CENTRAL WORKSHOPS

NLC INDIA Ltd.

(“NAVARATNA”--A GOVERNMENT OF INDIA ENTERPRISE)

NEYVELI –TAMILNADU –INDIA.

CCQC-2018

AT CHENNAI

FROM: 22.09.2018 TO: 23.09.2018.

CASE STUDY PRESENTATION

AT

CENTRAL WORKSHOP

2

THE NLC INDIA LIMITED, NEYVELI, TAMIL NADU, A GIANT PUBLIC SECTOR UNDERTAKING IS

AN INTEGRATED INDUSTRIAL COMPLEX

COAL IS THE WORLD’S LARGEST AND MOST POPULARLY USED SOURCE OF POWER. THOUGH

IT IS NON-RENEWABLE, IT PLAYS A VITAL ROLE IN POWER GENERATION.

IN INDIA, LIGNITE, A BASIC FORM OF COAL IS AVAILABLE IN TAMIL NADU, RAJASTHAN AND

KASHMIR, U.P. BUT 90% OF THE TOTAL AVAILABILITY OF LIGNITE IS IN TAMIL NADU.USING

LIGNITE AS FUEL TO POWER GENERATION.

IT HAS THE FOLLOWING UNIT

UNIT PRODUCTION CAPACITY1. OPEN CAST MINES – I LIGNITE 10.5 M.TONNES /ANNUM

2. OPEN CAST MINES – II LIGNITE 15.0 M.TONNES /ANNUM

3. OPEN CAST MINES – I A LIGNITE 3.0 M.TONNES /ANNUM

4. THERMAL POWERSTATION – I POWER 600 M.W

5. THERMAL POWER STATION – II POWER 1470 M.W

6. THERMAL POWER STATION– I EXP. POWER 420 M.W

7. BARSINGSAR PROJECT, LIGNITE 02.1 M.TONNES/ANNUM

BIKANER, RAJASTHAN. POWER 250 M.W.

8. THERMAL POWER STATION II EXP. POWER 500 M.W.

9. WIND POWER PLANT POWER 51 M.W.

10. SOLAR POWER PLANT POWER 440 M.W.

CENTRAL WORK SHOPS, A SERVICE UNIT OF INDUSTRIAL COMPLEX CATERS TO THE

NEEDS OF ALL THE PRODUCTION AND ANCILLARY UNITS OF N.L.C. CONCERN.

3

MINES–I

MINES–II

MINES–IA

THERMAL POWER STATION–I EXP

THERMAL POWER STATION-I

THERMAL POWER STATION - II

OUR MAJOR UNITS

4

Q.C. BIO-DATA

NAME OF THE UNIT : CENTRAL WORKSHOPS

NAME OF Q.C : EXCELLENT

Q.C.No. : 03

UNIT HEAD : SRI. K.THANGARAJU,G.M.,CWS&MSS,

AREA CO-ORDINATOR : SRI.V.BALAJI, Ad.DGM.,

FACILITATOR : Mr. R.KALAIARASAN, EE.,

LEADER : Mr. K.NATARAJAN,FOREMAN,

Dy. LEADER : Mr. A.SIVAKUMAR.FOREMAN,

MEMBERS : Mr. RM.MUNIAPPAN, SR.FOREMAN,

: Mr.M.MURUGANANDHAM.Sr.Tech.II,

: Mr. M.JUSTUS. TECH II B,

5

DATE OF STARTING : 02.03.1992

MEETS ON : ALL FRIDAYS

No. OF MEETINGS IN 2018-2019 : 24

ATTENDANCE (AVERAGE) : 95%

PROBLEMS IDENTIFIED : 60

PROBLEMS SOLVED : 40

CASE STUDY PRESENTED SO FAR : 38

39th

CASE

STUDY

6

60%

32%

4% 4%

JOBS CARRIED OUT IN MACHINE SHOP

RECONDITIONING JOBS - 2370 Nos.

PRODUCTION JOBS - 1264 Nos

MODIFICATION JOBS - 158 Nos

OTHER JOBS - 158 Nos

TOTAL JOBS - 3950 Nos

THE PIE CHART BELOW SHOWS VISUALLY

THE QUANTUM OF JOBS UNDERTAKEN

BY US IN MACHINE SHOP.

WE ARE FROM CENTRAL WORKSHOPS A VITAL UNIT OF NLC LIMITED FULFILLING THE

NEEDS OF ITS LIGNITE MINES, THERMAL POWER STATIONS AND OTHER UNITS.

DURING THE YEAR 2018 -19, 3950 JOBS OF PRODUCTION, RECONDITIONING, MODIFICATION,

FABRICATION AND OTHER NATURE OF JOBS WERE UNDERTAKEN BY US.

