SYNOPSIS

ON

PRODUCTIVITY IMPROVEMENT OF CONVENTIONAL DRILLING MACHINE

FOR B.E. MECHANICAL ENGINEERINGOF

UNIVERSITY OF MUMBAI

PREPARED BYName of the students

HARSHAD V.SURYAWANSHI

Bharati Vidyapeeth College of Engineering,Navi Mumbai- 400 614

Certificate

This is to certify that

HARSHAD V.SURYAWANSHI

Have satisfactorily completed project entitled:

PRODUCTIVITY IMPROVEMENT OF CONVENTIONL

MACHINES (RADIAL DRILLING MACHINE)

In partial fulfillment of the Degree of B. E. in Mechanical

Engineering affiliated to the UNIVERSITY OF MUMBAI for the

academic year 2009-10.

ACKNOWLEDGEMENT

In this partial fulfillment of our project, we present the synopsis of our

project. Sincere appreciation and warmest thanks are extended to the many

individuals who in their own ways have inspired us in the completion of

this project.

This task would not have been possible without the help and guidance

of our esteemed project guide Prof.L.Suryavanshi, without his expert help

and guidance, this project would not have reached this stage. We are

extremely grateful for his friendly support and professionalism.

We are also thankful to our project coordinator Prof.R.K.Agarwal for

his help and guidance.

We express our heartfelt gratitude to our Head of Department

Prof.Jadhav for her help and support.

We extend our thanks to Mechanical Department of B.V.C.O.E for

providing valuable resources needed for our project.

ABSTRACT

In this project we have given the solution for different problems

occurring in radial drilling machine.

The problem such as like because of less speed the time taken for

drilling the hole is more ,chip removal & coolant application time is

more, cutting tool material have less specifications, clamping device is

poor etc.

On this problem solution may be like using specified speed of

machine, using chip breaker tool & automatic coolant flow, improved

cutting tool material with higher specification etc.

INDEX

INTRODUCTION TO COMPANY

INTRODUCTION TO PROJECT

LITERATURE REVIEW

CAUSES & EFFECT ANALYSIS OF LESS

PRODUCTIVITY

METHODOLOGY

ANALYSIS

BIBLIOGRAPHY

CHAPTER 1-

INTRODUCTION

INTRODUCTION TO COMPANY

Godrej is a part and parcel of every Indian’s life. From locks to

personal care. From appliances to air care. From furniture to construction.

There are innumerable ways we enrich quality of life - everyday,

everywhere. Godrej offer an entire spectrum of industrial solutions from

storage to material handling to process equipment and many, many more.

Whether clients are looking for standard equipment or custom engineering

solutions, the first name is Godrej.

The Godrej Group was established in 1897 and has since grown into a

US$1.875 billion conglomerate with a workforce of 18,000. Inseparable

from daily life in India, the Godrej name has been built on a spirit of

innovation that has made it one of the country's most remarkable industrial

corporations.

WORKING DEPARTMENT

Process Equipment Division (ISO 9001)

Heavy Walled Reactors, High Pressure Vessels, High Pressure

Shell and Tube Heat Exchangers, Reactor/Tower Internals and Trays.

The Process Equipment Division (PED) of Godrej is a leader in

fabricating unit static equipment for process industries. Established in

1976, PED manufactures the entire range of process equipment for end-

users in core industry segments like Refineries, Petrochemicals,

Fertilizers, Oil & Gas, Chemicals, Pharmaceuticals and Power around

the world.

Located in the industrial garden township of Vikhroli, a northern

suburb of Mumbai, in India, the lush green Godrej complex and PED's

impressive manufacturing facilities strike the eye.

Product range –    

Heavy Walled Reactors

Equipment Internals

Fractionating / Distillation Columns

High Pressure Shell & Tube Heat Exchangers

Custom built Equipment

The bedrock of PED operations is its large, highly skilled

workforce.

Skilled workmen and trained, competent and highly

committed people have repeatedly been able to channelize the

knowledge and experience that PED has gained over the years,

through its robust systems, to ensure that projects are

successfully executed on time. Through continuous

improvement in quality, a deep commitment to on-time delivery

and a clear policy of keeping in step with the latest

manufacturing technology, PED is

fully equipped to meet the challenging

demands of its global customers for

process equipment.

