1. International Journal of Applied Engineering Research
ISSN 0973-4562 Volume 9, Number 18 (2014) pp. 5197-5208
© Research India Publications
http://www.ripublication.com
Productivity Improvement in Bottleneck Machine for
Automated Cylinder Block Line
Ajinkya P. Patil#1
and Yash B. Parikh#2
#1
PG Student, Department of Mechanical Engineering,
Symbiosis Institute of Technology, Pune, India.
#2
Assistant Professor, Department of Mechanical Engineering,
Symbiosis Institute of Technology, Pune, India.
1
ajinkya.p.patil@sitpune.edu.in 2
yash.parikh@sitpune.edu.in
Abstract
Production lines in the industries are not that simple. Many parts of different
sizes are produced through various combinations of the equipments.
Bottleneck machines are those which are of high importance in any production
line. In this paper a detailed study about productivity improvement for the
automated cylinder block line was carried out. Initially the production output
of cylinder block line was studied for the duration of six months starting from
June 2013 to November 2013. From this study it was concluded that cylinder
block line was facing intricacy in attaining the desired number of cylinder
blocks in comparison to what was expected. Further, breakdown study
revealed that the high pressure washer machine was vastly responsible in
hampering the productivity of the cylinder block line. To overcome this
dilemma an extensively study was carried out taking critical problems into
consideration to improve the productivity of the cylinder block line.
Modifications were successfully implemented which in turn helped attaining
the higher productivity for the cylinder block line.
Keywords: Productivity, Bottleneck Machine, Breakdowns, Modifications,
Improvement.
Introduction
Productivity is defined as the ratio of what is produced to what is required to produce
it. Productivity measures the relationship between outputs such as goods and services
produced, and inputs such as cost, labour, material and other resources. Increasing the
productivity is always considered to be main driver of competitiveness in the price

2. 5198 Ajinkya P. Patil and Yash B. Parikh
sensitive market [1]. Manufacturing facility mainly focuses on the equipment
management and their maintenances to meet its profitability goal [2]. In
manufacturing process there is always one part of the process usually a machine that
is slowest and it may affect the production, this is called as the bottleneck machine.
Bottleneck stays in one place and continuously slows down whole line. Industrial
washing has significant importance as it removes the oil, chips and shop dirt/dust
accumulates on the components before they get packed. The machine considered for
the study is a high pressure washer machine, which is referred to as a bottleneck
machine because of its high importance. It cleans the cylinder block by following
three main processes namely cylinder block washing, drying in a vacuum station and
then cooling it to the room temperature. This machine not only restricts components
to get spoiled but also enhances their precision and performance. In such a critical
scenario if the high pressure washer machine works with less efficiency then it affects
the entire cylinder block line and makes it a less productive. The problem considered
here for the study dealt with finding the root causes which hampered the productivity
of the high pressure washer machine. To overcome the problems faced certain
remedial measures were also established.
The basic structure of the high pressure washer machine is shown in the figure
below. It has mainly three stations which are washing station, Vacuum station (with
the help of vacuum) and cooling station.
Fig. 1. High pressure washer machine (Courtesy: Valiant, USA.)
Case Study
This study was carried out in the car manufacturing unit in Pune, Maharashtra, India.
This study was conducted during the period of June 2013 to March 2014 and the
values chosen are meant for justifying the research initiatives only. The study

3. Productivity Improvement in Bottleneck Machine 5199
involved taking readings and observations pertaining to the efficiency loss of the high
pressure washer machine during the month of June 2013 to November 2013. After
which a remedial measure was established and successful implementation of the same
was done in the month of December 2013. Post implementation of the remedial
measure again the study was carried out during the month of January 2014 to March
2014 which showed significant improvement in the productivity of high pressure
washer machine.
Calculations on efficiency of high pressure washer machine from June, 2013 to
November, 2013 (before implementation):
Initially the study focuses on obtaining the total efficiency of the cylinder block
line from the month of June, 2013 to November, 2013 along with the total breakdown
of the cylinder block line. (See Table I) Further investigation focuses on finding the
time available with the high pressure washer machine which is considered here as a
bottleneck machine and to calculate the total efficiency of cylinder block line for the
said months. Also the breakdowns pertaining to the productivity loss at high pressure
washer machine were also calculated.
TABLE I
Sr.
No
Months Total Working
Time (Minutes)
Total Breakdown
Time ( Minutes)
Total Efficiency
of Cylinder
Block Line (%)
1 June’13 14440 2152 85
2 July’13 15360 1685 89.03
3 August’13 13440 2421 81.98
4 September’13 20160 2357 88.3
5 October’13 20160 3010 85.069
6 November’13 12480 1943 84.43
Total efficiency of an automated cylinder block line from June’13 to November’13.
The study revealed that the major portion of the productivity loss in cylinder block
line during the said months were due to the often breakdowns of high pressure washer
machine. The following calculations were carried out to understand the status of
productivity of the bottleneck machine. The sample calculations shown below are for
the month of June’2013. The remaining results have been tabulated. (See Table II)
Total working time of the cylinder block line for the month of June, 2013 = 14440
Minutes
Total breakdown time of the cylinder block line for the month of June, 2013 = 2152
Minutes
Total efficiency of the cylinder block line for the month of June, 2013 = (14440 –
2152)/(14440) * (100) = 85%
Status of productivity of high pressure washer machine for the month of June, 2013:
Total breakdown time of the cylinder block line for the month of June, 2013 = 2152
Minutes

