
crimson 13315
yellow 12184
c blue 80505
o blue 14275
pearl blue 133101blue 4183916
yellow 1786
EVOH 100
Admer 75
red 6213
pearl blue 28760
p blue 41954034
yellow 12180
HDPE b5500
red 11155
orange 30444
green 15404
-
8/22/2019 Saraswati plasto DPR August
106/205
cycle
Time
(Sec)
weight
(Grams)
No. of
Cavity Grade Color Target
Actual
Production
in Pcs
Production
In Kgs
19 37 8 B52A003 Natural 6063 4760 176
24 37 8 B52A003 blue 21600 19320 715
30 100 8 B52A003 Natural 23040 22074 2207
22 18 4 B52A003 white 11782 11000 198
22 22 4 B52A003 white 7855 7392 163
22 23 4 B52A003 white 3927 2400 55
45 305 2 B52A003 white 1280 1105 337
24 64 2 B52A003 pearl white 7200 6600 422
24 48 8 B52A003 tsl yellow 28800 26496 1272
15 5.5 14 B52A003 golden 40320 37855 208
23.5 35.5 6 ASPET white 12868 11520 409
19.5 9.6 6 H110MA white 26585 26250 252.0
26 10.5 8 MI3530 Blue 26585 22000 231.0
13 1.5 32 H110MA Black 212677 135000 202.518 2.56 32 H110MA golden 153600 150000 384.0
18 8.5 8 MI3530 white 38400 37800 321.3
29.5 13.5 16 MI3530 white 21478 17100 230.9
20 4.5 32 C Trans 11520 10000 45.0
16 6.6 6 C blue 32400 31500 207.9
20 3.6 16 C Trans 46080 42000 151.2
28 6.8 32 MI3530 golden 98743 56000 380.8
17.5 2 32 C tp violet 0 0 0.0
19.5 6.5 8 C red 35446 31500 204.8
27.8 19 8 MI3530 yellow 0 0 0.0
golden 40000
white 1300
white
blue 25000
Daily Production Report
-
8/22/2019 Saraswati plasto DPR August
107/205
white 9500
yellow 1300
white
Golden 16000
black 55000
L yellow 142000
Violet 48000
yellow
white 42000
21000
2000
7000
10500
868248 1130272 8774
Other
Items Qty
a
Received
in Pcs size QTY issuedpolybag
45*45 50 bayer logo 46.4
shipper
555 bayer logo 29.6
shipper
465 plain 19.8
shipper
590 100 camel 22.6
Shipper
510 ep wad 22.6 110000
Ovensackmayerplain 46.4 66300
325 shiper dupont 19.2
20 x 500
shipper wad 43.4 42600
10 x 1 ltr DX excel 46.4
465
shipper 3
ply 150
mayer
plain 34.5
-
8/22/2019 Saraswati plasto DPR August
108/205
shipper
600 x 430 20 board 46.4
40 x
250ml dupont 19.2
20 x 500 rallis 46.4
bayer logo 26.4
bayer logo 19.8 110000
-
8/22/2019 Saraswati plasto DPR August
109/205
Opening RM
Balance
RM
issue
details Total
closing
balance
Rejectio
n in pcs
Regrind
generate
d kg
Regrind
/
reproces
s used
Lumps
(Kg)
Plan
Hour
0 340 12.58 12.6 3 4
21 1000 1021 118 780 28.86 28.9 8.8 18
18 2200 2218 5 970 97 97.0 6 24
0 0 0 340 6.12 6.1 18
0 0 450 9.9 9.9 12
63 400 463 40 780 17.94 17.9 8 6
14 350 364 8 230 70.15 70.2 19 8
57 400 457 29 780 49.92 49.9 5.5 24
220 1125 1345 66 560 26.88 26.9 7 24
0 225 225 13 340 1.87 1.9 4 12
1454 0 1454 1042 560 19.88 19.9 3 14
15 250 265 13 80 0.768 0.8 24
20 225 245 14 230 2.415 2.4 24
8 100 108 0 240 0.36 95.0 2417 400 417 33 400 1.024 1.0 24
9 325 334 13 240 2.04 2.0 24
0 0 0 0 1200 16.2 16.2 11
57 275 332 52 650 2.925 2.9 5 2
14 200 214 6 240 1.584 1.6 24
0 175 175 22 340 1.224 1.2 2 16
14 375 389 9 670 4.556 4.6 24
0 0 0 0 0.0 0
0 225 225 20 450 2.925 2.9 24
0 0 0 0 0.0 0
bottling plant
-
8/22/2019 Saraswati plasto DPR August
110/205
2002 8250 10252 1501 10870 377 472 71
% of Wastage 5.1
% of wastage which can
not used 0.81
-
8/22/2019 Saraswati plasto DPR August
111/205
-
8/22/2019 Saraswati plasto DPR August
112/205
Mold
change
& Other
BD time Efficeancy Mold change/Break down
79%
2 89% COEX started + @ 6Am Hydraulic hose pipe burst
96%
93%
94%
6 61%
loaded
16 86%.