A FEW IMPORTANT JOBS CARRIED OUT ARE

1] MANUFACTURING AND RECONDITIONING OF DRIVE SHAFTS OF B.W.E’S

AND CONVEYORS.

2] MACHINING OF CONVEYOR IDLER SHAFTS.

3] MACHINING OF LARGE GEAR BOX HOUSINGS.

4] MACHINING OFCAM WHEELS OF BUCKET WHEEL EXCAVATORS.

5] MANUFACTURING OF 20” DIA. PLAIN PIPES AND SLOTTED PIPES.

6] SHRINK FITTINGS OF B.W.E.’S TRACK CAM WHEELS WITH SHAFTS

OUR WORK AREA

7

COST WORTH OF MACHINES- 50 CRORES

TYPE OF MACHINES

3035

31

97

5 5 5

2 2 1

0

5

10

15

20

25

30

35

40

45

No

. O

F M

AC

HIN

ES

WELDING MACHINES LATHES

MILLING MACHINES

VERTICAL TURRET LATHES

DRILLING MACHINES GRINDING MACHINESSHAPING MACHINES

PLANING MACHINES

BORING MACHINESSLOTTING MACHINE

8

WE HAVE CONDUCTED BRAIN STORMING SESSION

FOR IDENTIFYING THE PROBLEMS AND CLASSIFIED

THEM UNDER THREE CATAGORIES AS BELOW

1.PROBLEM IN CUTTING SHORT LENGTH TOOLS IN CUTTER GRINDER MACHINE. B

2.PROBLEM IN SUPPORTING FEED SHAFT IN LC.125 LATHES. A

3.PROBLEM IN MACHINING INNER SPLINES OF PIPE SLOTTING

POWER TRANSMISSION GEARS A

4.PROBLEM IN SHIFTING OF HEAVY JOBS FROM BAY TO BAY A

5.FREQUENT BRAKE FAILURE IN 10 TON OVERHEAD CRANE. B

6.PROBLEM TO EOT CRANE OPERATOR DURING THE SHRINK FIT ASSEMBLING. C

7.PROBLEM IN INTERNAL GRINDING IN CENTER LATHES. A

8.PROBLEM IN GAUGE PLATE THICKNESS MACHINING. A

9.PROBLEM IN CARRIAGE MOVEMENT WIRING SYSTEM IN LC.125 LATHES B

10.PROBLEM OF REMOVING THE TURNING CHIPS IN HEAVY DUTY LATHES. B

IDENTIFICATION OF PROBLEMS

9

IDENTIFICATION OF PROBLEMS

A – CAN BE SOLVED BY OUR Q.C. : 8 PROBLEMS

B – NEED SUPPORT FROM OTHER DEPARTMENT : 9 PROBLEMS

C– CAN BE SOLVED BY OUR MANAGENENT : 3 PROBLEMS

11. PROBLEM IN OFFSET SETTING OF SPLIT JOBS IN FACE PLATE LATHE. A

12. PROBLEM IN STORAGE OF RAW MATERIALS. B

13. PROBLEM IN ROOF LEAKAGE OF THE WORKSHOP SHED. C

14. PROBLEM IN CUTTING TOOL PREPARATION. C

15. PROBLEM IN MEASURING OF OUTSIDE DIAMETER OFJOBS MORE THAN 1000 mm. A

16. PROBLEM IN AUTO FEED ARRANGEMENT OF LATHE TAILSTOCK

SPINDLE MOVEMENT. B

17. PROBLEM IN SETTING THE CAM WHEEL FOR MACHINING AT FACE PLATE LATHE A

18. PROBLEM IN LABYRINTH MACHINING. B

19. PROBLEM IN DRILL BIT REGRINDING B

20. PROBLEM IN AUTO FEED SYSTEM IN FACE PLATE LATHE. B

10

SELECTING THE “A” GRADE PROBLEMS

BY RATING METHOD

I

F – FREQUENCY, I – IMPORTANCE, FE – FEASIBILITY

1 – LOW, 2 – MODERATE, 3 – HIGH, 4 – VERY HIGH,

ON : 13.04.2018

SL.

NO.

