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ELIMINATION OF CHANGEOVER BY RE-DESIGNING THE FIXTURE

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The aim of project is to eliminate the change over time of Wheel Cylinder unit by redesigning the fixture for reducing the failures and retest that mostly gets rejected while conducting the four types of tests (Vacuum test, Stroke test, Bleed test, Air-leak test) on wheel cylinder. This redesigned fixture for conducting the Air leak test is done on the motive of replacing the usage of two different fixtures for testing two different Wheel cylinder models that does not need to be changed for the production of a particular model. So, the operator does not need to change the fixture every time when every different model comes for the production. By implementing this redesigned fixture, the failure parts or rejected jobs will decrease and also the retest percentage will also be considerably reduced. Redesigning of fixture is done by using mechanical means of Shigley’s design process initially and by the Quality control tools and techniques.

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ELIMINATION OF CHANGEOVER BY RE-DESIGNING THE FIXTURE

  1. 1. ELIMINATION OF CHANGE OVER BY RE-DESIGNINGTHE FIXTURE Dr. M.HENRYXAVIER InternalGuide P.RAJA External Guide HARI SHANKAR .G (113011114035) DHANDAPANI .C (113011114307) VINOD KUMAR.P (113011114327)
  2. 2. COMPANY PROFILE Company Name BRAKES INDIA,Padi. Established 1962 Net Worth 128 m USD Sales (2011) 591.80 m USD Employees 6655 Engineers 980 Built up Space 1000,000 Square feet Mfg Locations 12 No. Customers 70 Certifications TS16949, ISO 14001,TPM*,Deming**
  3. 3. MAJOR CUSTOMERS OF BRAKES INDIA
  4. 4. PRODUCTS MANUFACURED CALIPERS BRAKE HOSE & CLUTCH HOSE ASSY. BRAKE FLUID FRICTION MATERIAL SEALS BOOSTER ASSY CASTINGSDRUM BRAKES HCV BRAKE CALIPERS
  5. 5. ABSTRACT The aim of project is to eliminate the change over time of Wheel Cylinder unit by redesigning the testing clamp for reducing the failures and retest, that mostly gets rejected while conducting the four types of tests (Vacuum test, Stroke test, Bleed test, Air-leak test) on wheel cylinder test rig during the replacement of job. This redesign of clamp for conducting the Air leak test is done on the motive of replacing the usage of two different fixtures for testing two different Wheel cylinder models that does not need to be changed for the production of a particular model. So, the operator does not need to change the fixture every time when another model comes for the production. Our project is directed towards finding a solution • To avoid changing of testing clamp for every wheel cylinder model. • To make the operator easy to work. • For Less Rejection of jobs or failure rate.
  6. 6. Wheel Cylinder terminology
  7. 7. CHANGEOVER Changeover is the process of converting a line or machine from running one product to another. Changeover times can last from a few minutes to as much as several weeks in the case of automobile manufacturers retooling for new models. Changeover can be divided into the 3 Ups:  Clean-up  Set-up  Start-up
  8. 8. FINDING THE PROBLEM BY TRADITIONAL SHINGLEY’S PROCESS 1.REGONITION OF NEED DATA COLLECTION:  Two weeks of data study, Time study, procedure study on the jobs and machines had taken.  Collected information and made a study over the jobs.  Finally decided to have a project on rejection of failure jobs. Labels,Assembly-13,0 Labels,Assembly-06,0 Labels,Assembly-05,0 Labels,Assembly-04,0 Labels,Assembly-11,0 Labels,Assembly-09,0 Labels,Assembly-08,0 Labels,Assembly-12,0 Labels,Assembly-02,0 Labels,Assembly-01,0 Cumulative% RetestQuantity Assembly line PARETTO DIAGRAM Vital Few Useful Many Cumulative% Cut Off % [42]
  9. 9. PROCESS FLOW CHART
  10. 10. 2.DEFINITION OF PROBLEM:  The problem can be defined by 4W+1H Method.  What - Fail, fault and Re-test problem. Where - at Assembly line-13. When - Quiet Frequently particularly on changing the specified wheel cylinder model during testing. Who - Operator notices the problem. How - To reduce the severity or occurrence as much as possible. SUMO GOLD BOLERO
  11. 11. TESTING SEQUENCE IN ASSEMBLY LINE
  12. 12. 1. Sealing rubber damage 2. low Clamping pressure 3 . More Fail After Change Over 4. Port Sealing Arm Misalignment 5. Wrong fixture selection 6. Wrong loading CAUSES OF THE PROBLEM
  13. 13. More fail after the changeover During the changeover port sealing adaptor height wrongly set After the changeover Port sealing shifted Height setting is manual control 4.ANALYSIS OF THE CHAGE-OVER PROBLEM : Fixture design
  14. 14. 5.ANALYSIS OF THE MISALIGNMENT PROBLEM : Port sealing arm soft materiel Swing arm mounting face damaged Port sealing arm orientation misalignment During port clamping & de clamping arm damaged Fixture design Wheel cylinder more fail
  15. 15. 7.SOLUTION OF THE PROBLEM: 1.Eliminate the setting height and commonise the fixture for both models. 2.The new fixture that suits for both the models is designed and implemented. 3.The fixture’s adaptor and arm should be changed to avoid the misalignment because of damage in the mounting face. Therefore swing arm hardness to be increased. 6.IMPORTANCE OF THE PROBLEM 1.Cell Overall equipment effectiveness will reduced. 2.Difficult to meet the customer demand 3.Retest time will increase 4.Possibility of rejection part to meet the customers. 5.Operator can confuse due to frequent fails.
  16. 16. DRUM BRAKE LINE Wheelcylinder testing fail Due to wheelcylinder fail customer line stop Impact Of The Job Fail WHEEL CYLINDER ASSEMBLY LINE
  17. 17. EXISTING FIXTURE 35 MM 15 MM SUMO GOLDBOLERO
  18. 18. COUNTER MEASURES ON THE ANALYSIS OF CHANGE-OVER PROBLEM: 1.ELIMINATE THE HEIGHT SETTING. 2.COMMONIZE THE FIXTURE FOR ALL PRODUCTS COUNTER MEASURES ON THE ANALYSIS OF MISALLIGNMENT PROBLEM: 1.ARM TO BE HARDEN
  19. 19. HOW WE ARE CHOOSING COMMON ADOPTER
  20. 20. Trial & Error Method S.NO SUMO GOLD BOLERO 1. Adopter 35mm Fail Ok 2. Adopter 20mm Ok Fail 3.Adopter 30mm Fail Ok 4. Adopter 22mm Fail Fail 5. Adopter 23mm Ok Ok 6. Adopter 24mm Ok Ok 7. Adopter 25mm Ok Ok We are choosing 25mm adopter for safe and good clearance between job to top dead Center (TDC) RESULT : Adopter __mm + Nylon Rubber 15mm + Harm Thickness 12mm
  21. 21. Designed Fixture Drawing Update

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