Fr. CONCEICAO RODRIGUES COLLEGE OF ENGINEERINGBANDRA, MUMBAI - 50

April - 2014

A presentation on

DESIGN & COSTING IMPROVEMENTS IN OPERATING SYSTEM OF INSPECTION TABLE BY CONVERTING IT FROM PNEUMATIC TO HYDRAULIC SYSTEM

AT

CEAT TYRES LTD.

BY ASHISH SANJAY MENKUDALE(B.E. Production Engineering)

Under the guidance ofProf. Zoya Rizvi (Faculty Guide)

Mr. Pradeep B. Gargote (Company guide)

PROJECT OBJECTIVE

• To overcome all the problems faced by operators handling inspection table.

• To provide the alternative ergonomic solution for existing pneumatic operated system.

• To design the components and the entire assembly of the new system using CAD.

• To increase the operator efficiency by using work measurement.

• To prepare Inspection sheet to ensure working life of system by means of proper maintenance.

• To assess the replacement analysis on the basis of• Depreciation cost• Work measurement• Maintenance cost• Electricity consumption

INSPECTION TABLE

START

Observing the problems occurring in the company and discussing them with the field engineer.

Detecting the problem, discussing with the workers, field engineers.

Study of the existing system which involves analyzing actual site.

Drawing the layout & all views of the system in CAD for ease of work.

Systematic study of each part which includes its functions & efficiency.

Study on the proposed idea i.e. hydraulic system which includes its principles of working, components included in it & its efficiency.

Costing of various engineering drawings.

Comparisons of the drawings whose costing is done analytically with its present price sold by the vendor.

Study of the working of the new system (Hydraulic system)

Costing of the system

Finding vendors from the market who will manufacture these parts in minimum price.

Fabrication or manufacturing of the system.

Installation of the system

Analysis of the system i.e. its’ working after its’ installation.

Annual performance analysis & its comparison with the pneumatic system.

Annual performance analysis & its comparison with the pneumatic system.

Conclusion from the comparison done.

END

Steps involved in project planning

PRACTICAL PROBLEMS - 1/2

• The table is not rotating properly due to jamming ofrollers & excessive wear of rollers.

• There is sudden drop in pressure - constant pressuresupply is not available due to air leakage.

• Compressor efficiency is less & consumption ofelectricity is more than required for operation.

• It is not possible to hold the table at certain height forlong time due to air leakage. It comes downautomatically after some time.

• Due to improper functioning of the system it leads todefects in the tyres.

• Operator fatigue comes into picture & therefore hisefficiency & productivity is reducing.

Actual site location

CAD - Area layout of site location

• System is not compact therefore more space is required.

• If the table falls suddenly it may harm the worker as well as the product.

• Range & capacity of pneumatic system is very less.

• Lubrication does not sustain for longer duration therefore, it should be lubricated frequently.

• Operation is very noisy.

PRACTICAL PROBLEMS - 2/2

PROPOSED SOLUTION

Advantages of Hydraulic operating system over pneumatic:

• Less electricity consumption

• No need of lubricator

• Lower susceptibility towards leakages

• Lesser maintenance

• Lesser load on valves and actuators

• Longer working life of machines

• Ergonomic working conditions

• Compact system

• Most efficient in economic aspect

Hydraulic system overcomes the existing problems in greater extent than any other alternative solution.

Hence it was chosen.

DESIGN OF HYDRAULIC SYSTEM USING CAD

CAD model of hydraulic system assembly – side view CAD model of hydraulic system assembly – top view