4. 5200 Ajinkya P. Patil and Yash B. Parikh
Total breakdown time of the high pressure washer machine for the month of June,
2013 = 260 Minutes
Total Productivity of the high pressure washer machine for the month of June, 2013 =
(2152 – 260) / (2152) * (100) = 87.92%
Fig. 2. Total efficiencies of cylinder block line and high pressure washer machine
from June’13 to November’13.
After analyzing the productivity of high pressure washer machine, which has mainly
three sections, namely washing station, vacuum station and cooling station, the fish-
bone diagram (See Figure 4) was prepared to further investigate the possible problems
in the bottleneck machine.
Further, each of these problems was analyzed for their individual contributions
towards the productivity loss of high pressure washer machine. The sample
calculations shown below are for all the three sections for the month of June’2013.
Total available time of the cylinder block line for the month of June, 2013 = 14440
Minutes
Total breakdown time of the cylinder block line for the month of June, 2013 = 2152
Minutes
Calculations of the productivity of high pressure washer machine for the month of
June, 2013:
Total available time of High Pressure Washer Machine for the month of June, 2013 =
9488 Minutes
Total breakdown time of High Pressure Washer Machine for the month of June, 2013
= 1345 Minutes
Total productivity of High Pressure washer machine for the month of June, 2013 =

5. Productivity Improvement in Bottleneck Machine 5201
(9488 – 1345) / (9488) = 85.58 %
Total loss of productivity for the month of June, 2013 = 14.42 %
Calculations for contribution made by washing station: June, 2013
Total breakdown time of bottleneck machine for the month of June, 2013 = 1345
Minutes
Breakdown time of bottleneck machine because of washing station for the month of
June, 2013 = 939 Minutes
Percentage contribution by washing station in productivity loss of high pressure
washer machine in the month of June, 2013 = (100) - (1345 – 939) / (1345) = 69.81%
Calculations for contribution made by vacuum station: June, 2013
Total breakdown time of bottleneck machine for the month of June, 2013 = 1345
Minutes
Breakdown time of bottleneck machine because of vacuum station for the month of
June, 2013 = 330 Minutes
Percentage contribution by vacuum station in productivity loss of high pressure
washer machine in the month of June, 2013 = (100) - (1345 – 330) / (1345) = 24.53%
Calculations for contribution made by cooling station: June, 2013
Total breakdown time of bottleneck machine for the month of June, 2013 = 1345
Minutes
Breakdown time of bottleneck machine because of cooling station for the month of
June, 2013 = 76 Minutes
Percentage contribution by cooling station in productivity loss of high pressure
washer machine in the month of June, 2013 = (100) - (1345 – 76) / (1345) = 05.66%
Fig 3 Contribution of total breakdowns for June 2013

6. 5202 Ajinkya P. Patil and Yash B. Parikh
Fig 4-Fish Bone diagram of the bottleneck mahine.
Table II Contributions made by parameters towards total breakdowns (Before
Improvement)
Sr.
No
Duration
of Study
(Month)
Total
Productivity
(%)
Loss
Of
Productivity
(%)
Contribution by
each Parameters (%)
By Washing
Station
By
Vacuum
Station
By
Cooling
Station
1 June’13 85.58 14.42 10.06 3.53 0.81
2 July’13 85.67 14.33 12.60 1.01 0.72
3 August’13 86.90 13.1 09.63 3.17 0.3
4 September’13 87.45 12.55 08.00 4.34 0.21
5 October’13 85.34 14.66 09.20 5.01 0.45
6 November’13 86.38 13.62 10.30 3.06 0.26