PROBLEM

RATING

LEADERDY

LEADER

MEMBERS

TOTALPRIO-

RITY

1 2 3

F IF

EF I

F

EF I

F

EF I

F

EF I

F

E

1PROBLEM IN SUPPORTING FEED SHAFT IN

L.C.125 LATHES2 4 3 2 3 2 2 3 3 2 4 2 2 3 2 39 V

2PROBLEM IN SETTING CAMWHEEL IN

FACEPLATE LATHE3 3 2 3 2 2 2 2 1 2 2 2 2 3 2 33 VIII

3PROBLEM IN GAUGE PLATE THICKNESS

MACHINING.3 3 3 3 2 3 3 4 4 4 2 3 4 2 3 46 II

4PROBLEM IN INTERNAL GRAINDING IN

CENTRE LATHES2 3 2 2 3 2 2 3 2 2 2 3 2 3 3 36 VI

5PROBLEMIN SHIFTING OF JOBS FROM BAY TO

BAY.2 3 2 2 4 3 2 3 2 2 2 2 2 3 1 35 VII

6

PROBLEM IN INNER SPLINES

MACHINING OF PIPE SLOTTING

POWER TRANSMISSION GEARS.

4 4 4 4 4 3 4 4 4 3 4 4 4 4 4 58

7PROBLEM IN OFFSET SETTING OF SPLIT

JOBS IN FACE PLATE LATHE2 3 3 2 4 3 2 3 2 2 3 3 2 4 2 40 IV

8PROBLEM IN MEASURING JOBS OF OUTSIDE

DIAMETER MORE THEN 1000 mm.2 4 2 3 4 3 3 3 2 2 4 3 4 3 2 44 III

I

11

SI.

NO.

PROBLEM / TOPICS

THEME NATURE

1PROBLEM IN SUPPORTNG OF

FEED SHAFT IN L.C.125

LATHES_ _ _ __ III

2PROBLEM IN INTERNAL

GRINDING IN CENTER LATHS. _ _ IV

3

PROBLEM IN INNER

SPLINES MACHINING OF

PIPE SLOTTING POWER

TRANSMISSION GEARS.

_I

4PROBLEM IN MEASURING

JOBS OF OUTSIDE DIAMETER

MORE THEN 1000.mm_ _ _ V

5PROBLEM IN OFFSET SETTING

OF SPLIT JOBS IN FACE PLATE

LATHE_ _ VI

6PROBLEM IN GAUGE PLATE

THICKNESS MACHINING _ _ II

PROBLEM SELECTION MATRIX

ON:13.04.2018

12

TOPIC

PROBLEM IN INNER SPLINES

MACHINING OF PIPE SLOTTING

POWER TRANSMISSION GEARS

13

DATE OF BEGINNING : 13. 04. 2018DATE OF COMPLETION : 20. 07. 2018PROJECT NO : 39.

PROJECT : PROBLEM IN INNER SPLINES MACHINING

OF PIPE SLOTTING POWER TRANSMISSION GEARS

DEPT : MACHINE SHOPQC NAME : EXCELLENT

FOLLOW UP / REVIEW10

REGULAR IMPLEMENTATION9

TRIAL IMPLEMENTATION8

7

DEVELOPING SOLUTION6

ANALYSING ROOT CAUSES5

IDENTIFING CAUSES

DATA ANALYSING3

DEFINING THE PROBLEM2

7SELECTION OF PROBLEM1

MONTHSL.

NO.

.ACTIVITY

ACTIVITY PLANING CHART

LEADER: K.NATARAJAN

Dy. LEADER : A.SIVAKUMAR

WEEK

APRIL-18 MAY-18 JUNE-18 JULY-18

I III I I III II II

IV III III IIIIV IV IV

12

6

4

4

6

MEMBER’S NAME:

RM.MUNIAPPAN

M.MURUGANANDHAM

M.JUSTUS

MEETING DAY : FRIDAY, TIME : I shift 12.00 TO 01pm, II shift. 08.30 TO 09.30 pm.

FORCEING RESISTANCE

4

T

T-Target

2

3

FACILITATOR: R.KALAIARASAN

II

7

63

TOTAL DAYS 114

14

DATA COLLECTION-ITHE DETAILS OF PIPE SLOTTING POWER TRANSMISSION

GEARS COMPLETED

COLLECTED FROM WORK ORDER REGISTER 2018-19.

15

MONTHWORK ORDER NO., QUANTITY

APRIL MAY-17 0199,0200 6

JUNE JULY-17 0346,0347 12

AUG. – SEP. -17 0441,0476,0478 8

OCT. – DEC. -17 0561,0599,0600,0699 8

JAN. -MARCH-18 0766,0804,0822 10

TOTAL 44

16

MINING OPERATION IN NLC

16

UNDERSTANDING THE PROBLEM

IN OUR NLC MINE I, MINE IA, MINE II, MINE II-EXP, TPS I, TPS II, TPS I-EXP, TPS II-EXP ARE

THE IMPORTANT PRODUCTION UNITS NEYVELI.