STUDY OF PROPOSED SOLUTION

Basic principle of hydraulic system Working of hydraulic system

OIL TANKPUMP

MOTOR

Pressure relief valve

Single acting cylinder

Two way solenoid valve

Pascal’s law

Force Multiplication

Sr. No Hydraulic lifter capacity 1 ton Weight Rate Total

1 Plate 3 Nos = Dia 1200 X Thk 8 mm = Weight 70 Kg X 3 Nos = 210 Kgs 210 50 10,500

2 Bottom Plate = Dia 1200 X Thk 25 mm = 220 Kgs 220 50 11,000

3 Bidding 8 mm Thk. X 40 Width = Wt. = 20 Kgs 20 50 1000

4 Cylinder Dia 200 X length 1500 mm = weight = 367 kgs 367 50 18,350

5 Piston Dia 150 X length 1200 = Weight = 165 Kgs 165 50 8,250

Total weight = 100 Kgs X 50 / Kg = Rs 50,000 982 49,100

Rate M.S. Conversion 1000 Kgs X 100 Rs = Rs 100,000 78,560

6 Dowty pump 3015 Type 6,500

7 Pressure relief valve 1,200

8 Oil Filter 500

9 Breather 200

10 Electric motor 7,500

11 Assembly 2,000

12 Delivery 1,000

13 Erection and commissioning 5,000

14 Training to end users / 3 days 1,500

15 Guarantee & free replacement of parts -

Total cost 1,03,960

Adding variation @ 20% 20,792

COSTING OF HYDRAULIC SYSTEM

Sr. No. FACTORSEXISTING EQUIPMENT

(PNEUMATIC STSYEM)

PROPOSED EQUIPMENT

(HYDRAULIC SYSTEM)

1 COST OF SYSTEM Rs. 1,00,000 (Approx.) Rs. 1,24,752.00

2 OPERATING EXPENSES Rs. 12,000 Rs. 9,600

3 SCRAP VALUE Rs. 1,000 Rs. 1,500

4 INTEREST 10% 10%

5 LIFE OF EQUIPMENT 10 YEAR 20 YEAR

6 DEPRACIATIONRs. 1,00,000 − 1,000 = Rs.

99,000

Rs. 1,24,752 –1,500 = Rs.

123252

7 OPERATING EXPENSES (IN TOTAL SPAN OF LIFE) Rs. 12,000 × 10 = Rs. 1,20,000 Rs. 9,600 ×20 = Rs. 1,92,000

8 INTEREST @10% Rs. 11200 Rs. 13435.2

9 TOTAL LIFE COST OF EQUIPMENT Rs. 2,30,200 Rs. 328687.2

10 AVERAGE COST PER YEAR Rs. 2,30,200/10 = Rs. 23020 Rs. 328687.2/2 = Rs. 16434.36

ASSESSMENT FOR REPLACEMENT ANALYSIS

Sr. No.CUMULATIVE INTEREST

CALCULATIONCOST/YEAR

1 (99000 × 10/100) = Rs. 9900 Rs. 9900

2 (89100 × 10/100) = Rs. 8910 Rs. 8910

3 (80190 × 10/100) = Rs. 8019 Rs. 8019

4 (72171 × 10/100) = Rs. 7217.1 Rs. 7217.1

5 (64953.9 × 10/100) = Rs. 6495.39 Rs. 6495.39

6 (58458.51 × 10/100) = Rs. 5845.85 Rs. 5845.85

7 (52612.66 × 10/100) = Rs. 5261.26 Rs. 5261.26

8 (47351.39 × 10/100) = Rs. 4735.1 Rs. 4735.1

9 (42616.25 × 10/100) = Rs. 4261.625 Rs. 4261.625

10 (38354.63 × 10/100) = Rs.3835.463 Rs.3835.463

TOTAL CUMULATIVE COST OF

SYSTEMRs. 55,571.143

Sr. No.CUMULATIVE INTEREST

CALCULATIONCOST/YEAR

1 (123252 × 10/100) = Rs. 12325.2 Rs. 12325.2

2 (110925.8 × 10/100) = Rs. 11092.58 Rs. 11092.58

3 (99834.12 × 10/100) = Rs. 9983.412 Rs. 9983.412

4 (89850.708 × 10/100) = Rs. 8985.07 Rs. 8985.07

5 (80865.63 × 10/100) = Rs. 8086.563 Rs. 8086.563

6 ( 72779.07 × 10/100) = Rs. 7277.9 Rs. 7277.9

7 (65501.17× 10/100) = Rs.6550.117 Rs. 6550.117

8 (58951.05× 10/100) = Rs.5895.105 Rs. 5895.105

9 (53055.95× 10/100) = Rs.5305.595 Rs.5305.595

10 (47750.35× 10/100) = Rs.4775.035 Rs.4775.035

11 (42975.32× 10/100) = Rs.4297.523 Rs.4297.523

12 (38677.783× 10/100) = Rs.3867.77 Rs.3867.77

13 (34810.01× 10/100) = Rs.3481.001 Rs.3481.001

14 (31329.013× 10/100) = Rs.3132.9 Rs.3132.9

15 (28196.113× 10/100) = Rs.2819.61 Rs.2819.61

16 (25376.5× 10/100) = Rs.2537.65 Rs.2537.65

17 (22838.9× 10/100) = Rs.2283.89 Rs.2283.89

18 (25376.5× 10/100) = Rs.2537.65 2537.65

19 (18499 × 10/100) = Rs. 1849.9 Rs. 1849.9

20 (16649 × 10/100) = Rs. 1664.9 Rs. 1664.9

COST ANALYSIS FOR DEPRICIATION

TIME STUDY FORM

Product: Tyres Time Study Engineer :