MACHINE SHOP DEPARTMENT :-

PED has fabrication shops dedicated to manufacturing of

Heavy, Medium & Light equipment, spread across an area of

50,000 m2 (under Cranage). The shops are laid out for

fabricating Process Equipment category-wise i.e. Column,

Pressure Vessels,

Reactors, Heat

Exchangers, Reactor

Internals, Trays & Tower

Internals and Heavy

Equipment. PED

manufactures critical

equipment of:

CHAPTER 2-

INTRODUCTION TO PROJECT

TITLE:-

PRODUCTIVITY IMPROVEMENTS IN CONVENTIONAL

MACHINES (RADIAL DRILLING MACHINE)

RADIAL DRILLING MACHINE:-

Description of machine

It’s a design for operation conveniences and high production in

applied such as drilling, reaming, tapping, countering etc.

Base plate

This is rigid structure on which there columns and sleeve assemble is

fixed this also contain the coolant chamber .three T slot running length

wise facilities fixed of the work piece or auxullatre work table.

Colum and sleeve

The sleeve is suspended top of the truest ball bearing 32 through a

heavy spring table plate 33. It’s a centered by a ball bearing 34 or roller

bearing at the top & specially roller bearing 35 at the bottom .thus the

arm which is mounted on the sleeve swings easily to the light figure

touch the sleeve is also suspected and there will be the clearness of 0.05

mm between the lower annular surface of the sleeve and corresponding

surface of the column in the unlocked condition .the cleanse which has

been adjust screw 36, 37 climbing ring -38 spring plate 33 , eccentric

shaft 39. Ship ring and brush ring is also housed in the top chamber of

the sleeve.

Arm

The liberally proportioned arm of diagonally ribbed box section is

designed for maximum rigid .the climbing machine is amounted at rear

arm .The arm housing which surrounded this mechanism has the oil tank

integral with it.

Drilling head

The drill head balanced on two ball bearing roller 46 runs on a

hundred steel taps stretched on the top guide away of the arm. The

drilling head housed the main drive feed mechanism, main drive control

and drilling spindle, countering balanced mechanism

Main drive

Spindle speed are provided through the selective arrangement of

one three position sliding gear block 47 one mute disc ,double clutch 48,

two spread revisable motor 49,with this arrangement the number of shaft

and gear have been reduces to minimum . The speeds cover most the

operation like drilling reaming and tapping within the capacity of the

m/c .engagement of the clutch is smooth in the both direction and

provide an increase reveres speed for a rapid withdraw of tap while

tapping .the clutch also proceed the machine against over loads

Feed mechanism

The feed drive housed in a separate housing which in turn is

housed in a front of the drill head .6 feed are obtain by a single level.

The warm drive assures uniform drill thrust at the drilling spindle the

feed mechanism is protected from any adverse over load by a spring

loaded safety clutch situated between the feed drive and warm drive. The

feed mechanism offer three type of feeds viz. automatic feed. Fine feed,

by hand and coarse feed is obtained by them.

SPECIFICATION OF RADIAL DRILLING MACHINE:- MACHINE CODE:- RM65

CAPACITY STEEL CAST IRON

Drilling in solid 50 60Drilling in solid with reduced speed & feed

75 85

Tapping (metric fine threads)

56 70

Tapping (with worth) 1.25inches 2.5inches

WORKING RANGE:-ALL IN MM

Max. drilling radius 2350

Min. drilling radius 550

Dia. of sleeve 400

Max. distance (sleeve to spindle) 2150

Min. distance (sleeve to spindle) 350

Spindle traverse 325

Max. distance base plate to spindle 1645

Min. distance base plate to spindle 380

Working surface of base plate(length) 2330

Working surface of base plate (width) 1000

Std. box table 600*500*500

DRILLING SPINDLE:-

Morse taper in spindle nose MT5

Spindle speed 12 no.

Range of speed (standard) 40-1800 rev/min

Range of speed (on request) 50-2240 rev/min

Feeds 6 no.

Range of feeds 0.125-1.25 mm/rev

Max. drilling thrust 1650 kg.

POWER:-

Drilling head motor at 1500/3000 rpm 4.5 kwElevating motor 3 kw

Coolant pump motor 0.11kwApprox. weight of machine 4560 kg.