FROM THE ABOVE PLANTS VARIOUS TYPES OF WORKS COME TO OUR WORKSHOP FOR

RECONDITION, MODIFICATION, AND PRODUCTION.

WE CARRIED OUT VARIOUS KINDS OF JOBS SUCCESSFULLY LIKE CAM WHEEL, DRIVE

SHAFTS, 20’’SLOTTED PIPES BUSHES, HOUSINGS, PIPE, SLEEVES, LABRINGTH, HOLLOW SHAFTS ETC..

IN OUR MINES GROUND WATER CONTROL IS AN IMPORTANT PROCESS .FOR THE ABOVE

PROCESS DRILLED MORE THAN 150 BOREWELLS AND DISCHARGE THE GROUND WATER

BY HEAVY DUTY PUMPS 24X7 ROUND THE CLOCK.

IF THE WATER PUMPING HAD STOPPED MINES FULLY DROWNING BY WATER.SO WE

PRESERVE THE STANDBY PROPERLY.

TO MAKING BOREWELLS PLAIN STEEL PIPES,SLOTTED PIPES ARE MANUFACTURE IN OUR

WORKSHOP.

SLOTTED PIPES ARE MANUFACTURED IN TWO PIPE SLOTTING MACHINES IN OUR

WORKSHOP.

IN THE PIPE SLOTTING MACHINES 11 NOS. OF SPUR GEARS ARE USED TO TRANSMIT THE

POWER TO SLOT CUTTER SPINDLE.

DUE TO CONTINIOUS WORKING POWER TRANSMISSION GEARS WERE DAMAGED AND

REQUIRE REPLACEMENT.

17

UNDERSTANDING THE PROBLEM

IN OUR MACHINE SHOP WE MANUFACTURING THE REQUIRED GEARS.

IN THE GEARS INNER SPLINES MACHINING WORK CARRIED OUT IN SLOTTING MACHINE.

THERE IS ONLY ONE SLOTTING MACHINE IN OUR WORK SHOP.

VARRIOUS OTHER WORKS LIKE INNER KEYWAY MACHINING,LUBRICATION GROOVES OF

GUNMETAL BUSHES, RECONDITIONING WORNOUT GEARS, INNER SQUARE MACHINING

WORK ALSO CARRIOUT IN THE SLOTTING MACHINE.

INNER SPLINES MACHINING WAS VERY LABOURIOUS AND CHALLENGING TO US. IT TAKES

MORE TIME.

SO WE WERE UNABLE TO DELEVER THE PIPE SLOTTING GEARS WITHIN TIME.

SO, WE SELECT THE PROBLEM AS OUR CASE STUDY

18

SLOTTED PIPES

19

MANUFACTURING OF SLOTTED PIPES

20

POWER TRANSNISION GEARS

PIPE SLOTTING POWER TRANSMISSION GEAR CLAMPED IN SLOTTING MACHINE TABLE FOR INNER SPLINES

MACHINING

21

SLOTTING

MACHINE

22

MARKINGMARKED GEARS

PROCESS FLOW DIAGRAM FOR PIPE SLOTTING POWER TRANSMISSION GEAR INNER SPLINES MACHINING

( BEFORE IMPLEMENTATION )

23

JOB ALLOCATION

START

JOB RECEIVED

TURNING

LATHE

AVAILA

-BILITY

JOB

WAITINGNO

TEETH MACHINING

MILLING

AVAILA-

BILITY

JOB

WAITING

NO

JOB ALLOCATION

END

SPLINES MACHINING

MARKING

SETTING

NOT OKOK

INSPEC

- TION

YES

YES

NOT OKOK

WAY OF THINKING

SAFETY

TECHNIQUES-

TOOLS-

TIME-

METHOD

--

MAN POWER

CU

ST

OM

ER

SA

TIS

FA

CT

ION

CO

ST

RE

DU

CT

ION

WO

RK

SIM

PLIF

ICA

TIO

N

MU

RA

[DIS

CR

EPA

NC

Y]

MU

RI

[ST

RA

IN]

MU

DA

(WA

ST

E]

QUALITY

CHARACTERS

3’MU’ AIM

ON : 20.04.2018

REDEFINING THE PROBLEM

--

---

--

-

-

--

24

CUSTOMER SATISFACTION

WORK SIMPLIFICATION

COST REDUCTION

25

BRAIN STORMING - I

ON : 20.04.2018.

( TO FIND OUT THE POSSIBLE CAUSES )

26

ONLY ONE SLOTTING MACHINE.

OLD MACHINE.

MORE MAN POWER.

DIFFICULT TO SETTING.

