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.

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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

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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

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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 .

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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.

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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

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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

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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

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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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