Operation No: 1 No. of cycles: 1

Std. Time found: 5 minutes Operation Description: Analysis

Element DescriptionObserved Time (Stop

Watch Reading) (Minute)

Average Observed Time

(Minute)Normal Time (Minute) Allowance (Minute) Standard Time (Minute)

Taking tyre to the work

space table1 1.25 1.5 0.5 1

Inspection and repairing

of tyre4.7 5 4.85 1 4

Keeping the repaired tyre

in the store room1.25 1.625 2 1 1

TIME STUDY FORMAT

TIME DISTRIBUTION FORMAT

Sr. No Work Specification Time (Minute)

1 Taking tyre to the work space table 1

2 Inspection and repairing of tyre 4.7

3 Keeping the repaired tyre in the store room 1.25

Sr. No Work Specification Time (Minute)

1 Taking tyre to the work space table 1

2 Inspection and repairing of tyre 3

3 Keeping the repaired tyre in the store room 1.25

For pneumatic system:

Official working hours = 8 hrs/shift

Actual working hours = 7 hrs/shift

Actual working time (mins) = 7 × 60 = 420mins

Number of Tyres repaired per day = 50-60 tyres

Therefore, we cannot get the actual time spent for onetyre. It depends on the number of defect the tyre is having. Ifthe tyre has many flaws, it will take time to repair, while theone with less flaws will take less time. Therefore, we willconsider approximate time for 1 tyre.

Time required to complete one tyre =420

60= 7 mins

For Hydraulic system:

Official Working hours = 8 hours/shift

Actual working hours = 7 hours//shift

Actual working hours (mins) = 7 × 60 = 420 mins

Number of tyres required per day = 70-80 tyres

Therefore, we cannot get the actual time spent for one tyre.It depends on the number of defect the tyre is having. If the tyrehas many flaws it will take long time to repair, while the one withless flaws will take less time. Therefore, we will considerapproximate time for 1 tyre.

Time required to complete 1 tyre =420

80= 5.25 mins

Operation Performance

=Units of work actually produced by worker

Units of work which could be produced at standard performance

× 100

Suppose 8 hour duty, 30 min required to complete job (standard),

But 7 hours. = 60 jobs possible

P. A.=60

85× 100

= 0.7051 × 100

= 70.51%

Operation Performance

=Units of work actually produced by worker

Units of work which could be produced at standard performance

× 100

Suppose 8 hour duty, 30 min required to complete job (standard),

But 8 hours = 14 jobs possible

P. A.=80

85× 100

= 0.941 × 100

= 94.11%

COMPARISON OF PERFORMANCE ANALYSIS FOR WORKER

COMPANY: CEAT Tyres Ltd. NAME OF THE MACHINE:

RESPONSIBLE PERSON DATE OF INSPECTION:

LOCATION OF UNIT: SIGNATURE OF INSPECTOR:

TYPE OF INSPECTION:

DAILY/MONTHLY/YEARLY CHECK LIST:

SR. NO ITEM CHECK SATISFACTORY UNSATISFACTORY REMARK

1 Oil tank

2 Leak

3 Wear of table bearings

4 Electrical wire carrier

5 Oil filter

6 Dusty environment

7 Motor condition

8 Pump condition

9 Actuation switches

10 Noise level

11 Speed of the system

12 Hydraulic hoses

13Lubrication and wear of moving

parts

INSPECTION SHEET 1/2

SR.

NO.ITEM CHECK SATISFACTORY UNSATISFACTORY REMARK

14Operator remote control devices to check for proper

operation

15 All structure member for damage

16 Any leaks at fittings, seals and between sections

17Hoses and tubes for leakages, abrasions, damage,

blistering

18 Cracking, deteriorating, fittings leakage

19 End limits of extension rods or bars

20 All values like pressure relief valve, non return valve

21 Direction of control valve

Note: all unsafe items shall be repaired or replaced before continuing the use

Is unit ready for use? Yes No

If no time shop notified

Operator/Inspector Signature:

Description on Repairs Performed

Signature: Time:

Operators/Inspectors are required to read and fully understand the operation manual.

