mechanical training project

8/11/2019 mechanical training project

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Training Semester

Scooters India Limited

Shubhankar Shukla

101108102


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Projects

Analyze and Provide Solution for Reducing

rejections at different operations on Clutch

Housing.

Optimize The post-procurement process.

Study manufacturing of the drive shaft and

reduce rejections.

Monday, September 08,THAPAR UNIVERSITY, PATIALA 2


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Department

ScootersIndiaLimited

R & D

Production

Engine

Assembly

Casting

Paint

Weld

Machine

Sales and SupplyChain

Store

BOF

BOSF

Tool



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Project 1

Analyze and Provide Solution for Reducing

rejections at different operations on Clutch

Housing.


Clutch/gear

Box housing


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Sub Projects

Study Of Die casting process involved inmanufacturing of Clutch/gear Box Housing andstudy rejections for a month and suggest

improvements. Study various machining process performed on

Clutch/gear box housing and identify defects andsuggest ways to eliminate them.

Study and Validate the complete clutch/gear boxassembly and perform Assembly Line balancing inorder to improve productivity.



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Rejection Report (Initial)

Sno. Total production

Rejection

1 75 2

2

76

2

3 76 3

4

72

2

5 77 4

6

68

2

7

76

18 74 4

9 76 0

10

74

2

11 81 6

12 76 2

13 75 1

14

75

3

15 74 0

16

76

1

17 76 6

18 71 5

19 75 2

20 76 2


Rejection Rate 3.7%


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Defects


Thermal cracks- coolant failure, holding furnace.


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Die Wear



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Countermeasures

Make a 3mm Radius

Installation of Temperature Controller

training of operators



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Rejections (improved)

S no.

Total no. of produce

Rejections

1 78 1

2 76 0

3 78 2

4 73 0

5 51 4(die wear)

6 72 0

7 82 1

8

78

1

9

75

0

10 76 0


0

10

20

30

40

50

60

70

80

90

1 2 3 4 5 6 7 8 9 10

total rejections Series 3

Improved Rejection

Rate = 1.21%


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Machine Shop (Ln No. 2)

Operation No. Machine no. Details

--

--

Face milling with a HSS tool with a

Carbide tip to rectify the height of

Clutch box housing.

Operation 20 2602 Drilling and daweling

Operation 25 4047 Side milling(undercut for diesel

engines as they have large first gear)

Operation 50

3195

Drilling, counter, chamfering

Operation 100+90 -- Dawel Pin

Operation 60 2595 Boring, chamfering

Operation 20

--

Side stab

Operation 70 3567 Milling for gear pin

Operation 75

2155

Step drilling

Operation 80 2603 Tapping of all drills

Operation 120 145 Tapping of drills in operation 50

Operation 40 3202 Step boring off GB flange



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Problems

Unavailable tools

Machine vibrations

Machine breakdown Weak Inspection schemes

Less compression pressure

Voltage fluctuations (rare)



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Process Capability

Process capabilityis the ability of the process

to meet the design specifications for a service

or product.

Cp = Allowable Process Spread / Actual Process Spread

Cpk= Process capability index that indicates process actual

performance by accounting for shift in the mean of the

process within the upper and lower specification limit.


Equivalent, Cp value Capability to produce nonconformance

product, %

0.50 86.64

0.62 93.50

0.68

96.00

0.81 98.50

0.86 99.00

1.00 99.73

1.33

99.994


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Boring Process Capability


52mm and 16mm

4 readings for 15 days(initial)

4 readings for 19days(improved)

Analysis on minitab 17

Improvements


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52mm (Initial)



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16mm (intial)



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16mm (initial)



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Problems

Old machinery

High vibrations

Jammed Oiling Ducts Poor maintainance

Noise



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Improvements

Tool Holder changed

Shock Absorbers installed

Internal Oiling Oiling pipes and filters changed

Worker Training


Shock

absorbers


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52mm (improved)



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52mm (improved)



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16mm (improved)



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16mm (improved)



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Gear Box Assembly

Gear box assembly (sequential 4 gear system)

