A STUDY ON MATERIAL HANDLING AT TUBE PRODUCTS OF INDIA(TPI)

ARUN S 310011631007

INTRODUCTION
Materials handling is the art and science involving the moving, packaging and storing of substances in any form. Materials handling uses different equipment and

mechanisms called Materials Handling Equipment.

The foremost importance of materials handling is that it helps productivity and thereby increases profitability of an industry

OBJECTIVES
To oversee the overall material handling process in the

company
To determine the internal material handling and

thereby evaluate the flow in manufacture of strips

To analyze internal customers satisfaction levels relative to the existing system

NEED OF THE STUDY

To reduce overall cost by improving materials handling.

To reduce damage of materials during storage and

movement

To increase efficiency and sale ability of plant and equipment with integral materials handling features

To know about the internal customers satisfaction level after implementing changes in the material handling process

METHODOLOGY
SAMPLING DESIGN: Convenient sampling method has been adopted. SAMPLE SIZE: A sample of 200 employees were chosen for the study , the

people directly involved with the daily flow of materials

SOURCES OF DATA: The source of data collection was primary source. The

information required was collected from employees through

questionnaire. Secondary source like company records of employee was also used.

Tools used for Analysis

The following tests were used after data collection

Percentage analysis

Chi square
T-test Regression

Data Analysis and Interpretation

PERCENTAGE ANALYSIS:

Table showing age of respondents:

Chart showing age of respondents

52% of employees constitute the younger generation , 34% of the age between 30-40 yrs which is the productive age of persons life time, 10% of the age between 40-50 yrs and remaining 4% of the age above 50 years.

Table showing education of respondents

Chart showing education of respondents :

36% of the employees have finished diploma, 22% of the employees have finished school, 18% have finished graduation, 14% were professional and remaining 10% have finished their post graduation

Table showing experience of respondents

Chart showing experience of respondents

Nearly 50% of the respondents have an working experience from 0- 5 yrs., 30% of the respondents have an working experience between 6-10 yrs ,15% respondents have an working experience between 11-15 yrs and remaining 2.5% between 16-20 yrs and above 20 years with 2.5% respondents

Table showing marital status of respondents

Chart showing marital status of respondents

51% of respondents were single and remaining 48 % were married

Table showing monthly income of respondents

Chart showing monthly income of respondents

82% of the respondents earn between Rs.25000-50000 per month, 28% earn between Rs.50000-Rs.75000 per month, 8% earn between Rs.75000-Rs.100000 per month

CHI SQUARE

From the cross tabulation it is inferred that the maximum respondents agree that the cost of operations towards mechanical shutdown is relatively low.

Chi-Square Test between evaluate cost of operations and occurrence of mechanical shutdown :

Therefore according to Chi-Square Test there is an association between the evaluation of cost of operations and the occurrence of mechanical shutdown.

Table showing cross tabulation between evaluate cost of operations and occurrence of electrical shutdown:

From the cross tabulation it is inferred that the maximum respondents agree that the cost of operations towards electrical shutdown is relatively low.

Chi-Square Test between evaluate cost of operations and occurrence of electrical shutdown :

Therefore according to Chi-Square Test there is an association between the evaluation of cost of operations and the occurrence of electrical shutdown.

T-test:
Table showing t- test between the safety and the marital status:

Therefore according to t-test there is a significant difference between safety and marital status of the respondents

REGRESSION
Variables Considered For Regression Test

ANOVA between Independent And Dependent Variables :

The significance value is 0.042 and it shows that there is a very good level of significance at 4 degrees of freedom.

Regression Model Summary:

Dependent R square value is 49.4% it shows that the independent factor is influenced by 49.4% to the factor

Regression Coefficients

Level of satisfaction (Y): The overall assessment of material handling process is the dependent variable. The independent variables that are considered as the features that lead to the assessment of material handling process are cost (X1), safety(X2), reliability (X3), agility(X4)

Current State Mapping

Supplier

Weekly

Production Control

Weekly

Customer

Weekly

Supervisor
Daily Daily

Daily
Pickling Initial Slitting
I

Cold Rolling
I

Annealing
I

Final Slitting
I

5
CT = 60 sec C/0 = 10min

7
CT = 40sec C/0 = 45min Up T = 60%

3
CT = 60sec C/0 = 10min Up T = 100%

9
CT = 60sec C/0 = 2hrs

7
CT = 40sec
C/0 = 0 Up T = 60%

Shipping
I

Up T = 85%

Up T =100%

20 sec

40sec

60sec

60 sec

40sec

Process Time Line

Value-Added Time =

260 Seconds

FINDINGS
52% of the respondents ages are between 20-30 yrs 36% of the respondents have finished diploma

Nearly 50% of the respondents have an working experience

between 0- 5 yrs 51% of respondents are single Value added time is 260 seconds 82% of the respondents earn month The independent dependent factor. factor is influenced by 49.4% to the between Rs.25000-50000 per

 There is an association between the evaluation of cost of

operations and the occurrence of mechanical shutdown.

There is an association between the evaluation of cost of operations and the occurrence of electrical shutdown.

There is an

significant difference between safety and

marital status of the respondents

SUGGESTIONS
Employees feel that maintenance of the equipment should be improved so that breakdown of equipments can be reduced A separate team should be formed for material handling in order to get new ideas and improve material handling Operators should be trained how to handle the equipments with standard procedures

CONCLUSION

For selection of suitable material handling system the dominant factors considered were characteristics of the product, conveying speed ,cost , distance movements , load flexibility , physical shape of the product , and volume to be

moved .
Because of failures in service and low speed in material transport, the company was motivated to innovate internal processes that could increase the efficiency of services to manufacturing.