LABOURIOUS OPERATION.

MORE MACHINING TIME.

MORE NO. OF WORK ORDERS.

VARIOUS TYPES OF JOBS.

OPERATOR FATIQUE.

FREQUENT ADJUSTMENT OF STROKE LENGTH.

MORE MARKING TIME.

NO TEMPLATE TO MARKING

NO FIXTURE TO HOLD THE JOB.

MANUAL TABLE ROTATION.

OPERATOR ABSENTEESM

DATA COLLECTION-II

THE FOLLOWING DATA SHOWS THE AVERAGE TIME TAKEN TO COMPLETE THE INNER

SPLINES MACHINING OF PIPE SLOTTING POWER TRANSMISSION GEAR .

FROM : 21.04.2018 TO: 23.04.2018 NO.OF JOBS: 03

27

Sl.

NoACTIVITIES

TIME IN MINUTS

PER JOBPERCENTAGE

1 MARKING 30 Min 8.5%

2 PREPARATION 45 Min 12.5%

3 JOB SETTING 60 Min 17.O%

4 MACHINE SETTING 30 Min 8.5%

5 JOB RESETTING 20 Min 5.5%

6 MACHINING 90 Min 25.5%

7 TOOL GRINDING 30 Min 8.5%

8 TOOL CHANGING 20 Min 5.5%

9

OTHERS

( LOADING & UNLOADING,

MACHINE CLEANING)

30 Min 8.5%

TOTAL 355 Min 100%

0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

X

X

X

X

X

X

XX

XT

IME

IN

PE

RC

EN

TA

GE

100%

91.5%

86.5%

80.5%

72%

63.5%

55%

42.5%

25.5%

80/20 LINE

VITAL FEW

Y

OT

HE

RS

TO

OL

CH

AN

GIN

G

TO

OL

GR

IND

ING

JO

B

RE

SE

TT

ING

MA

CH

INE

SE

TT

ING

MA

RK

ING

PR

EPA

RA

TIO

N

JO

B S

ET

TIN

G

MA

CH

ININ

G

CAUSES

PARETO DIAGRAMBEFORE IMPLEMENTATION

ON: 24.04.2018

USEFULL MANY

28

25.5%

12.5%8.5%8.5% 8.5%

5.5% 5.5%8.5%

17%

CAUSE AND EFFECT DIAGRAMFOR PROBLEM OF PIPE SLOTTING POWER TRANSMISSION GEAR

INNER SPLINES MACHINING

PROBLEM OF

PIPE SLOTTING

POWER TRANSMISSION

GEAR INNER SPLINES

MACHINING

METHOD

MORE

SETTING TIME

NO FIXTURE

MORE MAN POWER

ONE MACHINE

ONLY

MORE No. OF

WORKORDERS

HARD MATERIALMACHINE NOT

AVAILABLE

STEEL METAL

UNABLE TO USE

OTHER MACHINE

SPECIFIC

OPERATION

OPERATOR

FATIGUEMORE

MACHINING

TIME

FREQUENT

RESESETTING

MAN

MACHINE MATERIAL

EFFECTMANUAL CLAMPING

OLD MACHINE

FREQUENT

STROKE

ADJUSTMENT

POOR CLAMPING

FREQUENT

RESETTING

SMALL BORE

NATURE OF THE JOB

NO JIG

MORE NO. OF

ROTATION

NATURE OF

THE JOB

ON :04.05.2018

29

BRAIN STORMING - II

ON :04.05.2018(TO FIND OUT THE SOLUTIONS)

30

SPECIAL FIXTURE MAY BE PURCHASED.

PURCHASE A NEW SLOTTING MACHINE. SPECIAL TYPE MULTI POINT TOOL MAY BE PURCHASED

MANUFACTURE A SPECIAL JIG.

SL.

NO.SUGGESTIONS ADVANTAGE DISADVANTAGE

1PURCHASE A NEW SLOTTING

MACHINE.

1.EASY TO MEET

REQUIREMENTS.

1. MORE COSTLY .

2.MORE TIMING.

3.NOT ECONOMICAL.

2SPECIAL FIXTURE MAY BE

PURCHASED.

1.EASY TO HOLD

ON SLOTTING

MACHINE TABLE.

2.EASY TO MEET

REQUIREMENTS.

1.TEDIOUS

PROCEDURE.

2.MORE TIMING.

3.MORE COST.

3SPECIAL TYPE MULTI POINT

TOOL MAY BE PURCHASED.

1.EASY TO HOLD IN

TOOL POST.

1.MORE COST.

2.TEDIOUS

PROCEDURE.

3.MORE TIMING.