Clutch assembly

Reverse gear assembly


Clutch/Gear box


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Line Balancing

Task

Time

Description

Preceed

A

43

Gear box house loading

B 76 Inner lever + gc shaft A

C

75

Lay shaft, davel pin, lay shaft spacer

B

D 88 Cluster gear C

E 97 Gb flange, sheam clearance D

F 38 Pt wheel E

G

69

Clutch well, torque nut

F

H

76

Clutch assembly, lock nut

G

I

61

Reverse gear 0093, lock nut, needle bearing

E

J 48 Push rod, sector A

K

36

TOP shaft

I, J

L 88 Spindle rod, reverse gear set K

M 87 Gasket, top cover, o ring, speed pinion L

N 93 Companion flange, reverse gear selector M

O 92 Engine mountings, unloading of clutch box

housing

N, H


AB C D E

F G H

O

I K L M N

J


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Line Balancing

Calculate the theoretical minimum number

of workstations.

NUMBER OF WORK STATIONS = ( SUM OF TOTAL

TASK TIMES) / (CYCLE TIME)

= 1109 secs / 180 secs = 6.31 = 7(rounded)



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Line Balancing

STATION

TASK

TIME

FOLLOWING TIME REMAINING

1 A

B

J

43

76

48+10

14

12

6

137

61

3

2 C

D

75+10

88

11

10

94

5

3

E

I

97

61+10

9

5

83

12

4 F

G

K

38+10

69

36+10

2

1

4

132

63

17

5

LM

8887

32

925

6 N

H

93

76+10

1

1

87

1

7

O

92

0



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Line Balancing

Benefits

1. Equal Work Load distribution

2. No idle time3. High efficiency

4. Less Human resource required



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Post Procurement


Main gate Security Check Store manager

Quality

controldepartment

store manager store

assembly line/manufacturing


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BOF store


Finished Items Glass Store, Tyre store, leaf spring suspension store etc.

Online database


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Current scenario


Area destroyed in fire

18.6*60 m2

Used for various BOF stores

located at the entrance eg.Glass store, Silencer store,

tyre store etc


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Layout Initial



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Proposed Layout


Bins Added Min path width 3m

Major BOF stores shifted to

fire destroyed area

No ground storage

Extra storage for extra

inventory


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Detailed Look



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BOSF store


BOSF- Bought of semi finished

Unplanned

High Ground Storage

No FIFO

Degradation Slow material flow


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Initial Layout



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Proposed Layout


Min 3.5 mm pathway

U shaped for quick material flow

Bins added

Special area for packaging

material Ground storage for extra

inventory


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Detailed Look



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5s implimentation

Good layout not enough

At present no principles to follow for store

management.

New products would put more pressure

5s for sustainable organization maintainence

suggested

Special set of instructions



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Principles

Sort:

No useless wrappers, cartons or boxes should be present in the store premises.

Keeping material on ground not allowed.

Degraded items should be reported and removed.

Straighten

Bins should be arranged properly with no bins blocking others. Strict use of FIFO methodology, so as to minimize wastage due to degradation of

material.

Use big bin numbers which are clearly visible. And numbering to be done in such away so that finding a bin becomes easier.

A manual trolley specifically for store so that in store movement is smooth and fast

as well. Shine

Packaging of materials to be moved out of the storage thrice every day.

Maintain safety is case of dealing with heavier material.



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Standardize

Store Manager is to be held accountable for all problems in storage.

Handle all materials following the instructions especially with handle

with care items.

Divide areas for specific materials eg. Shelves for smaller items andbings for bigger ones.

Sustain

To keeps check on store workers so the instructions are followed

Keep the workers updated with rules and regulations.



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Drive Shaft

Cutting

Lathe turning

Hobbing

Heat Treatment

Grinding

Visual Inspection



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Month Rejections

Feb 17

March 19

April 22

May 21

June 15

July 12


The number of rejections for feb july are recorded and are as follows:

0

5

10

15

20

25

feb april june

Rejection

f ( d)


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Defects (rod)

Dents

Material Defect

Grinding Fault- unbalanced, vibrations

Rust



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Improvements

The unbalanced wheel of the grinding wheelfixed.

Inspection schedule made.

Training to workers as visual inspection isdone

Coolant temperature varied so as the

abrasives do not get attached to the workpiece. Filters changed.

Feed maintained

mechanical training project

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