welcome to bosch presentation · project overview productivity improvement in crp housing define...
TRANSCRIPT
Welcome to
BOSCH Presentation 1
Team Members : Product Development - Ms. Akansha Chauhan
Process Development - Mr. Naveen Reddy
Manufacturing - Mr. Mohan K V
Engineering - Mr. Gopinath/Mr. Sunil Kumar
Quality - Mr. John Victor
Strategic Partner - Mr. Ramsharan
Profile
Innovative approach using mould flow analysis for productivity improvement
In Common Rail Fuel Injection Pump Housings
Team Leader : Mr. Palanivel V
Video
Products at Bidadi Plant
Inline Pumps Single cylinder Pumps Common Rail Pumps
Common Rail Fuel Injection Pumps
Passenger Cars
Light Commercial Vehicles
Project Overview
ControlImproveAnalyzeMeasureDefine
Productivity Improvement in CRP Housing
MAT cost reduction 7.45 MINR
Tool cost reduction 2.70 MINR
Output Increase 6795 Housings
Total cost savings 16.75 MINR
Challenges:
Pilot Batch manufacturing
“Q” Validation and approval
More material machined in
radial machining (OP20) on G320.
Generating high axial load to remove more
material stock
Vital cause for down time - Frequent alarm in
“A” Axis clamping tolerance
Leads to reduced output/high tool cost
Output Increase by 10%
MAE availability increase by 7%
Core hole in casting stage
Material weight reduction by 15%
Pre SC drill elimination in OP20
Initial Situation Manufacturing Feasibility : Core hole in casting stage
Target State Benefits & challenges Time Line
Functional Analysis
T9033 + T9435
Dia 20/21.5 drill
Phase 1
Phase 2
Phase 3
Pattern Ram/Swing check
Simulation check
Mould Flow AnalysisStep 2
Step 1 Centre axis offset by 1.5 mm
After Core longitudinal shift
(Import substitution avoidance 6.60 Mio INR)
(Recurring)
Start : 20.03.2017
Pilot Batch : 12.08.2017
‘Q” Validation : 03.09.2017
Bulk Trial : 21.11.2017
Approval &
Implementation : 14.01.2018
A B
A B
Housing Manufacturing Process Flow
Axial
Machining
Radial
Machining
Robotic
DeburringPre cleaning
Thermal
Deburring
Final
cleaning
Endoscopic
Inspection
Visual
Inspection
Finished Housing
Casting
High Speed HMC
Twin Spindle
17 Axes machine
90 bar coolant pressure
Modular Machining
ControlImproveAnalyzeMeasureDefine
5
Video
Productivity Improvement in CRP Housing
6
ControlImproveAnalyzeMeasureDefine
Cycle
Tim
e [
s]
Problem :
Delivery Takt > Customer Takt
Customer Takt = 39.5 secs
Delivery Takt = 44.8 secs
Line Takt = 39 secs
Productivity Improvement in CRP Housing
Need for Improvement
Technical Loss OEE trend chart
High Technical Loss - Avg. 10%
Impact on Customer fulfilment
ControlImproveAnalyzeMeasureDefine
Financial Impact through imports
to fulfil customer order
CPC Increase by 484 INR/pc
Jan'17 Feb'17 Mar'17 Apr'17 May'17 Jun'17 Jul'17 Aug'17 Sep'17 Oct'17 Nov'17 Dec'17
Cost 0.19 0.11 0.50 0.68 0.55 0.87 1.05 1.43 1.37 1.38 0.83 1.26
-
0.20
0.40
0.60
0.80
1.00
1.20
1.40
1.60
Mio
IN
r
Import Cost
Productivity Improvement in CRP Housing
Problem Definition
Machine frequent stoppage (“Alarm in G-320 m/c - “A -Axis clamping angle tolerance (±10˝) exceed”)
Higher Axial load during Ø20.0 cylinder bore pre drilling
Higher Stock removal in high speed machining centre
Impact on Cycle time
ControlImproveAnalyzeMeasureDefine
220 G
ram
s
Axes Load chart – Pearl softwareHousing– Ø20.0 Pre DrillAlarm History
Kg
A-Axis
clamping
angle >10˝
Productivity Improvement in CRP Housing
