Post on 12-Apr-2017
1Guided by:(COLLEGE) Guided By:(INDUSTRY) By:
Dr.S.Sampathkumar, Mr.T.Sowrirajan , V.Vignesh(2012250023) Professor, Senior manager, Manufacturing, M.E.MSMCentral Workshop Division, Tractor Wheel Division IIIRD SEMESTERDepartment of Mechanical Engineering,CEG 03/05/2023
IMPROVING THE PRODUCTIVITY OF EXISTING DISC LINE THROUGH KAIZENS
(PHASE-II)
A LIVE INDUSTRIAL PROJECT DONE AT WHEELS INDIA LIMITED-PADI
2 OBJECTIVE
This project mainly focusses on increasing the productivity of disc produced for tractor wheel section.
It is aimed to improve the production rate to a considerable amount at a low cost ,such that the demand is met.
The project deals with the implementation of KAIZENS within the layout (DISC Section of TRACTOR Wheel division) consisting of various machining processes, so as to improve the productivity.
03/05/2023
WORK DONE DURING PHASE I
Studied the existing layout. Identified the problem. Conducted time study. Analysed present cycle time using Time study. Calculated target cycle time. Identified no of areas for scope of improvement =14. Categorised Kaizens according to the priority level. Conducted brain storming sessions. Found the conceptual ideas for higher priority Kaizens. Evaluated each conceptual idea.
PHASE II WORK METHODOLOGY
Selected Concept through qualitative analysis Design of the selected concept Part and Assembly drawing Fabrication Installation Feedback Conclusion
FOR ALL KAIZENS K.H.1-K.H.5
CHART REPRESENTING THE OPERATION TIME AT EACH STATION
Reaming Boring Chamfering De burring Marking Inspection Despatching0
10
20
30
40
50
60
70 PRESENT CYCLE TIME =64sec
TARGET CYCLE TIME =41sec
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6
AREAS FOR SCOPE OF IMPROVEMENT
S.NO TASK ID ACTIVITY KAIZEN NEEDED
KAIZEN NUMBER
01 A.2 Pushing the disc from lifter to the machine
Y K.L.1
02 A.3 Upstroke of the fixture Y* K.H.1
03 A.5 Down stroke of fixture Y* K.H.1
04 A.6Cleaning of scrap on the disc
Y * K.H.2
05 B.2 Boring Operation Y* K.H.3
06 B.4 Cleaning of scrap Y K.L.2
Y*-HIGHER LEVEL PRIORTY KAIZENY- LOWER PRIORITY KAIZEN
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7S.NO TASK ID ACTIVITY KAIZEN
NEEDEDKAIZEN NUMBER
07 C.5Waits for the lifter to get free
Y K.L.3
08 C.8 Cleans the machine Y K.L.4
09 D.2Removal of Burrs (inside)
Y* K.H.4
10 D.4Removal of burrs (outside)
Y* K.H.4
11 E.1Stands and pulls the disc onto the machine
Y* K.H.5
12 E.2Sets the disc onto the machine
Y* K.H.5
13 E.7
Applying non corrosive resistant onto the disc
Y* K.H.5
14 E.8
Pushes the disc to next station
Y* K.H.5
Y*-HIGHER LEVEL PRIORTY KAIZENY- LOWER PRIORITY KAIZEN
8
CONCEPTUAL IDEAS FOR KAIZEN K.H.1-REAMING STATION
03/05/2023
POSSIBLE IDEAS FOR KAIZEN K.H.1
Decreasing the bore
diameter of the
cylinder
Decreasing the stroke length of
the cylinder
Decreasing the weight
of the fixture
Fig 3.Reaming station
SELECTED CONCEPT FOR KAIZEN K.H.1 Decreasing the Bore Diameter of the
Cylinder: Earlier the weight of the disc was 55kg(max),so higher bore diameter
was needed to lift the higher load. But now the disc weight is 34kg(max),so cylinder of relatively lesser
bore diameter is feasible to be replaced. A lesser bore diameter cylinder can traverse the load with faster rate. So we can expect time saved by 6 seconds at least. Existing borediamter of the cylinder=160mm.
