PREPARATION OF PROCESS SHEETS FOR HEAVY MACHINE SHOP IN FABRICATION COMPLEX

1. SUMMER TRAINING ON
PREPARATION OF PROCESS SHEETS
FOR HEAVY MACHINE SHOP IN
FABRICATION COMPLEX
Guided by-
Mr. Pritesh Kankariya
Assistant Manager
Heavy Machine Shop
Fabrication Complex
Submitted by-
Asit KumarSahoo
2013JE0859
Mechanical Engineering
Final Year, B. Tech.

2. TITLE OF PROJECT
Preparation of process sheets for various assembled parts
of excavators during machining in the heavy machine shop
(HMS) inside the fabrication complex.
OBJECTIVES
•Increase productivity and easy operation for the workers.
•To reduce equipment related losses which are always a big
problem for the production department
•Create a format that will give the most information with the
least amount of effort
•Keep the data collection process as easy as possible

3. EXCAVATORS
Excavators are heavy construction equipments, consisting of a boom, arm,
bucket and cab on a rotating platform (Main Frame).The house sits at the top
of an undercarriage with tracks or wheels.

4. SIDE FRAME
BUCKET
ARM
TRACK
MAIN
FRAME
BOOM
USAGE
•Digging of trenches, holes, foundations
•Material handling, Forestry work, River dredging
•Mining activities, General grading/landscaping

5. COMPONENTS
Boom
Side frame

6. Bucket
Arm

7. Centre Frame Upper (CFU)
Centre Frame Lower (CFL)

8. PROCESS SHEET
A process sheet is a formal document that includes a series of performance instructions
and guidelines regarding a specific process or its part, and describes the operating
parameters and settings for the process to produce an associated product or service.
Constituents of a process sheet
A complete process sheet includes the following:
Model: Model of the excavator as EX-1200, ZX-650.
Component: Part of the excavator ,such as, Side frame, CFL.
Work: The machine which manufactures the component, such as, SNK, SHW.
Part no.: Every component is assigned a part no.
Date: Date of machining.
Process: Main process of machining, such as job setting, dialing of bores, etc.
Sub-process Sub-processes, which come under the main process.

9. Process Details: Complete details of the process which include the machining process
along with the dia. size (in case of boring) and the thread specification (in case of tapping).
Critical Points: Critical points include some important points related to safety of operation
and quality of product.
Photographs: Photographs of the machining operations
Drawing: Isometric and orthogonal views of the component
Other columns include the sign of operator, name of the person who has prepared the
process sheet and name of the person who has verified it.
Source Information
 Name of project
 Location of data collection
 Name of person recording data
(if applicable)
 Date(s)
 Other important identifiers
Requirements of a process sheet
Content Information
 Column with process details
 Columns with sequence/part
no. and sub-process
 Columns for photographs
 Columns with operator’s sign
 Space for drawing

10. SAMPLE PROCESS SHEET

11. Process Sheet for EX-1200 Hoe Bucket for TOS
•The Hoe Bucket is placed on the machine bed with the help of jacks
and blocks and it is clamped with the help of rope chains
•2 no. of side pushers of height 650 mm and 2 no. of side pushers of
height 450 mm are placed on the machine bed to support the job and
other parts of the bucket are supported by jacks of different heights.

12. •Dialing of the machine bed is performed by a dial gauge.
•Dialing of bores is done for both the bucket dump cylinder
holes and the bucket pivot holes.

13. •Boring Operation is performed on the Bucket Dump Cylinder holes
to maintain dimensions Φ 150.0 to Φ 150.2 mm.
•Front Facing Operation is performed on the front surfaces of the
Bucket Pivot holes.
•Drilling Operation of 5 no. of holes of Φ 19.5 mm is performed on
the front faced surfaces of the Bucket Pivot holes.

14. • Tapping Operation of those previously drilled holes
is done with a specification of M22X2.5 .Depth of
thread is 35 mm.
• Back Facing Operation is performed on the back surfaces of the
bucket pivot holes with the help of single and multi point cutting
tools.

15. • Step Turning Operation is performed on the back-faced surfaces
to get two cylindrical surfaces, one of Φ 314 mm and the other
surface of Φ 300 mm.
• Finally, Chamfering Operation is performed between the two
step-turned surfaces with the help of a chamfering single point
cutting tool to obtain a chamfered surface.

16. Other process sheets were prepared for:
• EX-1200 Side frame for SNK
• ZX-650 Side frame for SNK
• ZX-650 Hoe Boom for SHW
• EX-1200 Loader Rear Bucket for TOS
• ZX-650 Centre Frame Lower (CFL) for SNK
• EX-1200 CFL for SNK
• ZX-650 Loader Boom for SNK
• EX-1200 Hoe Boom for SHW
• EX-1200 Centre Frame Upper (CFU) for TOS
• ZX-650 CFU for SNK
• ZX-650 Hoe Arm for TOS

17. Benefits:
The benefits of process sheets are:
 Reduces the time to process and decide cases
 Reduces both process planning and manufacturing cost
 Creates more consistent plans
 Produces more accurate plans
 Increases productivity
 Reduces the skill required of a planner
 Minimizes equipment related losses
 Reduces the chances of any important aspect from being left out
while submitting case

18. Conclusion:
• Although process sheets are simple, process sheets are extremely
useful for process improvement and problem-solving tools.
• Mainly they concern on the different process sequences in main
frame fabrication.
• Process sheets show the whole sequence in an easy tabulated
manner and can serve the operators to perform their task in a
well-defined manner.

19. THANK YOU