Problem Definition
Time study check sheetHourly monitoring chart
Operation Element Time Radial Machining-I
Running Quality Level
ControlImproveAnalyzeMeasureDefine
PEARL Software
Video
Productivity Improvement in CRP Housing
ViCTA Analysis
9033
Data Collection
48
33
2928
2324
2221
1918 18
17
1413
12 1211
10 10 109 9 9 9 9
87 7 7
6 6 6 6 6 6 6
0
20
40
60
80
100
120
0
10
20
30
40
50
60
Ø2
0 P
re d
rill
Form
Sin
ker
Mill
ing
Cu
tter
Form
dri
ll
End
Mill
dri
ll
Tap
Twis
t D
rill
Tap
Dri
ll
Pre
Dri
ll
Twis
t d
rill
Gu
n d
rill
Bal
l No
se
End
Mill
Tap
End
Mill
Form
dri
ll
Mill
ing
End
Mill
Flat
dri
ll
Dri
ll
Form
dri
ll
Form
dri
ll
Form
dri
ll
Form
dri
ll
Dri
ll
Dri
ll
Form
dri
ll
Form
dri
ll
Form
dri
ll
Form
dri
ll
Tap
dri
ll
Form
dri
ll
Form
dri
ll
Time consumption/tool (sec) Cumulative cycle time %
Radial Machining Elemental Time (ET)
ControlImproveAnalyzeMeasureDefine
Prioritization of the element times
Vital element times identified
Focussed for root cause analysis
Ø20 Pre drill
Vital ET Tool
Ø21.5 Form
sinker
Tim
e in “
SEC
”
Productivity Improvement in CRP Housing
Pareto Analysis
• Ishikawa diagram
Cause validation done for all probable causes
• Through simulation
• At Gemba
High significant causes identified for process optimization
ControlImproveAnalyzeMeasureDefine
Why? Why? Analysis
Why ? -
Why ? -
Why ? -
Why ? -
Why ? -
Higher cycle time at radial machining
More material stock removal
Casting stage pattern profile
Pattern drawing specification
Conventional casting method
Existing casting design
Productivity Improvement in CRP Housing
Root Cause Analysis
Casting180 (MH)
type283 (KD) type
Material Removal rate
Casting 4.70 Kg 3.50 Kg
After OP10 4.24 Kg 3.21 Kg 10%
After OP20 3.40 Kg 2.57 Kg 28%
Expected
MAT
Saving
~220 gms
Productivity Improvement in CRP Housing
Casting Weight Proportion
ControlImproveAnalyzeMeasureDefine
Short Term Intermediate Solution:Pre-determined Tool life - 60%
Impact on Tool cost Tool CPC increase by 3%
Process optimization
• Reduced cutting Speed of Drilling Increased cycle time
Output reduction Cost per part increase
Feasible to implement but not economical
Long Term Permanent Solution:
To introduce A-Axis external pneumatic clamping system
Resistance from OEM
Additional investment (1.30 Mio INR)
Not satisfied with outcome Need Out of box thinking Focus on Ø20.0 Drilling
ControlImproveAnalyzeMeasureDefine
Productivity Improvement in CRP Housing
Development of Solution
Idea : To Introduce shell type core (pre-cast hole) in casting process
Innovative Idea
Finish Hole : Ø21.5
Core Hole: Ø15.0
MMC 3.5 mm on radius
263 Type 180 Type Shell Type core
Casting shell Core
Productivity Improvement in CRP Housing
Potential Improvement
ControlImproveAnalyzeMeasureDefine
Foundry code 6043
Customer name BOSCH
Description PUMP HOUSING
Customer Part
NumberC445014952
Description PUMP HOUSING
Material N2580-1
Report sent date 14.07.2017
SolidificationPattern with core Feed flow check Porosity check Casting
Phase 1: Core with casting simulation check
Phase 2: Pattern Ram and swing check
Phase 3: Mould Flow Analysis
No Disconnection
- No Core breakage
- Orientation checked
ControlImproveAnalyzeMeasureDefine
No Shrinkage effect in mould flow analysis
Productivity Improvement in CRP Housing
Feasibility Study – Mould flow analysis
Axial
Ø40.0mm
Radial
Ø15.0mm
A B
- Offset of 1.50 mm in side cores wrt CH bores in OP20