4MANUFACTURE A SPECIAL JIG.

1.EASY TO MEET

REQUIREMENTS.

2.SAVE TIME &

MAN POWER. NIL

FOR PROBLEM OF PIPE SLOTTING POWER TRANSMISSION GEAR

INNER SPLINES MACHINING

31

Sl.

No.RECOMMENDATIONS EFFECT COST TIME PRIORITY

1SPECIAL TYPE SLOTTING

MACHINE MAY BE

PURCHASED

MORE MORE MORE III

2 SPECIAL TYPE FIXTURE MAY

BE PURCHASEDMORE MORE MORE II

3 SPECIAL TYPE MULTI POINT

TOOL MAY BE PURCHASEDLESS MORE MORE IV

4 SPECIAL TYPE JIG MAY BE

MANUFACTURED BY OUR Q.CMORE LESS LESS

E.C.T. OPTION CHARTFOR PROBLEM OF PIPE SLOTTING POWER TRANSMISSION

GEAR INNER SPLINES MACHINING

I

ON :11.05.2018.

32

[SEQUENTIAL TYPE]

FOR MANUFACTURING A JIG

TO DESIGN AS

PER REQUIREMENT

TO COLLECT MATERIAL

NOT O.K O.K

FABRICATE

TEST

TO DISCUSS WITH UNIT HEAD

P.D.P.C

SUITABLE JIG

MANUFACTURED

DECIDED TO MANUFACTURE

JIG BY Q.C

AGREED FOR THE

INTRODUCTION OF JIG NOT AGREED

TO COLLECT

SUPPORTING DATA

33

ACTION PLAN

DOCHECK

DESIGNING THE JIG

FIX THE JIG AT SLOTTING

MACHINE TABLE

MACHINED INNER SPLINES

SUCCESSFULLY. FOUND IT

SUITABLE.

COLLECTING THE

MATERIALS, MACHINING

AND WELDING DONE. JIG

MANUFACTURED.

P.D.C.A.CHART

STARTED ON : 14.05.2018 COMPLETED ON: 25.05.2018

TOTAL NO. OF DAYS : 12.

FROM : 14.05.2018

TO : 15.05.2018

FROM : 16.05.2018

TO : 18.05.2018

FROM : 21.05.2018

TO: 23.05.2018

FROM : 25.05.2018

PUT IN TO REGULAR

OPERATION.

34

THE 20mm THICK BOTTOM PLATE WAS

MACHINED FOR 245mm DIA AND TWO

SLOTS (22mm WIDTH 30MM LENGTH) ARE

MADE IN THE PLATE OPPOSITE TO

EACH OTHER FOR CLAMPING

PURPOSE. BOTTOM SIDE TWO

TENENTS ARE FIXED FOR PROPER

SEATING THE JIG IN THE CENTRE OF

THE MACHINE TABLE ACCURATELY.

GUIDE PLATE

CLAMPING BOLT

JIG CLAMPING

BOLT

A HOLLOW PIPE OF 170mm HEIGHT X

140mm OUTER DIA X 124.2 mm INNER

DIA WAS MACHINED AND WELDED

OVER THE BOTTOM PLATE. TWO

NUMBERS OF M20 BOLT PLACED

OPPOSITE TO EACH OTHER PROVIDED

ON TOP SIDE OF THE HOLLOW PIPE

FOR CLAMPING THE WORK PIECE AND

GUIDE PLATE.

A TOP GUIDE PLATE 20mm THICK

HAVING TWO SLOTS OPPOSITE EACH

OTHER, IT WAS PLACED ON TOP OF

THE HOLLOW PIPE. IN THE GUIDE

PLATE EIGHT SLOTS ARE (6mm DEPTH

X10mm WIDTH) MACHINED FOR

GUIDING THE CUTTING TOOL.

TENENTS

GUIDE PLATE

IMPLEMENTATION

35

IMPLEMENTATION

36

GUIEDE PLATE

CLAMPING BOLT

JIG CLAMPING

BOLT

SLOTS FOR GUIDING

THE CUTTING TOOL

COMPLETED

GEARS

LIFTING PLATE

37

GUIDE PLATE

TENENTS

38

RECURRENCE PREVENTION MEASURES

39

THE JIG, WE HAVE MADE IS SIMPLE TO USE. IT REQUIRES LITTLE

MAINTENANCE.

ALL THE PRECAUTIONARY MEASURES WERE CONSIDERED AT THE

DESIGN AND FABRICATED THE JIG TO ENSURE FOOL PROOF AND

FAIL SAFE.