This Check List is not intended to replace it.

INSPECTION SHEET 2/2

Sr.

No.Month

Frequency of

maintenanceDetected problem Description of the problem

Repair

costRemark

1 Aug 2012 4 Filter, leakage, valve, wear

Filter-Filter cleans the air supplied which contains

lots of dust therefore it is necessary to clean and

replace the filter periodically,

Leakage-due to the great time elapsed since

installation there is leakage problem in the cylinder

that has to be solved,

Valves- Different valves like pressure relief valve,

non returning valve are not functioning properly.

1000Satisfactorily problem is

solved

2 Sept 2012 3 Filter, Leakage, Noise As explained above 800Satisfactorily problem is

solved

3 Oct 2012 3Filter, Leakage, Electrical connection

problem

Electrical connection problem- there might be same

electrical connection problem800

Satisfactorily problem is

solved

4 Nov 2012 2 Filter, Leakage As explained above 300Satisfactorily problem is

solved

5 Dec 2012 4 Filter, Leakage, Valve, Noise

Noise- Due to the moving parts and decrease in

lubrication there is noise while the system is in

work.

1000Satisfactorily problem is

solved

MAINTENANCE SHEET FOR PNEUMATIC SYSTEM 1/2

Sr.

No.Month

Frequency of

maintenanceDetected problem Description of the problem

Repair

costRemark

6 Jan 2013 3 Filter, Leakage, Wear

Wear- Due to the moving parts and decrease in

lubrication wear occurs between the moving parts

in touch with each other

800Satisfactorily problem is

solved

7 Feb 2013 2 Filter, Leakage As explained above 300Satisfactorily problem is

solved

8 Mar 2013 3Filter, Leakage, Electrical connection

ProblemAs explained above 800

Satisfactorily problem is

solved

9 Apr 2013 4 Filter, Leakage, Valve, Noise As explained above 1000Satisfactorily problem is

solved

10 May 2013 2 Filter, Leakage As explained above 300Satisfactorily problem is

solved

11 Jun 2013 3 Filter, Leakage, Wear As explained above 800Satisfactorily problem is

solved

12 Jul 2013 3 Filter, Leakage, Noise As explained above 800Satisfactorily problem is

solved

TOTAL 36 8700

MAINTENANCE SHEET FOR PNEUMATIC SYSTEM 2/2

Sr.

No.Month

Frequency of

maintenanceDetected problem Description of the problem

Repair

costRemark

1DEC

20132 Lubrication, Filter

Lubrication- since the Hydraulic system works on

oil, it serves the purpose of lubrication as well as

oil supply therefore periodically lubrication is

very much necessary.

Filter- Since the oil might contain dust filtering is

very important and therefore filter should be also

cleaned properly.

200 Satisfactorily problem is solved

2JAN

20142 Lubrication, Filter As explained above 200 Satisfactorily problem is solved

3FEB

20142 Lubrication, Filter As explained above 200 Satisfactorily problem is solved

4MAR

20143

Lubrication, Filter, Oil

Supply

Oil supply- Because of the moving parts moving

continuously some heat is generated and

temperature increases due to this the viscosity of

the oil is decreased therefore it is essential to

supply new oil at regular interval

400 Satisfactorily problem is solved

MAINTENANCE SHEET FOR HYDRAULIC SYSTEM 1/2

Sr.

No.Month

Frequency of

maintenanceDetected problem Description of the problem

Repair

costRemark

5APR

20142 Lubrication, Filter As explained above 1000 Satisfactorily problem is solved

6MAY

20143

Lubrication, Filter, Dusty

Environment

Dusty Environment- since oil is the working fluid in this

system, dust from the surrounding might settle down on

the oil and may enter the system therefore it is required

to take preventive action for it

800 Satisfactorily problem is solved

7JUNE

20142 Lubrication, Filter As explained above 200 Satisfactorily problem is solved

8 Jul 2014 3Lubrication, Filter, Oil

supplyAs explained above 400 Satisfactorily problem is solved

9AUG

20144 Lubrication, Filter As explained above 200 Satisfactorily problem is solved

10 SEP 2014 2 Lubrication, Filter As explained above 200 Satisfactorily problem is solved

11OCT

20143 Lubrication, Filter As explained above 200 Satisfactorily problem is solved

12NOV

20143

Lubrication, Filter, Oil

supply, Dusty EnvironmentAs explained above 600 Satisfactorily problem is solved

TOTAL 30 3300

MAINTENANCE SHEET FOR HYDRAULIC SYSTEM 2/2

COMPARISON OF ELECTRICITY CONSUMPTION 1/2

• For Pneumatic System:

• 1kWh = 1 unit

• Out of this the only time where the electricity is

consumed is the table uplifting and towering. Since in

the existing Pneumatic system, whole inspection and

repairing time.