CYLINDER SPECIFICATION
S.NO CATEGORY DATA01 MAKE FESTO
02 BORE DIAMETER 8003 TYPE DNC04 STROKE LENGTH 150mm05 STROKE TYPE BOTH FORWARD AND REVERSE06 SPECIAL THREAD ON
PISTONYES (PLUS A FEMALE THREAD)
RESULTS
ACTIVITY NO
ACTIVITY NAME TIMING (BEFORE)Sec
TIMING (AFTER)Sec
A.3 Upstroke Of the Fixture 9 5
A.4 Reaming Process 12 12
A.5 Downstroke of the Fixture 7 4
TOTAL 28 21
TOTAL TIME SAVED=7 SEC
COST ANALYSIS
Cost of the cylinder = Rs 70,000 Cost of labour involved = Rs 500 * 7 = Rs 3500 Cost of forklift used = Rs 750
----------------- TOTAL COST = Rs 74,250 -----------------
13
KAIZEN NUMBER– K.H.5AUTOMATED MATERIAL HANDLING SYSYTEM
AT MARKING STATION
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14
03/05/2023
TASK ID
ELEMENT NAME VA/NVA BASIC TIME
E.1Stands and pulls the disc onto the machine
NVA 5.2
E.2 Sets the disc onto the machine
NVA(PT) 3.5
E.3 Down stroke of the machine NVA(PT) 2.9
E.4 Marking operation (machining) VA 17.6
E.5 Upstroke of the machine NVA(PT) 2
E.6 Lifting of the disc NVA(PT) 2
E.7Applying non corrosive resistant onto the disc NVA 12.5
E.8 Pushes the disc to next station NVA(PT) 2.2
ELEMENTAL TIME AT MARKING STATION
15 CONCEPTUAL IDEA FOR KAIZEN AT MARKING STATION
This station constites more proportion of non value adding activity due to present technology.
They are very tough to remove separately as one activity links to the other.
The company feels the use of labor force to such a simple activity is not cost effective.
IDEA Automating the entire marking station .
03/05/2023
CORE OBJECTIVES OF THE NEW MACHINE
There are six core objectives of the new machine. Those are: Marking of wheels India logo and the part number on the corresponding
disc. Elimination of human work on the marking workstation. Flexible to mark both inside and outside of the part, as accordingly. Reducing the non-value adding activity at the workstation. Reducing the overall labor cost involved in the tractor disc line. Keeping the payback period to the minimum
WHY SIMPLE AUTOMATION??
Cost of variable labour cost increasing day by day. Scarcity of labour availability. Other overheads pertaining to the labour. Savings made from automating the process is high. Pay back period is minimum for simple automation.
OLD SETUP OF THE MARKING STATION
A roller conveyor is used to transmit the disc from De burring station to the marking station.
ROLLER CONVEYOR LIFTER
MARKING TABLE
IDEA GENERATED
A simple idea of replacing the present roller drive mechanism to the chain drive was generated.
A total number of fixtures was increased to 5 (3 on the top and 2 on the bottom),such that 3 disc are on the machine at the same time.
A central control panel is made to control the entire automation unit of the machine (PLANNED BY ELECTRICAL DEPARTMENT).
An automatic lifter was planned to position the disc on the de burring machine.
