3. Module 2: Layout
Fillet Rolling Taper
Bore
Crack
Detection Complete
Inspection Area
Bush Pressing
and
Broaching
Keyway
Broach
(Vertical
Broaching)
Wash/Anti-
Rust
Application
Packaging
Number
Punching
4. Problems Faced on Knuckle Line
• Number Punching operation being done manually
• Doors of CNC machines need to be closed manually
• One person doing multiple jobs on module 1
• Center drill remains idle
• Checking for tooling problems
• Insert wear
• Turret shifts downwards when idle for long times on FMS
5. Process Time(T1)(Seconds) T2 T3 T4 T5 T6 T(avg) in sec
1. Pick up job and place
on center drill
41.6 37.4 43.7 31.3 48.2 46.1 41.38
2. Center drill operation 66 64 62 63 63 64 63.66
3. Pick up job from central
drill and place for rough
turning
25.9 32.9 30 37 33.8 31.2 31.8
4. Rough turning 248 240.078 240.076 240.078 240.08 240.07 241.4
5. Remove and Punch 22.6 21.2 18.1 42.8 20.9 21 24.43
6. Pick and place for
finishing and complete
operation time
212 235 206.3 210.5 205 207.6 212.73
7. Inspection after
finishing(Includes picking
job from FMS)
137 57 29.8 44 43 62.16 62.15
Total Average time 677.56
Process Time Evaluation (Module 1)
6. Process Time T1 T2 T3 T4 T5
T(avg) in
sec
1. Pickup job and place on Centering machine 53.6 54.2 68.9 92 72
68.14
2. centering machine operation time 60.1 59.6 55.8 62 60.2
59.54
3. Pickup from centering machine and place on Proteck 45 32 33.1 36 44
38.02
4. Proteck operation time 248 248 248 248 248 248
5. Pickup job from Proteck and place for number punching 25 19.1 18.6 20 23
21.14
6. Pickup job from punch and place on FMS 30 54 32.9 52 29.3 39.64
7. FMS operation time 216 209 210 212 205 210.4
8. Pickup from FMS place for inspection/complete inspection 70.2 70.8 78 65 72
71.2
Total average time
756.08
Process Time Evaluation(Module 1)
7. Error Proofing – MCD II
Source of Defect Knuckle Line
Problem Statement
Number punching operation missing & Number
punching location shift
Analysis
Number punching missing & location shift due to
number punching activity is manual.
Occurred at Knuckle Line
8. Lift the job from input
pallet.
Keep the job on stand
manually with proper
orientation for number
punching –
(Unsafe working
condition )
Manual number
punching operation
done by holding number
punching machine in
hand
ProcessFlowat jobloadingstage-Before
Facing & centeringRough turningFinish turning
9. Lift the job from input
pallet.
Facing & centering
operation Rough turning
ProcessFlowat jobloadingstage-After
Automatic number
punching operation
with button start.
Finish turning
operation
10. ErrorProofing–Checklist
Principles Questions to be asked to the process Solution
Effectiv-
ness
Cost
Implim
entatio
n
SPN
Elimination
Can we eliminate the error-prone process in totally? No
Can we eliminate the error from process partially? No
Replace-ment
Can we automate the process? Yes , automation can be done for number
punching operation 3 3 3 27
Can we provide supporting tools like
checklists/gages/samples?
Yes
1 3 3 9
Facilitata-tion
Can we simplify the operation or introduce changes
in the operation? (standardization, color coding,
unique shape, etc)
No
Detection
Can we record the outcome / product parameters of
the earlier operation and verify it before starting
next operation
No
Can we restrict the motion in such way that the
operator will see the abnormality?
No
Can we verify the outcome / product parameters of
the said operation before passing the part to next
operation ?
No
Mitigation
Can we make detection at multiple levels? No
Can we make ergonomic condition better so as not
to produce / miss the defects?
Yes
1 2 3 6
Solution Priority Number (SPN) Criteria
Effecive-ness 1 : Less Effective 2 : Effective 3 : Very Effective Solution
Cost 1 : High 2 : Medium 3 : Low
Automation is required at number punching station
Implemen-tation 1 : Difficult 2 : Easy 3 : Very Easy
13. ErrorProofing–DesignReview
Sr.
No.
Design Review
Parameter
Description
1 Fail-Safe
performance
Unsafe working condition eliminated at manual number
punching
2 Cost effectiveness Proposed solution is cost effective.
3 Ease of operation Easy to operate as button start.
4 Protection from
external damage
Automation setup is mounted on stand hence no chance of
damage.
5 Simplicity in design Proposed solution is simple to implement.
14. Grinding
Operation
Time
T1 T2 T3 T4 T5 Average
Loading 22.5 64 53 61 47 49.50
Commands 6.3 4 14.01 10.58 8.4 8.66
Operation time 180 181 180 180 181 180.40
Inspection 73 63 68 71 62 67.40
Unloading 32 29 31 26 27 29.00
Rotate Job 12.26 12.15 12.33 12.01 11.48 12.05
Input Job Number on
record 12.17 12.35 12.48 12 13.2 12.44
Total time 359.44
Time in min 5.99
15. Hardening
Operation
Time(sec)
T1 T2 T3 T4 T5 Average
Loading 47.37 25.28 65 50 54 48.33
Operation Time 170 172 170 171 170 170.60
Unloading 97 54 34 45 68 59.60
Total time 278.53
Time in
min 4.64
16. 16
Action plan
Sr. no Machine Activities
Time saved by
(sec) Remark
Grinding and
Hardening
1
Make provision for parking crane near
operator for ease of operation 6
2 Job should be ready prior to operation 8
3
Fixture for resting job and air nozzle for
removal of central burr 5
4
Provide stand near grinding operation for
inspecting the job 40
5
Provide conveyor along with coolant after
hardening 15
6 Stand for log book for better ergonomics 4
7 Combine two snap gauges 12