Challenge : Disproportionate stock at cast hole Improper Tool wear
ControlImproveAnalyzeMeasureDefine
Stock MinMax Analysis
Productivity Improvement in CRP Housing
Functional Robustness Analysis
Centre axisCylinder bore axis
RH side pump offset
ControlImproveAnalyzeMeasureDefine
Pump centre axis to cylinder axis shift by 1.50 mm
Productivity Improvement in CRP Housing
Functional Robustness Analysis
SolidificationPattern with core Feed flow check Porosity check Casting
- Core axis Longitudinal shift by 1.50 mm
- Porosity analysis
- Mould flow analysis
Solution feasible for
manufacturing
Core shift
ControlImproveAnalyzeMeasureDefine
No Shrinkage effect in mould flow analysis
Productivity Improvement in CRP Housing
Feasibility Re Study – After core axis shift
Internal shrinkage
• No shrinkage defect seen
Feed Modulus
• Feeder feed well to casting
Copyright Brakes India Private Limited, Foundry Division
Simulation Report
ControlImproveAnalyzeMeasureDefine
No disconnection b/w feeder and casting
Core
Productivity Improvement in CRP Housing
Solidification
Copyright Brakes India Private Limited, Foundry Division
Simulation Report
ControlImproveAnalyzeMeasureDefine
Directional solidification towards feeder
Productivity Improvement in CRP Housing
Modified casting
After machining
Cylinder head bore in casting and machining are Co-axial
Uniform stock removal
Modified Casting Model Material Stock Distribution
Core Hole
Shell Core
ControlImproveAnalyzeMeasureDefine
No functional effect with modified casting
Productivity Improvement in CRP Housing
Functional Analysis –After core axis shift
Pulsation
Radial Machining
Chemical Composition
Brinell Hardness
Microstructure Analysis
Strength Properties
Magnetic Particle Inspection
Ultrasonic Testing
Dye Penetrant Testing
Validation Result
Chemical Composition
Mechanical Properties:
Hardness
Strength Properties
Microstructure Analysis
Crack Check : Magnetic
Particle Inspection
Internal soundness:
Ultrasonic Testing
Dye Penetrant Testing
Productivity Improvement in CRP Housing
Critical parameters found within Specification
Casting Validation
ControlImproveAnalyzeMeasureDefine
Pulsation Test results
Radial Machining
• Ppermissible (1020 bar) > Pqz (940 bar) (Max. fatigue strength)
• Fatigue strength of machining validated for High Pressure circuit
• High pressure pulsation test Passed
Productivity Improvement in CRP Housing
Initial samples machined &
subjected to Part Validation
Machining Validation – High Pressure Pulsation test
ControlImproveAnalyzeMeasureDefine
Pump label
Endurance test duration : 500hrsInitial visual inspection : OK Functional test : OK Dimensional check : OK Axial play : OKLow pressure leak : No leakage Loosening torque check : OK
PC-PDL test cycle:
Endurance Test Result : Passed
Test
point
Pump
speedCurrent
Rail
pressureFlow rate 0 hrs 500 hrs Remarks
Efficiency (RPM) (A) (bar) (l/h) (l/h) (l/h) Pump
flow rate
is OK2000 1.5 1600 >69 74.53 74.91
Housing bush Flange bush
Productivity Improvement in CRP Housing
Product validation – Endurance test
ControlImproveAnalyzeMeasureDefine
Trial Order
REPORT
Radial machining Project Report
ControlImproveAnalyzeMeasureDefine
Productivity Improvement in CRP Housing
Implementation
PDS
Hole Position
Hole Concentricity
• Critical
characteristic
analysed
through “Q”-
DAS
• Critical
dimensions
Cmk >1.66.
