About CUMI
The company broke new ground in the manufacture of Coated and Bonded Abrasive in India in addition to the manufacture of Super Refractories, Electro Minerals, Industrial Ceramics and Ceramic Fibres. Today the company's range of over 20,000 different varieties of abrasives, refractory products and electro-minerals is immensely popular among consumers and being manufactured in ten different locations across various parts of the country.
With state-of-the art facilities and strategic alliances with global partners, CUMI has achieved a reputation for unmatched quality and path-breaking innovation. CUMI is one of the five manufacturers in the world with fully integrated operations that include mining, fusioning, wind and hydro power stations, manufacturing, marketing, and distribution.
Objective: To track the FG of coated from RM.
Coated Abrasives
It is mainly used in light polishing applications. Its principal use is in automobiles, white goods, tannery and plywood industries. Other coated products comprise scrubber pads and sandpaper etc.
Present ERP
Presently ERP is done by RAMCO with SQL back end.
Application information.
The customer is looking for the tracking of the Raw material used to finished goods.
The Raw materials are kept in a store in various forms such as Fabric roll, powder (bags), semi solid, solid etc. From the store RM is issued to the kitchen/cooking department, which is automated by M/s Mels automation, Chennai for formulating the coating compound.
Mels have an independent system which works on PLC. This is not connected to the CUMI ERP.
Kitchen
Batch: Each batch will have different ingredient mixed in the kettle poured manually, or automatically by hopper.
They have various type of material feeding to the kettle in the kitchen. There are 7 silos hanging on the mezzanine for bulk volume raw materials, which feeds the kettle through a hopper, which is having load cells fixed and recorded in the kitchen PC.
Also there are around 20 bins, which are controlled again by PLC, which will allow the operator to carry small quantities of raw material. The bins are accessible by automatic doors, which are activated by the PLC as per the sequence of the particular batch. These raw materials are poured in to the kettle manually. After weighing these, the weights are also stored in the PLC.
After cooking, the kettle will go to the coating area where the uncoated fabric will be printed with a cylindrical print block. After printing, it will go through a process where the mixed compound is coated to the fabric (this process is conducted at temperatures as high as 1000 degrees and the entire area is fully enclosed). Then the coated fabric comes out for re-winding after cooling down process. Now, the fabric rolls are coated and called Jumbo’s.
JUMBO’s and Conversion
- These jumbo rolls are stored in the next shed where it is stored in RACKS.
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And then issued to the conversion department which is in the same shed. These Jumbo’s are then converted to either sheets, belts, rolls, die cuts (round) etc.
Every product is attached with a code number with the help of which it is traceable to the batch it belongs.
All these FG’s are then packed in carton boxes.
Solution proposed
IN REVERSE- FROM FG TO RM
The FG boxes need to be labelled with the JUMBO code no. The jumbo code will help in tracing the product to the particular batch it belongs.
The batch code no. has been attached on to the core of JUMBO.
The batch code has to be generated after the recipe is ready at the kitchen (generated by MELS). The M/s Mels PLC will be having the ingredient list and actual quantity to be mixed in the batch.
The Raw material should be bar-coded at the time of receipts so that those codes are used to pick the material from store to issue to the kitchen.
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