A must needed presentation for B.TECH (Mechanical Engg) final year students. In this slide i have covered almost all topics that are presented in lean manufacturing process.

1. LEAN
MANUFACTURINGPresented By:
Mayank Tamrakar
ME(16)
1601440025

2. INDEX
 Introduction
 Features
 Dimensions
 Specifications
 Bogie
 Traction motor
 Braking system
 Regeneration brakes
 Roof
 Cab
 Cab overview
 Advantages

3. INTRODUCTION
 Lean manufacturing is a methodology that focuses on minimizing
waste within manufacturing systems while simultaneously
maximizing productivity.
 Through lean manufacturing, what adds value becomes clear by
removing or reducing everything that doesn’t add value.
 The idea of lean manufacturing was first championed by the Toyota
Production System and called lean in the 1990s.
 This coincided with the growth of Toyota from a small company to
one of the world’s most successful seller of motor vehicles.

4. TOOLS
 From the various tools of lean manufacturing some
of them are discussed below :-

5. 5S
 SEIRI (eliminate that which is
not needed)
 SEITON (organize remaining
items)
 SEISO (clean and inspect
work area)
 SEIKETSU (write standards
for above)
 SHISUKE (regularly apply
the standards)
Eliminates waste that results
from a poorly organized work
area (e.g. wasting time
looking for a tool).
Figure-5

6. • Beside these 5S there is also a 6th s recently launched known as safety,
which is also an important aspect in industries now a days.
BENEFITS FROM 5S:-
• Reduced costs
• Higher quality
• Increased productivity
• Greater employee satisfaction
• A safer work environment
EXAMPLE:-

7. KAIZEN
 Kaizen is the Japanese word for “continual improvement.”
 The term refers to activities that improve every function of a
business and is generally applied to manufacturing, but can be used
to make almost any business more efficient.
 By definition, Kaizen includes the involvement of all employees,
from upper management to assembly line workers and can be used
to improve every process in a supply chain, from purchasing to
logistics.
 The lean manufacturing tool was first used by the Japanese in World
War Two.

8. What is the goal of Kaizen?
• Kaizen seeks to improve standardized processes in order to eliminate
waste, fix workflow issues, and solve business problems.
How is Kaizen implemented?
• The Kaizen method generally involves 5 primary steps:
1. Identify problem area that will be given focus.
2. Utilize videotape to analyze current method.
3. Test and evaluate improvement tactics.
4. Implement improvements.
5. Analyze results and present to upper management for feedback.
What is Kaizen most applicable to?
• The Automotive industry. In fact, the Toyota Production System made the
tool famous.

9. JUST IN TIME
 Just in Time is a lean tool that calls for the production of what a
customer wants, when they want it, in the quantity they want it, and
where they want it.
 Instead of creating a large stock of a product that sits in warehouses,
we only create as much of an item as a customer actually wants.
 This reduces unnecessary inventory and ensures that companies
only spend on stock that will be paid for.
 Just in Time was invented by Toyota during WWII.
 The tool was invented at a time when producing extra stock
was simply too expensive and not possible.
 Companies could only afford to produce what a customer
actually wanted.

10. ADVANTAGES :-
• Highly effective in reducing inventory levels.
• Improved cash flows.
• Reduces space requirements.

11. CELLULAR MANUFACTURING
 Cellular Manufacturing is the process of producing similar products
in one cell.
 The product, in Cellular Manufacturing, moves through the
production process in a single unit without interruptions.
 In Cellular Manufacturing, similar products can be produced on the
same assembly line.

12. What are the benefits of Cellular Manufacturing?
The benefits of Cellular Manufacturing include:
• Group similar products together to reduce time of changeover.
• Effectively utilize space during entire production process.
• Increase flexibility and transparency.
• Reduce lead time.
• Increase overall productivity.
• Enhance teamwork and communication between employees and
departments.

13. SIX SIGMA

14. PRINCIPLES
 Recognition of waste
 Standard processes
 Continuous flow
 Pull production
 Quality at the source
 Continuous improvement

15. TYPES OF WASTE
In order for lean project management to be most effective, waste
is defined in three specific ways.
Mura: Unevenness, or waste due to fluctuations in demand.
This can come from customer requests, but it can also be due to
an organization adding new services and thus additional work.
Muri: Overburden, or waste due to trying to do too much at
once. This has to do with resource allocation.
Muda: Non-value-adding work, or process waste. This waste
comes as a byproduct of something else.
Therefore, lean maximizes value, minimizes necessary waste
and removes unnecessary waste altogether.

16. BRAKING SYSTEM
There are 5 types of brakes available on this loco.
1. Automatic Train Brake (A9)
2. Direct Brake (SA9)
3. Parking Brake (Spring Loaded)
4. Emergency brake
5. Regeneration Brakes.(Elect)
Note: All the brake system functions are monitored by brake electronics and if there
any wrong configuration, the brake electronics do protective action along with the
indication of message on the screen in the drivers cab.

17. REGENERATION BRAKES
 Regenerative braking system system
is one in which motor acts as
generator. Due to reverse action it
produces electricity which is used to
charge the batteries or send back to
the system.
 . The first regenerative system was
used in the car Amitron in 1967.
 Efficiency is only 20 percent rest is
discarded through friction.
Regenerative braking increases this
up-to 45 percent and rapidly reduces
the fuel consumption. Hydraulic
regenerative braking steeply ascends
the potential of a vehicle
Figure-6

18. ROOF
Main components present on roof of WAG 9H loco are :-
1. Pneumatic horn
2. Vaccum ckt breaker
3. Pantograph
4. Lightening arrestor
5. High voltage transformer
6. OCB filter

19. CAB
Figure-7

20. CAB OVERVIEW
There are total 25 controllers and components present in cab. Some of them are:-
1. Crew fan
2. Lamp driver’s desk illumination
3. Pneumatic horn controller
4. Emergency flash light wiper
5. Panel A loco brake
6. Reverser
7. Brake handle direct loco brake
8. Brake handle automatic train brake Panel
9. Foot switch SANDING
10. Emergency brake cock
11. Parking Brake (PB) gauge
12. Wiper motor

21. ADVANTAGES
 The size of traction motor for the same output power is much less in
case of a 3-phase induction motor compared to DC motor.
 Maintenance cost of a 3phase locomotive is less due to absence of
brush-gear/ commutator in the traction motors and switchgears in the
power circuit.
 Induction motors are very robust. Consequently reliability of a 3-phase
locomotive is higher.
 In case of 3-phase loco motives, full power is available up to the
maximum speed.
 Overload capabilities in 3-phase locomotives are more Liberal.
 Regeneration of power is available in 3-phase locomotives.
 Regenerative braking effort is available from the full speed till dead
stop.
 Due to lesser weight of the traction motors, the un-sprung masses in 3-
phase locomotive are low. This reduces track forces and consequently
minimizes wear on rails and disturbance to track geometry.

22. REFERENCES
 From Engineers of BHEL Jhansi
 From internet :-
https://www.google.com/search?q=WAG+9H+LOCOMOTIVE+BHEL+JHANSI&o
q=WAG+9H+LOCOMOTIVE+BHEL+JHANSI&aqs=chrome..69i57.8967j0j8&sou
rceid=chrome&ie=UTF-8
https://www.google.com/search?q=regenerative+brake+of+wag+9h&oq=rege
nerative+brake+of+wag+9h&aqs=chrome..69i57j33.13080j0j8&sourceid=chr
ome&ie=UTF-8

23. THANK YOU…