26
Hole Ø21.8
Productivity Improvement in CRP Housing
Quality Validation
ControlImproveAnalyzeMeasureDefine
• Cycle time Before Vs After
39
36
30
35
40
45
Before After
Cycle
Tim
e in s
ecs 280
260
250
255
260
265
270
275
280
285
Before After
INR
1700
1850
1600
1650
1700
1750
1800
1850
1900
Before After
Pcs
• Output per day Before Vs After
Radial machining
8% 7%
4.7
5.2
3
4
5
6
Before After
Pcs/
Manhour
9% 11%
ControlImproveAnalyzeMeasureDefine
MAT Cost
Productivity
Productivity Improvement in CRP Housing
Results
Productivity :
Housing output increased from 1700 to 1850 pcs/day
Capacity increased by 9%.P
Quality:
CmK achieved >1.66 for all critical Dimensions
FPY Improved from 98% to 99% through minimized tool breakage .Q
Innovation:
Innovative core design
Tool change cycle with macro program.
Cost :
MAT Cost saving through core hole 7.45 Mio INR
Cost saving through Import avoidance 9.30 Mio INR
Total cost saving through productivity improvement 16.75 Mio INR-Recurring
16.75 Mio INR
Productivity Improvement in CRP Housing
C
I
Dia 21.5 Form drill
Benefits
ControlImproveAnalyzeMeasureDefine
OEE improvement through technical loss reduction by 6%
Avoiding external clamping system 1.3 MINR
One magazine pocket available for process optimization
Employee fatigue reduction Morale improvement
Environment Reduce Iron ore consumption by 105 Tonne/Yr (7%)
Customer delivery fulfilment Output increase by 150 Housing/day
Vision-2021 KPR
Investment
DescriptionCash Out Flow
(Mio INR)
Sample Tooling and Housings 0.8
Series Tooling – Pattern and Core box 2.4
Project
Investment
3.2 Mio INR
ControlImproveAnalyzeMeasureDefine
Productivity Improvement in CRP Housing
Benefits
Inta
ngib
le B
ene
fits
ControlImproveAnalyzeMeasureDefine
Productivity Improvement in CRP Housing
• Before • After
Technical loss reduced by ~5% & OEE improved to 85%
OEE Trend
Productivity Improvement in CRP Housing
0
2
4
6
8
10
12
14
Mar April May Jun July Aug Sept Oct Nov Dec Jan Feb Mar Apr
Pilot LotProject Identification Bulk Trials Implementation
• High Technical Losses
• Focus on axial Load reduction
• Machining stock optimization
• Casting design Improvement
• Core hole introduced
in Castings
• Process optimization
(∅20 pre drill
elimination)
• PPAP
sample
trials
• Key parameters monitoring
(Spindle load, tool life)
• Sustenance of improvement
• Stabilization of OEEGO
ALS
Target Limit
Improvement
confirmed
Target condition is reached and
stability has been confirmed
Definition of time period
for the confirmation of
stability of standard
Positive trend
Technical Losses Trend
ControlImproveAnalyzeMeasureDefine
ControlImproveAnalyzeMeasureDefine
Productivity Improvement in CRP Housing
• Before • After
Cycle time & delivery takt improved by 8%
Takt Time Chart
Improvement deployed to CP1H ,CB18 & CB28 Common rail pump housing.
Actions shared with International Production Network (IPN)
CP1H Housing
CB18 Housing
Best Innovation award -2017
Productivity Improvement in CRP Housing
Horizontal Deployment
THANK YOU
Productivity Improvement in CRP Housing