A WORKING METHOD OF THE JIG WAS CLEARLY DEMONSTATED TO

ALL OPERATORS AND SUPERVISORS.WORKING MANUAL ALSO KEPT

WITH OUR GM’S OFFICE FOR FUTURE REFERANCE.

A SEPARATE PLACE IS RESERVED FOR KEEPING THE JIG,

WHEN NOT BEING USED.

AN INSTRUCTION BOARD IS DISPLAYED NEAR THE SLOTTING

MACHINE FOR OPERATOR REFERENCE.

REVISED DATA COLLECTION

THE FOLLOWING TIME STUDY WAS TAKEN AFTER IMPLEMENTATION

FROM: 01.06.2018 TO :06.06.2018 NO. OF JOBS:06.

40

Sl.

NoACTIVITIES

TIME IN MINUTES

PER JOBPERCENTAGE

1 MARKING NIL NIL

2 PREPARATION NIL NIL

3 JOB SETTING 18 Min. 5%

4 MACHINE SETTING 10 Min 3%

5 JOB RESETTING NIL NIL

6 MACHINING 30 Min 8.5%

7 TOOL GRINDING 10 Min 3%

8 TOOL CHANGING 7 Min 2%

9

OTHERS

A] LOADING & UNLOADING

B] MACHINE CLEANING

20 Min 5.5%

TOTAL 95 Min 27%

X

X

X

X

X

X

X

X

X

X

TIM

E I

N P

ER

CE

NT

AG

E

100%

91.5%

86.5%

80.5%

72%

63.5%

55%

42.5%

25.5%

80/20 LINE

Y

17%

8.5% 8.5%8.5%8.5%

12.5%

5.5% 5.5%

TIM

E I

N P

ER

CE

NT

AG

E

X

CAUSES

Y

+

+ ++ + + + +

+

8.5%5% 5.5%

3% 3% 2%0% 0% 0%

73%

27%

21.5%

27%

21.5%21.5%

13.5%16.5%

19.5%

SOLVED

( AFTER IMPLEMENTATION )ON : 06.06.2018

COMPARATIVE RESULT OF THE STUDY

( BEFORE IMPLEMENTATION )

40

PROCESS FLOW CHART FOR INNER

SPLINES MACHINING

JOB ALLOCATION

START

JOB RECEIVED

TURNING

LATHE

AVAILA-

BILITY

JOB

WAITINGNO

TEETH MACHINING

MILLING

AVAILA-

BILITYJOB

WAITING

NO

JOB ALLOCATION

SETTING

END

INNER SPLINES

MACHINING

( AFTER IMPLEMENTATION )

INSPECTION

41

FOLLOW UP ACTIVITY

43

FOLLOW

UP

PERIOD

TROUBLE

IDENTIFIEDREASON RECTIFICATION

25.05.2018

TO

20.07.2018

CLEANING INSIDE

OF THE JIG

NO WAY TO

REMOVE

SCRAPS

HOLES PROVIDED

BOTH SIDES FOR

CLEANING

DATE OF BEGINING : 13 . 04 . 2018DATE OF COMPLETION : 20 . 07 . 2018

PROJECT NO : 39.

PROJECT: PROBLEM IN INNER SPLINES MACHINING OF PIPE SLOTTING POWER TRANSMISSION GEARS.

.

DEPT : MACHINE SHOPQC NAME : EXCELLENT

FOLLOW UP / REVIEW10

REGULAR IMPLEMENTATION9

TRIAL IMPLEMENTATION8

7

DEVELOPING SOLUTION6

ANALYSING ROOT CAUSES5

IDENTIFING CAUSES

DATA ANALYSING3

DEFINING THE PROBLEM27SELECTION OF PROBLEM1

MONTHSL.

NO.ACTIVITY

MILE STONE CHART

LEADER: K.NATARAJAN

Dy. LEADER : A.SIVAKUMAR

WEEK

APRIL-18 MAY-18 JUNE-18 JULY-18

I III I I III II IIIV III III IIIIV IV IV

12

6

4

4

6

MEMBER’S NAME:

RM.MUNIAPPAN

M.MURUGANANDHAM

M.JUSTUS

MEETING DAY : FRIDAY, TIME : I shift 12.00 TO 01pm, II shift. 08.30 TO 09.30 pm.

FORCEING RESISTANCE

4

T

ACTIVITY

T-TARGET, A- ACTUAL

2

3

FACILITATOR: R.KALAIARASAN

II

7

63

TOTAL DAYS

61

A

1

9

2

5

6

5

2

4

99114

4

44

SL.

No.AIM ACHIEVEMENT

1 WORK SIMPLIFICATION ACHIEVED

2 COST REDUCTION ACHIEVED

3 CUSTOMER SATISFACTION ACHIEVED

45

Sl.

