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Problem Origin
•Mechanized green brick production
•Theoretical capacity- 1440 bricks per working hour
•Actual productivity- 700 bricks per working hour
•Reduced productivity due to-
1. Unorganized production schedule
2. Improper labour distribution
3. Absence of efficient production layout
Objectives
• To develop a production layout for
TBMM
• Layout should enable
performance monitoring
• Efficiency of machine should be
about 80%
Development Alternatives
•One of the largest NGO in India.
•Works for sustainable development
•Works in close coordination with about 200 organization
Innovation Systems branch
• Addresses the multi faceted relationship between the people and the machine
•Aims to create sustainable livelihoods
•Prpducts to be produced are chosen after feasibility study and market analysis
TBMM(TARA BRICK MEK MACHINE)
Project Title
Development of Production layout for TBMM and Introduction of some Mechanizations in VSBK
Summer Internship 2009
Project Supervisor
Dr. Sangeeta Kohli
Project Mentor
Mr. Subhankar Bose
Project Coordinator
Dr. Sanjeev Jain
Existing Layout
Models Suggested
Abhinev Bhadauria
Mechanical Engineering Department
IIT Delhi
Data Collected Data Analysis
Material movement
Die movement
Not able to
fulfill the task
in required
time
Working area to be used by machine
Area covered by raw material
To be moved after every 84 minutes
Machine
position
24 m
16 m
6 m
2.5 m
Model 1 Model 2
Task Number of workers Details
Moving trolleys to
demould filled die
4 Workers to move the trolley from machine to
demoulding location to demould the mould
and place the empty moulds before the die
pusher.
Raw material filling in
machine
5 Two persons to fill the empty tasla and three
to take the tasla to machine to fill raw material
Die pushing for
cleaning
2 Both to push die for cleaning
Pushing cleaned die
in die pusher after
applying parting sand
1 Take the clean die apply parting sand and
place it before die pusher
Machine cleaning and
filled die collection
1 To clean the machine and to place filled
moulds in trolleys
Water supply to raw
materials
1 Supply water to raw material on a need basis
can also be used for some other bottleneck
operation for small time
Raw material
preparation for next
day
2 Mixing agro solvent waste , husk to soil for
use in next day's production
Labour details
VSBK (Vertical shaft brick kiln) Problem Origin
• Harsh conditions in unloading area
• Unhealthy environment for worker
• Fast unloading
• Sudden temperature shock to whole batch of bricks
• Low quality of fired bricks
Objectives
•To develop a motor based
unloading mechanism for VSBK
•Mechanism must enable unloading
at very slow speed so that there is a
gradual change of temperature in
the batch of brick above firing zone
Type of motor used 3 hp , 960 rpm
V-belt reduction ratio 3:1
Type of V-belt B type
Pitch diameter of smaller pulley 15 cm
Pitch diameter of larger pulley 44.1 cm
Centre to centre distance 62 cm
Gear box ratio used 60:1
Pitch diameter of Pinion 12 cm
Pitch diameter of Gear 96 cm
Module 6 mm
Number of teeth in pinion 20
System of gear teeth used 20 degree
involute system
Overall reduction ratio 3*60*8
Final rotating speed of nut 2/3 rpm
Models SuggestedModel 1 Model 2
Type of motor used 3 hp , 960 rpm
Type of chain Roller chain 08 B 1
Number of teeth in the pinion 23
Pitch of chain 12.7 mm
Pitch circle diameter of smaller
sprocket
94 mm
Velocity reduction ratio 4:1
Pitch circle diameter of larger sprocket 376 mm
Centre to centre distance 500 mm
Gear box ratio used 60:1
Pitch diameter of pinion 12 cm
Pitch diameter of Gear 96 cm
Module 6 mm
Number of teeth in pinion 20
System of gear teeth used 20 degree
involute system
Overall reduction ratio 4*60*8
Final rotating speed of nut ½ rpm

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Poster_Production Layout TBMM

  • 1. Problem Origin •Mechanized green brick production •Theoretical capacity- 1440 bricks per working hour •Actual productivity- 700 bricks per working hour •Reduced productivity due to- 1. Unorganized production schedule 2. Improper labour distribution 3. Absence of efficient production layout Objectives • To develop a production layout for TBMM • Layout should enable performance monitoring • Efficiency of machine should be about 80% Development Alternatives •One of the largest NGO in India. •Works for sustainable development •Works in close coordination with about 200 organization Innovation Systems branch • Addresses the multi faceted relationship between the people and the machine •Aims to create sustainable livelihoods •Prpducts to be produced are chosen after feasibility study and market analysis TBMM(TARA BRICK MEK MACHINE) Project Title Development of Production layout for TBMM and Introduction of some Mechanizations in VSBK Summer Internship 2009 Project Supervisor Dr. Sangeeta Kohli Project Mentor Mr. Subhankar Bose Project Coordinator Dr. Sanjeev Jain Existing Layout Models Suggested Abhinev Bhadauria Mechanical Engineering Department IIT Delhi Data Collected Data Analysis Material movement Die movement Not able to fulfill the task in required time Working area to be used by machine Area covered by raw material To be moved after every 84 minutes Machine position 24 m 16 m 6 m 2.5 m Model 1 Model 2 Task Number of workers Details Moving trolleys to demould filled die 4 Workers to move the trolley from machine to demoulding location to demould the mould and place the empty moulds before the die pusher. Raw material filling in machine 5 Two persons to fill the empty tasla and three to take the tasla to machine to fill raw material Die pushing for cleaning 2 Both to push die for cleaning Pushing cleaned die in die pusher after applying parting sand 1 Take the clean die apply parting sand and place it before die pusher Machine cleaning and filled die collection 1 To clean the machine and to place filled moulds in trolleys Water supply to raw materials 1 Supply water to raw material on a need basis can also be used for some other bottleneck operation for small time Raw material preparation for next day 2 Mixing agro solvent waste , husk to soil for use in next day's production Labour details VSBK (Vertical shaft brick kiln) Problem Origin • Harsh conditions in unloading area • Unhealthy environment for worker • Fast unloading • Sudden temperature shock to whole batch of bricks • Low quality of fired bricks Objectives •To develop a motor based unloading mechanism for VSBK •Mechanism must enable unloading at very slow speed so that there is a gradual change of temperature in the batch of brick above firing zone Type of motor used 3 hp , 960 rpm V-belt reduction ratio 3:1 Type of V-belt B type Pitch diameter of smaller pulley 15 cm Pitch diameter of larger pulley 44.1 cm Centre to centre distance 62 cm Gear box ratio used 60:1 Pitch diameter of Pinion 12 cm Pitch diameter of Gear 96 cm Module 6 mm Number of teeth in pinion 20 System of gear teeth used 20 degree involute system Overall reduction ratio 3*60*8 Final rotating speed of nut 2/3 rpm Models SuggestedModel 1 Model 2 Type of motor used 3 hp , 960 rpm Type of chain Roller chain 08 B 1 Number of teeth in the pinion 23 Pitch of chain 12.7 mm Pitch circle diameter of smaller sprocket 94 mm Velocity reduction ratio 4:1 Pitch circle diameter of larger sprocket 376 mm Centre to centre distance 500 mm Gear box ratio used 60:1 Pitch diameter of pinion 12 cm Pitch diameter of Gear 96 cm Module 6 mm Number of teeth in pinion 20 System of gear teeth used 20 degree involute system Overall reduction ratio 4*60*8 Final rotating speed of nut ½ rpm