1. PRODUCTIVITY IMPROVEMENT IN MANUFACTURING DIVISION OF SHEET
METAL INDUSTRY
Guided by : Dr. Gukan Rajaram
KANNAN P
Roll No : 13MM09
E-mail : Kanna1140@gmail.com
Mobile No : 9500254280
PROJECT WORK REVIEW : Phase 2 TITLE
Department of mechanical EngineeringDr.DRK- Prof.NGK- Prof.VVA ME : LM-4SEM13ML72 1
P S G T E C H

2. LITERATURE REVIEW
IMPROVING PRODUCTIVITY OF MANUFACTURING DIVISION USING LEAN
CONCEPTS AND DEVELOPMENT OF MATERIAL GRAVITY FEEDER
• Productivity improvement is achieved by optimizing the layout.
• Distance travelled by the material in the Proposed layout is compared with
current layout.
• Simulation of current and proposed layout is done by using Witness software to
identify the efficiency of each layout
PROJECT WORK REVIEW : Phase 2 LITERATURE REVIEW
Department of mechanical EngineeringDr.DRK- Prof.NGK- Prof.VVA ME : LM-4SEM13ML72 2
P S G T E C H

3. OBJECTIVES
• To achieve reduction in material movement distance for Gilbargo’s CE Carrier
assembly by 20%.
• To identify new spaces for Drilling station and Paint touch up station in powder
coating area instead of the packing area.
• To increase the utilization of resource by availing the suitable scrap sheets for
Punching operation.
• To introduce Multi hoist-Electrically operated overhead crane to load/unload
the part into pre-treatment process to reduce the waiting time
PROJECT WORK REVIEW : Phase 2 OBJECTIVE
Department of mechanical EngineeringDr.DRK- Prof.NGK- Prof.VVA ME : LM-4SEM13ML72 3
P S G T E C H

4. METHODOLOGY
PROJECT WORK REVIEW : Phase 2 METHODOLOGY
Department of mechanical EngineeringDr.DRK- Prof.NGK- Prof.VVA ME : LM-4SEM13ML72 4
P S G T E C H
Implementation and Follow-up phase
Proposed Layout
Analysis of results
Comparison of Layouts
Estimation of Performance
Simulation study
Redesigning of Layout
Problem identification
Collection of Data and Time study
Plant study

5. CATIA DIAGRAM OF PRODUCT
PROJECT WORK REVIEW : Phase 2 CATIA DIAGRAM OF PRODUCT
Department of mechanical EngineeringDr.DRK- Prof.NGK- Prof.VVA ME : LM-4SEM13ML72 5
P S G T E C H

6. PRODUCT DETAIL
• Product name - CE Carrier Assembly
• Customer - Gilbargo
• Demand
• Average demand - 450 products
• Lead time to delivery - 15 days
• Application - Fuel dispensing pump
PROJECT WORK REVIEW : Phase 2 PRODUCT DETAIL
Department of mechanical EngineeringDr.DRK- Prof.NGK- Prof.VVA ME : LM-4SEM13ML72 6
P S G T E C H
S.No Product name Demand
1 Aug2014 480
1 Oct2014 400
2 Dec2014 400
3 Jan2015 520

7. PROCESS MAP
PROJECT WORK REVIEW : Phase 2 DETAILED PROCESS MAP
Department of mechanical EngineeringDr.DRK- Prof.NGK- Prof.VVA ME : LM-4SEM13ML72 7
P S G T E C H
Punching Part removal Filing
DeburringWelding/
fabrication
Pre-treatment
Powder coating Drilling Assembly/packing