DETAILS OF CHAIN DRIVE S.NO
DATAS
VALUES
01
Type of Chain
Bush Roller Chains
02
Material
Alloy steel
03
Lubrication
Grease
04
No of Teeth on Chain Sprocket
40
05
Designed Power
2.10 Kw
06
Pitch
15.875mm
07
Roller Dia
10.16mm
08
ISO Standard
10B
09
Breaking Load
22.2KN
10
Load on Chain
950N
11
No of Chain Links
140
OVERALL MACHINE SPECIFICATION
S.NO DATAS VALUES
1 Length 1850mm
2 Width 510mm
3 Height 840mm
4 Distance between Pedestals 800 mm
5 No of Pedestals 5
6 Type of Drive Chain
7 No of Chains 2
8 No of Sprockets 4
9 Distance between sprockets 1600mm
10 No of Supporting Column 2
IMAGE OF THE NEW MACHINE
CHAIN
FIXTURES (5NOS)
STOPPER BLOCK
DISC
SUPPORTING COLUMN
CHAIN SPROCKET =4 NOS
COMPARISON OF PRODUCTION ANALYSIS BEFORE AND AFTER IMPLEMENTATION OF MARKING MACHINE
Avg.Prod Rate (Rp*) = 60/Tp*
= (60/0.85)
Rp* = 70discs/hr (9)
Rp* = 70 * 8
Rp *= 560 discs/shift (10)
DIFFERENCE IN PRODUCTION LEVEL
Rp*-Rp=560-424
= 136 discs/shift
ACTUAL COST FOR INSTALLING NEW MARKING MACHINE
Cost of the new machine = Rs 7,10,000 (CONTRACT MTM)
Cost of lifter assy = Rs 10,000
Cost of forklift used = Rs 1,500
Cost of labour involved = Rs 14*500
= Rs 7,000 per shift
Number of Shift = 2 Total cost of Labour = Rs 14,000
-----------------
TOTAL COST = Rs 7, 35,500 (A)
-----------------
ACTUAL SAVINGS ASSOCIATED AFTER INSTALLING NEW MACHINE
Annual Labour cost = Rs 2, 50,000 P.a for one labour.
Number of labour work saved = 2 ( One labour each shift)
Total Annual Labour cost Saved = Rs 5,00,000 P.a (B)
PAY BACK ANALYSIS
Pay Back Period = (Initial Investment of the machine)
-------------------------------------------
(Annual Savings)
Payback Period = (Rs 7, 35,500)/ (Rs 5, 00,000)
= 1.471 Years
= 1 Year 6 months.
Thus the new marking machine has a Payback Period of 1 Year and 6 months.
05/03/2023
27DE BURRING OERATION This operation is done to
remove burrs that are stucked on the outside portion of the holes.
It helps in producing a better surface finish.
The specification of wheel presently is:
MAKE PROFORMERGRIT SIZE 80MAX RPM 15280SPEED OF REMOVAL 80
28
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QUALITATIVE RATINGS FOR THE ALTERNATIVESIDEA
NOIDEA COS
TTIME
EASE OF CHANGE
LEVEL OF IMPROVEMENT
K.H.4.1 Changing the grit size 4 4 4 12
K.H.4.2 Increasing the wheel diameter
3 3 3 9
K.H.4.3 Changing the wheel material
2 3 4 9
K.H.4.4
Increasing the no of spindles
4 4 4 12
K.H.4.5 Automating the process
2 2 2 6
RATINGS DONE FROM 1 TO 5 SCALE…
1>>>POOR SOLUTION5>>>BEST SOLUTION
FEATURES OF MULTIHEAD SPINDLE By using the multihead de burring head, the productivity is improved. Time for one hole deburring is the time for multiple hole deburring. Multi spindle can be a fixed centre for construction and for batch
production.
MASTER GEAR
SUPPORTING COLUMN
MULTI DEBURRING HEAD
PARTS IN MULTI HEAD DEBURRING MACHINE
DRIVE MOTOR
MASTER GEAR
SUPPORTING COLUMN
MULTI DEBURRING HEAD
SPECIFICATION OF MULTIHEAD DEBURRING MACHINE
S.NO CRITERIA VALUES
01 NO of Spindles 3
02 Indexing Yes03 Pitch 160mm04 Length of column 1850mm05 Width of the base 1675mm06 No of Supporting Gear 407 Maximum Speed of Spindle
rotation450rpm
08 Name of the Supplier Tool Tek Special Machines-Pune09 Warranty 12months
05/03/2023
32BORING OPERATION Boring is the machining
process, where internal surface of revolution are created by single point cutting tool.