Day shift Recycle layer extruder open and clean the
92%
92%
94% mold change & PDN startup
10 90%Mold change & PDN startup, PDN completed M/c
stopped
99%
83%
63% Hot tip cleaning in day shift +100% Regrind usages98%
98%
80%
11 87%,
MCB change in Night Shift
97% Mold change & PDn startup
8 91% Mold loaded & PDN started
57%
tip cleaning
#DIV/0! M/c stopped
89%
#DIV/0! M/c stopped
-
8/22/2019 Saraswati plasto DPR August
113/205
-
8/22/2019 Saraswati plasto DPR August
114/205
M/c No. Product Name
Order
Quantity
(In pcs)
Total Qty.
Produced
pcs
Balanced
need to
produced
(pcs)
cycle
Time
(Sec)
EBM-1
250ML Cobra Coex Bottle
Blue 81565171 (Himat Nagar) 25000 25760 -760 24
1 ltr Round Bottle White @ 95
gram 30000 6240 23760 28
EBM-2
r oun o e w ec
ring 30000 30654 -654 30
1 ltr round Bottle with Neck
ring white 10000 11622 -1622 29
1 ltr cobra Bottle Mono 95
Gram 58470 2800 55670 29
EBM-3 50ml confidor super Bottle 45000 66000 -21000 22
100Ml confidor Super Bottle 40000 17400 22600 22
EBM-4
5 ltr BASF jery Can (BASF
Panoli) 2500 3944 -1444 48
EBM-5
m quare o e w
View Strip 13000 14520 -1520 24
EBM-6
Bottle, Logo,HDPE, 0,4L, y, IN
(Anupam) 67638678 60000 62641 -2641 24
IBM-1 10ml Fame Bottle 500000 117055 382945 15
ASB-3
m e o e
(Modern Insecticide) 10000 10000 23.5
IM-1 RD 15 juniar Base 350000 238250 111750 19.5IM-2 50mm Kr Logo cap 50000 65000 -15000 26
IM-3 10ml Camel Cap 300000 430000 -130000 13
80ml cobra measuring cup 35000 -35000 18
IM-4 22mm Fame cap 500000 500000 0 18
IM-5 46mm Plain white cap 50000 142200 -92200 16.4
IM-6 35ml cobra Measuring cup 432000 127500 304500 20
IM-7 RD Jr Lid 350000 66750 283250 16
IM-8 20ml Rallis measuring cup 100000 108500 -8500 20
IM-9 38mm cobra cap 200000 318000 -118000 28
IM-11
10ml corogon Measuring cup
TP violet 1000000 1000000 17.5
IM-12 50ml Plain Measuring cup 60000 214500 -154500 19
50ml Rallis Measuring cup 200000 25500 174500 19
IM-12 53mm Anupam Cap 200000 200000 27.8
Wadding M/c-1 22mm Fame cap
Date: 8/8/2013
-
8/22/2019 Saraswati plasto DPR August
115/205
Wadding M/c-2 50mm Plain cap
50mm white cap Kr logo
50mm KR logo blue cap
50mm Green Planet cap
50mm pursuite cap
53mm cobra cap
Wadding M/c-3 53mm Anupam Cap
Wadding M/c-4 10ml camel cap
10ml camel cap
10ml camel cap
10ml camel cap
10ml camel cap
10ml camel cap
10ml camel capWadding m/c-5 10ml corogon cap
Wadding M/c -6 94mm Anupam cap
no.7 46mm plain cap
assembly threded plug
53mm anupam cap packing
RD jr Lid & Base Assembly
Sr. No. Raw Material Name Grade Qty Kg
HDPE B52A003 5000
Other
Items
HDPE B56003
polybag
45*45
HDPE E5201S 500
shipper
555
MB WHITE 10055 75
shipper
465
orange 9.18E+08
shipper
590
pearl white t1
Shipper
510
MB TSL Yellow 9682 50 Ovensack
MB Blue 29443 325 shiper
HDPE 50ma180
20 x 500
shipper
TotalRaw Material Reconcilation :
-
8/22/2019 Saraswati plasto DPR August
116/205
PP 3530 1000 10 x 1 ltr