8. TIME STUDY
PROJECT WORK REVIEW : Phase 2 TIME STUDY
Department of mechanical EngineeringDr.DRK- Prof.NGK- Prof.VVA ME : LM-4SEM13ML72 8
P S G T E C H
DETAILS OF TIME STUDY
operati
on
number
Machine type
Numbe
r of
operat
ors
Numb
er of
compo
nent
Loading
&
unloadin
g time
(s)
Value
added
time per
compone
nt
Total cycle
time per
compone
nt
(s)
setup
time
cycle time allowance inventory
Material
movemen
t distance
1 Punching 1 1 70 850 920 54000 22
2 Part removal 2 6 40 200 240 0 2550 382.5 2932.5 10
3 Filling 2 6 50 27 77 0 600 90 690 11.1
4 Deburring 2 6 80 62 142 180 480 72 732 10
5 Pressing 2 6 50 150 200 300 1110 166.5 1576.5 14.3
6 Welding 6 6 100 600 700 1200 2700 405 4305 84.1
7 Pre-Treatment 3 12 720 3000 3720 4200 5400 810 10410 54.5
8
Powder
coating
5 6 100 2000 2100 1600 6480 972 9052 81.3
9 Drilling 1 6 120 40 160 120 10500 1575 12195 35.4
10 Inspection 2 6 40 100 140 60 720 108 888 16

9. CURRENT LAYOUT
PROJECT WORK REVIEW : Phase 2 CURRENT LAYOUT
Department of mechanical EngineeringDr.DRK- Prof.NGK- Prof.VVA ME : LM-4SEM13ML72 9
P S G T E C H

10. PROJECT WORK REVIEW : Phase 2 MATERIAL MOVEMENT
Department of mechanical EngineeringDr.DRK- Prof.NGK- Prof.VVA ME : LM-4SEM13ML72 10
P S G T E C H
MATERIAL MOVEMENT

11. PROJECT WORK REVIEW : Phase 2 CSVSM
Department of mechanical EngineeringDr.DRK- Prof.NGK- Prof.VVA ME : LM-4SEM13ML72 11
P S G T E C H
CURRENT STATE VALUE STREAM MAPPING

12. PROJECT WORK REVIEW : Phase 2 PROPOSED LAYOUT
Department of mechanical EngineeringDr.DRK- Prof.NGK- Prof.VVA ME : LM-4SEM13ML72 12
P S G T E C H
PROPOSED LAYOUT

13. DISTANCE TRAVELED BY OPERATOR WITH MHS
S.NO Station
Distance
traveled
with MHS
(m)
Distance
traveled
without
MHS
(m)
Distance
traveled
in
conveyor
(m)
1 Punching 0.73
2 Part removal 0.6
3 Filing
4 Deburring 2.45
5 Pressing 3.75
6 Welding 23.5
7 Pre-treatment 0.23 7.32
8 Powder coating 4.54 34.88
9 Drilling 7.55
10 Inspection 0.6
11
Assembly
/packaging
0.83
DISTANCE CALCULATION FOR CURRENT LAYOUT
PROJECT WORK REVIEW : Phase 2 DISTANCE CALCULATION
Department of mechanical EngineeringDr.DRK- Prof.NGK- Prof.VVA ME : LM-4SEM13ML72 13
P S G T E C H
DISTANCE TRAVELED BY MATERIAL
S.NO Station
Distance traveled with
MHS (ft)
Distance traveled
without MHS (ft)
1 Punching 14 8
2 Part removal 10
3 Filing 11.1
4 Deburring 3 7
5 Pressing 14.4 0
6 Welding 62.8 21.3
7 Pre-treatment 33.6 20.9
8 Powder coating 17.4 64
9 Drilling 31.9 3.5
10 Inspection 16
11 packing 3

14. DISTANCE CALCULATION FOR PROPOSED LAYOUT
PROJECT WORK REVIEW : Phase 2 DISTANCE CALCULATION
Department of mechanical EngineeringDr.DRK- Prof.NGK- Prof.VVA ME : LM-4SEM13ML72 14
P S G T E C H
DISTANCE TRAVELED BY MATERIAL
S.NO Station
Distance traveled
with MHS (m)
Distance traveled
without MHS (m)
1 Punching 14 8
2 Part removal 10
3 Filing 11.1
4 Deburring 3 7
5 Pressing 14.4
6 Welding 62.8 21.3
7 Pre-treatment 7.1 20.9
8 Powder coating 21 64
9 Drilling
10 Inspection
11 packing 31.9