In here, the central hole is bored.
The hole is enlarged by 10 % of the blanked size.
In order to achieve greater accuracy ,this operation is done.
In some disc, its done as there is a non availability of drill bits on a standard scale.
Hole to be bored
33 CONCEPTUAL IDEAS FOR KAIZEN 3(K.H.3) FOR ACTIVITY(B.2) AT BORING STATION
At present the cutting tool is Carbide steel material. Speed ,Feed, Depth of cut are varied according to the disc variety. A hydraulic cylinder helps in actuating the cutting tool up and down. .IDEAS GAINED FROM BRAIN STORMINGK.H.3.1Increasing the hydraulic fluid pressure from 4 bar to 5bar.K.H.3.2 Changing the essential parameters for MRR (Speed,Feed,Depth of cut).K.H.3.3Changing the tool material.K.H.3.4Reducing the percentage of enlargement from forming.
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POSSIBLE IDEAS FOR KAIZEN K.H.3
Reducing the
enlargement
percentage
Changing the
parameters of MRR
Increasing the
pressure
Changing the tool material
BRANCH OF IDEAS FOR KAIZEN K.H.3
35
03/05/2023
IDEA NO
IDEA COST
TIME EASE OF CHANGE
LEVEL OF IMPROVEMENT
K.H.3.1 Changing the parameters of MRR
4 4 4 12
K.H.3.2 Changing the tool material
2 4 4 10
K.H.3.3 Reducing the enlargement percentage
2 2 2 6
K.H.3.4 Increasing the pressure
3 4 4 11
QUALITATIVE RATINGS FOR THE ALTERNATIVES
RATINGS DONE FROM 1 TO 5 SCALE…
1>>>POOR SOLUTION5>>>BEST SOLUTION
1. Speed = 200rpm
2. Feed =0.09mm/rev
3. Depth of Cut =0.2mm
PRESENT INPUT PARAMETERS
COMPARISON RESULTS –PRODUCTION LINE CHARACTERSTICS—BEFORE AND AFTER KAIZEN IMPLEMENTATION
S.NO CRITERIA BEFORE ESTIMATED AFTER
01 Batch Processing Time
360mins 225mins 255mins
02 Average Production Time
1.2Mins/Disc 0.75Mins/Disc 0.85Mins/Disc
03 Average Production Rate
50Disc/Hr 80Disc/Hr 70Disc/Hr
04 Production Level 400Discs/Shift 650Disc/Shift 560Disc/Hr
05 Cycle Time 1.05Mins/Disc 0.36Mins/Disc 0.7Mins/Disc
06 No of labours Involved
07 05 06
07 No of station 07 07 07
08 No of automated Station
0 02 01
09 No of Manual Station 07 05 06
10 Labour cost Involved Rs 35,00,000 Rs 25,00,000 Rs 30,00,000
11 Annual Production Level
2,17,200 3,60,000 2,80,000
PRODUCTION LINE CHARACTERSTICS BEFORE, ESTIMATED AND AFTER KAIZENS
SUMMARY –PHASE 2 WORK
1. Selected Concept through qualitative analysis
2. Designed the selected concept
3. Part and Assembly drawing drawn
4. Fabricated or Purchased
5. Installed
6. Feedback
7. Conclusion
PHASE 2 WORK
FUTURE SCOPE OF WORK
1. Installation of Multihead deburring spindle for the KAIZEN K.H.4.
2. Studying of Results for the Kaizen K.H.4.
3. Feedback for the Kaizen K.H.4.
4. Performing the experiments for various input parameters (Speed, Feed, and
Depth of Cut) for increasing MRR for Boring operation (KAIZEN K.H.3).
5. Performing Design of experiments to find the optimized MRR.
6. Changing the existing parameters to the optimised input parameters found
through DOE.
7. Studying the results and feedback for KAIZEN K.H.3.
8. Increasing the velocity of the cutting fluid.
9. Solving Lower Priority Kaizens one by one.
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