RELPET 5841J
465
shipper 3
ply
PP H110MA 75
shipper
600 x 430
ASPET 20C
40 x
250mlPP srm100nc 1500 20 x 500
green 13965
silver grey 88901
red 29020
golden t3
white 10055
white t5
crimson 13315
yellow 12184
c blue 80505
o blue 14275
pearl blue 133101
blue 4183916
yellow 1786
PA 50
Admer 25
red 6213
pearl blue 28760
p blue 41954034yellow 12180
HDPE b5500
red 11155
orange 30444
green 15404
-
8/22/2019 Saraswati plasto DPR August
117/205
weight
(Grams)
No. of
Cavity Grade Color Target
Actual
Production
in Pcs
Producti
on In
Kgs
Opening
RM
Balance
RM
issue
details
37 8 B52A003 blue 7200 6440 238
96 8 B52A003 white 8229 6240 599 118 750
100 8 B52A003 Natural 2880 2184 218
96 8 B52A003 white 12910 11622 1116
96 8 B52A003 Natural 2979 2800 269 5 1650
18 4 B52A003 white 15709 15000 270 0
23 4 B52A003 white 15709 15000 345 40 600
305 2 B52A003 white 3600 2839 866 8 875
64 2 B52A003 pearl white 7200 6360 407 29 400
48 8 B52A003 tsl yellow 28800 19845 953 66 925
5.5 14 B52A003 golden 80640 79200 436 13 500
35.5 6 ASPET white 0 0 1042 0
9.6 6 H110MA white 21046 19250 184.8 13 17510.5 8 MI3530 Blue 26585 24000 252.0 14 250
1.5 32 H110MA Black 35446 30000 45.0 0
7.5 16 SRM100NC Trans 38400 35000 262.5 0 325
2.56 32 H110MA golden 153600 130000 332.8 33 300
8.5 8 MI3530 white 42146 42000 357.0 13 350
4.5 32 SRM100NC Trans 138240 117500 528.8 52 500
6.6 6 SRM100NC blue 32400 30000 198.0 6 200
3.6 16 SRM100NC Trans 69120 66500 239.4 22 225
6.8 32 MI3530 golden 98743 64000 435.2 9 250
2 32 SRM100NC tp violet 0 0.0 0 0
6.5 8 SRM100NC Trans 7579 7500 48.8
6.5 8 SRM100NC Trans 25768 25500 165.8 20 0
19 8 MI3530 yellow 0 0 0.0 0 0
golden 40000
Daily Production Report bottling
-
8/22/2019 Saraswati plasto DPR August
118/205
white
white
blue 20000
white
yellow 7150
white
yellow 28200
black 55000
white 10000
po green 10000
l green 10000
po red 15000
co blue 15000
brown 20000Violet 6000
yellow
white 29800
36000
9826
7000
874930 1077756 8766 1501 8275
Qty
a
Received
in Pcs size QTY issued
bayer logo 46.4
bayer logo 29.6
300 plain 19.8
130 camel 22.6
200 ep wad 22.6 110000
mayer
plain 46.4 22100
dupont 19.2
wad 43.4 42600
% of Wastage
% of wastage which
can not used
-
8/22/2019 Saraswati plasto DPR August
119/205
DX excel 46.4
mayer
plain 34.5
board 46.4
dupont 19.2rallis 46.4
bayer logo 26.4
bayer logo 19.8
-
8/22/2019 Saraswati plasto DPR August
120/205
Total
closing
balance
Rejectio
n in pcs
Regrind
generate
d kg
Regrind
/
reproces
s used
Lumps
(Kg)
Plan
Hour
Mold
change
& Other
BD time
Efficean
cy
0 0 300 11.1 11.1 6.8 6 89%
868 19 360 34.56 34.6 4.9 8 10 76%
0 50 5 5.0 3 76%
0 150 14.4 14.4 10 13 90%
1655 36 180 17.28 17.3 6 3 5 94%
0 0 200 3.6 3.6 7.8 24 95%
640 17 170 3.91 3.9 24 95%
883 0 290 88.45 88.5 17.2 24 79%
429 16 271 17.344 17.3 5.9 24 88%
991 24 600 28.8 28.8 14.2 24 69%
513 75 1000 5.5 5.5 2 24 98%
1042 1042 0 0.0 0 #DIV/0!