APPROXIMATE SHIPPING DIAMENSIONS:-Length 3.60 m

Width 1.32 m

Height 3.30 m

T H S R

3065 1016 436 2750

WORKNG AREA:-

Total Quality Management (TQM)

Total quality management (TQM) tools help organizations to

identify, analyze and assess qualitative and quantitative data that is

relevant to their business. These tools can identify procedures, ideas,

statistics, cause and effect concerns and other issues relevant to their

organizations. Each of which can be examined and used to enhance the

effectiveness, efficiency, standardization and overall quality of

procedures, products or work environment.

TQM tools illustrate and aid in the assimilation of complicated

information such as:

TQM Tools

The following are some of the most common TQM tools in use

today. Each is used for, and identifies, specific information in a specific

manner. It should be noted that tools should be used in conjunction with

other tools to understand the full scope of the issue being analyzed or

illustrated. Simply using one tool may inhibit your understanding of the

data provided, or may close you off to further possibilities.

1. Pie Charts and Bar Graphs

Used to identify and compare data units as they relate to one issue or the

whole, such as budgets, vault space available, extent of fonds, etc.

2. Histograms

To illustrate and examine various data element in order to make

decisions regarding them. Effective when comparing statistical survey or

questionnaire results.

3. Pareto Charts / Analysis (designed by Vilfredo Pareto)

Rates issues according to importance and frequency by prioritizing

specific problems or causes in a manner that facilitates problem solving.

Identify groupings of qualitative data, such as most frequent complaint,

most commonly purchased preservation aid, etc. in order to measure

which have priority.

Can be scheduled over selected periods of time to track changes. They

can also be created in retrospect, as a before and after analysis of a

process change.

4. Cause and Effect, Ishikawa or Fishbone Diagrams (designed by

Kauro Ishikawa)

Illustrates multiple levels of potential causes (inputs), and ultimate

effects (outputs), of problems or issues that may arise in the course of

business. May be confusing if too many inputs and outputs are

identified. An alternative would be a tree diagram, which is much easier

to follow.

5. Tree Diagram

To identify the various tasks involved in, and the full scope of, a

project.

To identify hierarchies, whether of personnel, business structure, or

priorities. To identify inputs and outputs of a project, procedure, process,

etc.

6. PDCA

The Plan-Do-Check-Act style of management where each project or

procedure is planned according to needs and outcome, it is then tested,

examined for efficiency and effectiveness, and then acted upon if

anything in the process needs to be altered.

This is a cyclical style to be iterated until the process is perfected.

CHAPTER 3-LITERATURE REVIEW

Drilling

Drilling is the operation of producing circular hole in the work-

piece by using a rotating cutter called DRILL.

The machine used for drilling is called drilling machine.

The drilling operation can also be accomplished in lathe, in which the

drill is held in tailstock and the work is held by the chuck.

The most common drill used is the twist drill.

Types of drilling machine:-

1) Based on construction:

Portable, Sensitive, Radial, up-right, Gang, Multi-spindle

2) Based on Feed:

Hand driven, Power driven

Drill Materials:-

The two most common types are

1. HSS drill

- Low cost

2. Carbide- tipped drills

- High production and in CNC machines

Other types areSolid Carbide drill, Tin coated drills, carbide coated

masonry drills, parabolic drills, split point drill.

Drill fixed to the spindle

Fig. 5 Drill fixed to a spindle

Tool

Nomenclature

The different methods used for holding drill in a drill spindle are

By directly fitting in the spindle hole.

By using drill sleeve

By using drill socket

By using drill chuck

Cutting data

Effects of cutting speed:

• the main factor in determining tool-life

• affects power consumption

Excessive cutting speed can lead to:

• rapid flank wear on drill

• plastic deformation of cutting edges

• poor hole quality

• out of tolerance

Cutting speed too low:

• built-up edge formation on drill

• negatively affect chip evacuation

• poor productivity/high cost per hole

Effects of feed rate:

• decisive for chip formation

• affects power consumption

• contributes to mechanical and thermal stress

High feed rate leads to:

good chip control

less time in cut

less tool wear

higher risk of drill breakage

hole quality can deteriorate

Low feed rate leads to:

longer chips

quality improvement

accelerated tool wear

longer time in cut/higher cost per hole

Importance of chip control:

Poor chip control can lead to unsatisfactory

hole-finishes and possible breakage of the Delta-C drill.