15. COMPARISON OF CURRENT WITH EXISTING LAYOUTS
PROJECT WORK REVIEW : Phase 2 COMPARISON WITH EXISTING LAYOUT
Department of mechanical EngineeringDr.DRK- Prof.NGK- Prof.VVA ME : LM-4SEM13ML72 15
P S G T E C H
Welding Pre-treatment Powder coating Drilling paint touch up packing
Current layout 14 11.1 3 14.4 62.8 33.6 17.4 31.9 16 3
proposed layout1 14 11.1 3 14.4 62.8 7.1 21 31.9
0
10
20
30
40
50
60
70
COMPARISON OF CURRENT LAYOUT & PROPOSED LAYOUT

16. EXPECTED RESULTS
• Total distance travelled by a material in current layout
= 207.2 ft
• Total distance travelled by a material in the proposed layout
= 165.3 ft
PROJECT WORK REVIEW : Phase 2 EXPECTED RESULTS
Department of mechanical EngineeringDr.DRK- Prof.NGK- Prof.VVA ME : LM-4SEM13ML72 16
P S G T E C H

17. FUTURE STATE VALUE STREAM MAP
PROJECT WORK REVIEW : Phase 2 FSVSM
Department of mechanical EngineeringDr.DRK- Prof.NGK- Prof.VVA ME : LM-4SEM13ML72 17
P S G T E C H

18. ARENA SIMULATION MODEL
PROJECT WORK REVIEW : Phase 2 Arena Model
Department of mechanical EngineeringDr.DRK- Prof.NGK- Prof.VVA ME : LM-4SEM13ML72 18
P S G T E C H

19. PROJECT WORK REVIEW : Phase 2 KAIZEN
Department of mechanical EngineeringDr.DRK- Prof.NGK- Prof.VVA ME : LM-4SEM13ML72 19
P S G T E C H

20. REAL TIME DATA TRACKING SYSTEM-FRONT END
PROJECT WORK REVIEW : Phase 2 Real time Data tracking system
Department of mechanical EngineeringDr.DRK- Prof.NGK- Prof.VVA ME : LM-4SEM13ML72 20
P S G T E C H

21. REAL TIME DATA TRACKING SYSTEM-BACKEND
PROJECT WORK REVIEW : Phase 2 Database
Department of mechanical EngineeringDr.DRK- Prof.NGK- Prof.VVA ME : LM-4SEM13ML72 21
P S G T E C H

22. PROJECT WORK REVIEW : Phase 2 KAIZEN
Department of mechanical EngineeringDr.DRK- Prof.NGK- Prof.VVA ME : LM-4SEM13ML72 22
P S G T E C H

23. PROJECT WORK REVIEW : Phase 2 KAIZEN
Department of mechanical EngineeringDr.DRK- Prof.NGK- Prof.VVA ME : LM-4SEM13ML72 23
P S G T E C H

24. PROJECT WORK REVIEW : Phase 2 KAIZEN
Department of mechanical EngineeringDr.DRK- Prof.NGK- Prof.VVA ME : LM-4SEM13ML72 24
P S G T E C H

25. PROJECT WORK REVIEW : Phase 2 Multi Hoist-Electrically operated overhead crane
Department of mechanical EngineeringDr.DRK- Prof.NGK- Prof.VVA ME : LM-4SEM13ML72 25
P S G T E C H

26. IMPLEMENTATION
PROPOSED LAYOUT:
Investment cost = Rs. 5000
Monthly cost saving = Rs. 500
Return Of Investment = 10 months
ROI calculation
PROJECT WORK REVIEW : Phase 2 Implementation
Department of mechanical EngineeringDr.DRK- Prof.NGK- Prof.VVA ME : LM-4SEM13ML72 26
P S G T E C H

27. FUTURE WORK
• Comparison of results for current and proposed layouts.
• Implementation of Visual studio application to store the necessary detail about
Scrap sheets.
• Implementation of Material Handling device to hold the material that is removed
from the conveyor.
• Design and development of Multi-Hoist Electrically operated overhead crane in
the pre-Treatment area.
PROJECT WORK REVIEW : Phase 2 FUTURE WORK
Department of mechanical EngineeringDr.DRK- Prof.NGK- Prof.VVA ME : LM-4SEM13ML72 27
P S G T E C H

28. THANK YOU
PROJECT WORK REVIEW : Phase 2
Department of mechanical EngineeringDr.DRK- Prof.NGK- Prof.VVA ME : LM-4SEM13ML72 28
P S G T E C H