• Therefore, Actual Electricity Consumption = 2.2 kW × 5

hours = 11 kWhr/ day

• Electricity Consumption for one month (30 days) = 11 ×

30 = 330 kWh/ day = 330 units

• Electricity Tariff Charges = Rs. 9.16 per Kwhr

• Energy cost= 330 units × 9.16 = 3022.8 Rs./Month

• FOR Hydraulic system

• 1kWh = 1 Unit

• In the replaced system i.e. Hydraulic system since there is no

leakage of electricity consumption is low as compared to

pneumatic system

• Therefore, Actual Electricity Consumption= 2.2 kW × 2 hours

= 4.4 Kwhr/Day

• Electricity consumption for one month (30 days) =4.4 × 30 =

132 Kwhr/Day = 132 units

• Electricity Tariff chargers = Rs. 9.16 per Kwhr

• Energy Cost = 132 Units × 9.16 = 1209.12 rupees/month

Sr

No.Month

No Of

Working

Days

Electricity

Consumption

in kWh/day

Electricity

Consumption

Per month

Energy Cost

In Rs(Units x

tariff

charges)

1 JAN 24 11 264 2418.24

2 FEB 23 11 253 2317.48

3 MAR 25 11 275 2519

4 APR 24 11 264 2418.24

5 MAY 25 11 275 2519

6 JUN 26 11 286 2619.76

7 JUL 26 11 286 2619.76

8 AUG 24 11 264 2418.24

9 SEPT 24 11 264 2418.24

10 OCT 23 11 253 2317.48

11 NOV 23 11 253 231.48

12 DEC 25 11 275 2519

TOTAL 292 132 3212 29421.92

Sr

No.Month

No Of

Working

Days

Electricity

Consumption

in kWh/day

Electricity

Consumption

Per month

Energy Cost

In Rs(Units x

tariff

charges)

1 JAN 24 5 120 1099.2

2 FEB 23 5 115 1053.4

3 MAR 25 5 125 1145

4 APR 24 5 120 1099.2

5 MAY 25 5 125 1145

6 JUN 26 5 130 1190.8

7 JUL 26 5 130 1190.8

8 AUG 24 5 120 1099.2

9 SEPT 24 5 120 1099.2

10 OCT 23 5 115 1053.4

11 NOV 23 5 115 1053.4

12 DEC 25 5 125 1145

TOTAL 292 60 1460 13373.6

COMPARISON OF ELECTRICITY CONSUMPTION 2/2

PNEUMATIC SYSTEM HYDRAULIC SYSTEM

Pneumatic System(Existing System) Hydraulic System(Replaced System)

Installation Cost=1,00,000 Installation Cost=1,24,752

Life of System=10Years Life of System=20 Years

Average Cost per Year=Rs 23,020 Average Cost Per Year=Rs 16,434.36

No of Tyres repaired per Day=50-60 No of Tyres repaired per Day=70-80

Working time required = 5mins Working time required = 3mins

Performance analysis = 70.15% Performance analysis = 98.11%

Annual Maintenance cost = 8700 Annual Maintenance cost = 3300

Annual electricity consumption = 3213kW Annual Electricity consumption = 1460kW

Annual Expenditure on Electricity =

Rs 29,421.52

Annual Expenditure on Electricity =

Rs 13,373.6

OVERALL COMPARISON

CONCLUSION

The Operator fatigue is reduced as the operator is provided with more ergonomic conditions. Hence the operator efficiency is increased.

Using CAD, the design of new system is drafted and analyzed.

Through work study, the average time required to inspect each tire is reduced to 3 minutes from 5 minutes.

No of tyres repaired per day is increased from 50 – 60 tyres to 70 – 80 tyres per day.

The maintenance sheet and inspection sheets were drafted for ensuring longer working life of hydraulic system.

Roughly calculated, by replacing pneumatic system by Hydraulic system the annual saving is Rs. 21,448.32 just in terms of Electricity consumption and maintenance.

THANK YOU