188 3 340 3.264 3.3 19 5 91%264 12 200 2.1 2.1 24 90%
0 760 1.14 1.1 4 85%
325 10 900 6.75 6.8 8 12 8 91%
333 1 210 0.5376 0.5 24 85%
363 6 80 0.68 0.7 24 100%
552 23 120 0.54 0.5 24 85%
206 8 95 0.627 0.6 24 93%
247 5 120 0.432 0.4 2 24 96%
259 0 340 2.312 180.0 24 65%
0 0 0 0.0 0 #DIV/0!
0 200 1.3 1.3 5 99%
20 0 230 1.495 195.5 17 2 99%
0 0 0 0 0.0 0 #DIV/0!
plant
-
8/22/2019 Saraswati plasto DPR August
121/205
9776 1296 7166 251 623 85
3.8
0.97
-
8/22/2019 Saraswati plasto DPR August
122/205
-
8/22/2019 Saraswati plasto DPR August
123/205
Mold change/Break down
@ 6Am Hydraulic hose pipe burst
startup+ 4 hrs Mold change delay due to no place to keep
finished goods.
color changeover
Mold change & PDN startup
Frequent stopage of M/c due to melt pressre high problem
Day shift Mold cooling problem till 3Pm & Night shift 4 nos. die
pin removed & changes due to leakage of material
M/c stopped
loaded & started
mold change & startup
Fermomatic Eng working on machine
M/c stopped
Insert change & PDN started
M/c stopped
-
8/22/2019 Saraswati plasto DPR August
124/205
-
8/22/2019 Saraswati plasto DPR August
125/205
M/c No. Product Name
Order
Quantity
(In pcs)
Total
Qty.
Produce
d pcs
Balance
d need
to
produce
d (pcs)
cycle
Time
(Sec)
weight
(Grams)
EBM-1
1 ltr Round Bottle (Krishi
Rasayan) 30000 22776 7224 29 96
EBM-2
r co ra o e ono
Layer 58470 26310 32160 27 96
EBM-3 50ml confidor super Bottle 45000 82000 -37000 21 18
100Ml confidor Super Bottle 40000 33000 7000 21 23
EBM-4
5 ltr BASF jery Can (BASF
Panoli) 2500 4454 -1954 48 305
5 ltr BASF Can COEX PAStromp 900 901 -1 48 305
EBM-5
500ml Square Bottle with
View Strip 13000 15600 -2600 24 64
100ml Square Bottle With
View Strip 35000 2880 32120 24 25
EBM-6
Bottle, Logo,HDPE, 0,4L, y,
IN (Anupam) 67638678 60000 87283 -27283 24 48
IBM-1 10ml Fame Bottle 500000 196255 303745 15 5.5
ASB-3
500ml White PET Bottle
(Modern Insecticide) 10000 0 10000 23.5 35.5
IM-1 RD 15 juniar Base 350000 245250 104750 19.5 9.6
50mm Green Planet cap 50000 9000 41000 28 10.5
IM-2 50mm Kr Logo cap 50000 66200 -16200 26 10.5
10ml camel cap black 200000 85000 115000 14 1.5
IM-3 80ml cobra measuring cup 300000 95000 205000 20 7.5
IM-4 22mm Fame cap 500000 640000 -140000 18 2.56
IM-5 46mm Plain white cap 50000 177200 -127200 17 8.5
IM-6 35ml cobra Measuring cup 432000 252500 179500 17 4.5
IM-7 RD Jr Lid 350000 78750 271250 14