No.DESCRIPTION

COST IN

Rs.

1 300 mm Dia X 20 mm PLATE (1No.) 300.00

2 200 mm X 150 mm X 20 mm PLATE (1No.) 250.00

3150 mm OD X 120 mm ID X 200 mm LENGTH

HOLLOW PIPE (1No.)400.00

4 130 mm Dia X 16 mm PLATE (1 No.) 150.00

5 30 mm X25 mm X 100 mm PLATE 150.00

6 20 mm Dia X 100 mm LENGTH ROD 50.00

7 M24 BOLT 100 mm LENGTH (2No.s) 60.00

8 22 mm X 10 mm X 30 LENGTH KEY (2 No.s) 40.00

9 MACHINING AND WELDING CHARGES 1,000.00

TOTAL 2,400.00

COST OF IMPLEMENTATION

45

COST BENEFIT ANALYSIS

DETAILSIMPLEMENTATION

BEFORE AFTER

MAN DAYS UTILISED FOR SPLAINS

MACHINING OF PIPE SLOTTING

POWER TRANSMISION GEAR 1 No.

01 0.33

TIME SAVED PER JOB = 0.67 MAN DAYS

No. OF JOBS PER YEAR = 44 Nos.

MAN DAYS SAVED PER ANNUM = 29.5 MAN DAYS

CHARGE PER MAN HOUR = Rs. 956

( INCLUDING SUPERVISING,OVERHEAD CHARGES )

TOTAL SAVINGS PER ANNUM (956X8X29.5) = Rs. 2,25,616.00

IMPLEMENTATION COST (DEDECTION) = Rs. 2,400.00

2,23,216.00

NET SAVINGS Rs.2,23,216.00

46

TANGIBLE BENEFITS

TIME SAVED IS 29.5 MAN DAYS / ANNUM

MONEY SAVED IS Rs.2,23,216 / ANNUM

PRODUCTIVITY IMPROVED BY 300%

INTANGIBLE BENEFITS

# PROBLEM SOLVING SKILLS

# CREATIVITY

# Q.C. TOOLS UNDERSTANDING

AND APPLICATION

# JOB KNOWLEDGE

# RELATIONSHIP BETWEEN

SUPERIORS AND WORKERS

# LEADER SHIP SKILL

# COMMUNICATION SKILL

# TEAM WORK

ALL ARE

IMPROVED

48

BEFORE IMPLEMENTATION

AFTER IMPLEMENTATION

LEGEND: 5 POINT SCALE

1. POOR

2. FAIR

3. GOOD

4. VERY GOOD

5. EXCELLENT

INTANGIBLE BENEFITS RADAR CHART

4948

50

CUSTOMER APPRECIATION CERTIFICATE

51

UNIT HEAD CERTIFICATE

52

FINANCE DEPARTMENT CERTIFICATE

CONCLUSION

53

BY MAKING A SPECIAL JIG WE WERE ABLE TO IMPROVE THE

PRODUCTIVITY AND ACCURACY. MARKING FULLY

ELIMINATED. THROUGH THIS PROCESS WE WERE ABLE TO

MACHINING INNER SPLINES OF PIPE SLOTTING POWER

TRANSMISION GEARS WITH ENHANCED PRODUCTIVITY WITH

REQUIRED QUALITY. ALSO THIS IMPROVEMENT RESULTED IN

A SAVINGS OF RS.2,23,216 / ANNUM AND ALSO

IMPROVED THE PRODUCTIVITY BY 300%.

FUTURE PLAN

WE HAVE PLANNED TO SOLVE THE FOLLOWING PROBLEMS

ALREADY SHOWN IN OUR PROBLEM SELLECTION MATRIX

PROBLEM IN SUPPORTNG OF FEED SHAFT IN L.C.125 LATHES.

PROBLEM IN SHIFTING JOBS FROM BAY TO BAY.

PROBLEM IN MEASURING JOBS OF OUTSIDE DIAMETER

MORE THEN 1000.m.m.

PROBLEM IN GAUGE PLATE THICKNESS MACHINING.

PROBLEM IN INTERNAL GRAINDING IN CENTRE LATHES.

54

55

OUR SINCERE THANKS TO

NLC INDIA LIMITED, NEYVELI.

GENERAL MANAGER, CENTRAL WORK SHOPS AND MSS.

Dy.GENERAL MANAGER,LEANING AND DEVELOPMENT CENTER.

QCFI CHENNAI CHAPTER.

HONOURABLE JUDGES AND COMMITTEE,CCQC 2018.

PLEASE

56