CHAPTER 4-CAUSES & EFFECT ANALYSIS OF LESS

PRODUCTIVITY

Time study on radial drilling machine

JOB DETAILS:-

1. MACHINE NO. :- DR-02

2. NAME OF JOB:- Tube sheet

3. ITEM CODE:- 105

4. PROJECT NO.:-130640

5. JOB-M.S.

6. DIA OF HOLE REQUIRED: - D-54mm

7. SPEED:-45rpm

8. FEED:-0.8mm/min

9. RAW MATERIAL:-Tool- HSS

SR.NO. TIME at am OPERATIONS DETAILS1 10.00-10.57 Idle Clamping of job(setting of job)2 10.58-11.06 Drilling Drilling3 11.06-11.08 Idle No work4 11.08-11.10 Drilling Drilling5 11.10-11.11 Idle Chip removal & using coolant6 11.11-11.14 Drilling Drilling7 11.14-11.15 Idle Chip removal8 11.15-11.20 Drilling Drilling9 11.20-11.21 Idle Chip removal & coolant10 11.21-11.30 Drilling Drilling11 11.31-11.40 Idle Chip removal12 11.40-11.50 Drilling Drilling13 11.51-12.45 Idle Lunch time14 12.45-12.47 Idle Position of tooling15 12.47-01.05 Drilling Drilling16 01.06-01.07 Idle Chip removal & using coolant17 01.08-01.17 Drilling Drilling18 01.17-01.20 Idle Chip removal & using coolant19 01.21-01.31 Drilling Drilling

20 01.31-01.32 Idle Chip removal & using coolant21 01.32-01.44 Drilling Drilling22 01.44-01.46 Idle Chip removal & using coolant23 01.46-01.51 Drilling Drilling24 01.51-01.52 Idle Chip removal & using coolant25 01.52-02.02 Drilling Drilling26 02.02-02.03 Idle Chip removal & using coolant27 02.03-02.15 Drilling Drilling28 02.15-02.17 Idle Chip removal & using coolant29 02.17-02.28 Drilling Drilling30 02.28-02.30 Idle Chip removal & using coolant31 02.30-02.40 Drilling Drilling32 02.40-02.42 Idle Chip removal & using coolant33 02.43-02.56 Drilling Drilling34 02.57-03.00 Idle Chip removal & using coolant35 03.00-03.15 Idle Machine off no work

RESULT:-

1. Idle time: - 162min

2. Working time:- 145min

3. Total time:- 307min

Chip Delay in clamping delay in cooling breaker less specification

Less speed Lack of

overview less feedLack of knowledge

maintenance

CAUSE IMPROVEMENT

METHOD TOOL MATERIAL

MACHINE

MAIN

CAUSE & EFFECT ANALYSIS

CAUSES & EFFECT ANALYSIS OF Radial Drilling

Machine:-

Time taken for manual cooling- workers are using manual

cooling by stopping machine.

Time taken for removing chips from job- chips are getting

around tool so worker used to stop the machine & then removing

chips from tool.

The workers are not using specified speed of machine-to get

smooth finishing & to minimize the wear of the tool.

Tool material is HSS (high speed steel) which have lesser

specification & low qualities-

Clamping system is not proper-taking too much time to set the

job

Worker tendency –using low specification.

CHAPTER 5-

METHODOLOGY

METHODOLOGY:

Various TQM tools are to be used to achieve the objectives by adopting

following procedure,

1. Brainstorm the quality characteristics and design parameters important

to the project or process In radial drilling machine

2. Draw cause and effect diagram for deciding the key factors.

3. Decide various solutions for removing problems.

4. Run confirmation test using the specified conditions.

5. Analyze the results to determine the improved productivity.

6. Conclusions.

Scope of Project:-

Productivity improvement in radial drilling machine gives following

scopes:-

1. It the objectives of owner and workers.

2. It contribute towards increasing production through efficient utilization

of resources and input rather than making workers to work hard.

3. It strives to minimize human hazards and human efforts with the view to

utilize them to those areas where they can contribute maximum to the

output.

4. It results in lower cost per unit by effective utilization of all the

resources and reducing wastage.

CHAPTER 6-

ANALYSIS

SUGGESTIONS

Use chip breaker in tool

Use pump for cooling system

Increase speed of spindle according to specification

Use carbide tool instead of HSS tool

Change the spindle motor for increasing speed

Use new clamping system

Change worker tendency

BIBLIOGRAPHY

WWW.GOOGLE.COM

WWW.WIKIPEDIA.COM

WWW.GODREJ&BOYCE.COM

WWW.HMT.COM

BOOK:- INDUSTRIAL ENGG. &

PRODUCTION MANAGEMENT-

Marten Telsang