Presented By - Rohit.R.Ranpise

Company Name - Kirloskar Oil Engines

Renovation of the existing assembly lines

To design an efficient Layout

To create conducive work Environment

To calculate the time required for various steps

which leads to the complete manufacturing of

the engine on the assembly line

The time calculated by using this process will be used to study and implement various methods to optimize and increase productivity and conversion costs respectively

Product Information

Engine Model HA R-1080 SL90

No. Of Cylender

2,3,4,6 2,3,4,6 6

WORK CONTENT EVALUATION & LINE BALANCING

WORK CONTENT EVALUATION & LINE BALANCING

WORK CONTENT EVALUATIONWORK CONTENT EVALUATION LINE BALANCINGLINE BALANCING

Enlist all the activities carried out on the Assembly Line

Identify the waste activity

Eliminate the waste activity

Reduction in work content

Enlist all the activities carried out on the Assembly Line

Identify the waste activity

Eliminate the waste activity

Reduction in work content

Everyone is doing the same amount of work

Variation is ‘smoothed’

No one overburdened

No one waiting

Everyone is doing the same amount of work

Variation is ‘smoothed’

No one overburdened

No one waiting

Number of activities are carried out

CLYLINDER HEAD FITMENT PIPE FITMENT

ALTERNATOR FITMENT

Introduction:Initially in the first week I was shown around the assembly lines, store, testing, packing areas.

Video shooting: Started with the Video Shooting of Assembly lines of SL-90, 4R-1080, 6R-1080, HA-6 and Later RA.

After Shooting the videos were loaded on the Desktop.

Stage wise break up of videosThe videos were stage wise broken up and labeled

accordingly. Video Analysis

The video analysis of the videos taken were done. Detail Break up of each Activity was done. The time required for each activity involved were listed according to the videos. The start and end time for each step of a particular activity, the manpower involved in itSTATION

NUMBERSERIAL NUMBER

ACTIVITYTIME

MANPOWER(PER STATION)

ORIENTATION

( SIDE UP )

OPERATION ON FACE

TOOL USED

START END

Identifying & Eliminating Non-Valuable Activity

Briefing of each activityThis Analysis was then briefed into the time taken for

each activity neglecting the non valuable activity.

Targeted dataData for the number of stations planned and number of

engines targeted was taken.

Existing Assembly Line Layout

Total Time = 144 min

Station Number

Operations Work Force Cycle Time(sec)

1 Crankcase plugging 1 0:07:13 2 Crankshaft fitment 2 0:15:44 3 Crankcase loading 1 0:04:31 4 Header, Lubrication Oil Pump assembly 2 0:06:39 5 Connecting Rod assembly 2 0:06:56 6 Bell housing & Flywheel assembly 2 0:09:54 7 Gear casing assembly 1 0:15:57 8 Lube. Oil Sump assembly 2 0:07:12 9 Fuel timing and alternator mounting 2 0:21:21 10 Engine unloading 1 0:06:14 11 Cylinder head fitment 2 0:09:52 12 Tappet and pipes fitment 2 0:15:04 13 Turbo accessories fitment 2 0:15:55 14 Leak testing - 0:01:31 15 Turbo completion - 0:07:13 16 Special engine completion 1 0:15:44

Total 23 144 min

Station No.16

Station No. 5

Number 5

Nu

Station No. 6

Station No. 7

Station No. 8

Station No . 9

Station No. 10

Station No.11

Station No.12

Station No.13

Station No.14

Station No.15

Station No.1

Station No.4

Station No.3

Station No.2

Everyone is doing the same amount of work

Doing the same amount of work to customer requirement

No one overburdened No one waiting Everyone working together in a

BALANCED fashion Variation is ‘smoothed’

Unbalanced Assembly Line

Unbalanced Assembly Line

Balanced Assembly Line

Balanced Assembly Line

The line balancing was done for each Assembly

lines

( 6R, SL-90, HA-6 ) according to the data given.

Change of Stations when orientation change,

clubbing of activities which can be carried on

the same side and which doesn’t depend on

other activities were done

For HA 6 Engine

Targeted Engines per shift = 10

Working hours per shift = 460 minutes

Efficiency = 90%

Effective Working Hours = 414 minutes

TAC time = 41 minutes 24 seconds

Time taken for the entire engine to be assembled = 2 hours 17

minutes 46 seconds.

After balancing of the line, the time required for one engine to

be completed is 1 hour 56 minutes 18 seconds.

For 6R 1080 Engine

Targeted Engines per shift = 20

Working hours per shift = 460 minutes

Efficiency = 90%

Effective Working Hours = 414 minutes

TAC time = 21 minutes 10 seconds

Time taken for the entire engine to be assembled = 2 hours

24 minutes 03 seconds.

After balancing of the line, the time required for one engine

to be completed is 1 hour 38 minutes 3 seconds.

For SL90 Engines

Targeted Engines per shift = 10

Working hours per shift = 460 minutes

Efficiency = 90%

Effective Working Hours = 414 minutes

TAC time = 41 minutes 24 seconds

Time taken for the entire engine to be assembled = 2

hours 44 minutes 10 seconds.

After balancing of the line, the time required for one engine

to be completed is 2 hour 09 minutes 29 seconds.

Proposed Assembly Line Layout

Total Time = 98 min

FLOW

Station Number

Operations Work Force Cycle Time(sec)

1 Core Plugging & Camshaft assembly 1 0:21:00 2 Loading, Deflector, LOP, Bell Hsg,

Flywheel ass. Con rod ,Header 2 0:20:32

3 Cam bush, Gear Casing, Tappet, Gear fitment, Cam shaft ,Crank pulley ,

2 0:18:53

4 Fuel Timing ,Alternator, Belt, Fuel Filter 2 0:11:04 5 Engine Unloading, Starter, Pipe fitment,

Push Rods, Rocker lever, Tappet Setting. 2 0:16:23

6 Rocker cover, Pulley and Belt fitment, Turbo pipes fitment, Turbo accessories fitment.

2 0:11:00

Total 11 98 min

Station No .1 Station No. 2 Station No. 3 Station No. 4 Station No. 5 Station No.6

Engine ModelRA

EnginesHA

EnginesSL90

Engines       

Present Work Force

23 15 11

Proposed Work Force

11 12 7

Reduction In Work Force

12 3 4

Percentage Reduction In Work Force

52.2% 20.0% 36.4%

Total Work Force Reduction 19

Reduction in the Work Force

Initially some of the stations were overloaded

High WIP

Excess workforce were allocated than required

Lot of engines were accumulated after station 2

Sharing of equipment increased the assembly

time

Work content was reduced

Assembly time was reduced

Line Imbalance was reduced

Optimum work force was calculated

Productivity will increase

THANK YOU