7. Productivity Improvement in Bottleneck Machine 5203
Fig-5 Trend Analysis of issues related with washing, vacuum and cooling station
(Before Improvement)
Major causes for the breakdown in Washing, Vacuum and Cooling station:
Further, to detect the root cause of the breakdown, detailed analysis was carried out
which showed the numerous factors affecting the productivity in washing, vacuum
and cooling stations. Each of these parameters were some or the other way
contributing in loss of productivity of high pressure washer machine. Following tables
shows the contribution made by each parameter in percentage from June, 2013 to
November, 2013.
TABLE –III Factors contributing in loss of productivity in washing station
Sr.
No.
Description of
the Problem
Break down
Time (Minutes)
Contribution of
Breakdowns in (%)
1 Unscheduled stoppage of machine 125 9.29
2 Robot stops at home position 200 14.86
3 Robot collision detected 350 26.02
4 Low water level
(transducer fault)
75 5.57
5 High water level
(transducer fault)
150 11.15
6 Fault with blower motor 39 2.89
Total breakdown in percentage- 69.81

8. 5204 Ajinkya P. Patil and Yash B. Parikh
TABLE IV Factors contributing in loss of productivity in vacuum station
Sr.
No.
Description of the
Problem
Breakdown Time in (
Minutes)
Contribution of Breakdown
In Percentage
1 Flickering of input
plitz
100 7.43
2 Fault in system
pump
80 5.94
3 Vacuum Zone Block
Error
150 11.15
Total Breakdown in Percentage 24.53
TABLE V Factors contributing in loss of productivity in cooling station
Sr.
No.
Description of the
Problem
Break down Time
(Minutes
Contribution of Breakdown In
Percentage
1 Issue with Coolant 30 2.23
2 Fault in Conveyor 46 3.42
Total Breakdown in Percentage 5.66
Fig 6- Contribution of total breakdowns from June to November, 2013.

9. Productivity Improvement in Bottleneck Machine 5205
Concentrating on Major Parameters Affecting Productivity Loss
From the above analysis it was clear that the major contribution towards loss in
productivity of bottleneck machine was due to problem in mainly washing station.
The percentage problems related to vacuum and cooling station were negligible in
comparison with washing station. Study further investigates the major problems
towards finding the remedial measures to correct them.
Problems related to washing station:
Study revealed that six different factors were affecting the smooth functioning of
washing station. From the list major contribution was due to collision in robotic arm
of the machine.
Description of the problem:
Robotic arm of the washing station was used to lift the cylinder block in washing
station. This robotic arm lifts the cylinder block from the fixture which was made up
of dowel pins and adapter plate. The problem was mainly because of these dowel pins
used to get jammed to cylinder blocks. After measuring the dimensions of these dowel
pins it was revealed that the dowel pins used were not of standard size. So when
robotic arm gripper tried to pick up the cylinder block from the adapter plate, it also
tried to lift the adapter plate. The designated pay load carrying capacity of robotic arm
gripper was between 45 – 50 kgs, if the load was more than this, it could lead to
damage of gears of robotic arm as well as falling of cylinder block mid way leading to
damage of the cylinder block. So to overcome this problem was a crucial task.
Solution:
By analysis we found that the problem occurred because of the dowel pins getting
stuck to the adapter plate. To overcome this problem we had designed a thin plate.
This thin plate was manufactured in-house and was welded to the turn table. This thin
plate was introduced between the adapter plate and the cylinder block. Also there
were provisions made in design of the thin plate that it was getting locked to adapter
plate by double acting cylinder. Now when robotic arm gripper picks up the cylinder
block from the fixture, this thin plate descent and separates the cylinder block from
the dowel pins and adapter plate. The schematic layout before and after improvement
are shown in the figure. (See Figure 7 and 8)
Fig. 7 Layout of fixture of washing station (Before Improvement)

10. 5206 Ajinkya P. Patil and Yash B. Parikh
Fig. 8 Layout of fixture of washing station (After Improvement)
D: Comparison of Results Post Implementation:
To understand the effectiveness of the implementation of fixture redesigned of
washing station, we had gathered the data from the month of December 2013 to
March 2014. The results showed significant improvement in the problem considered.
(See Table V)
TABLE V Contributions of total breakdowns (After Improvement)
Sr.
No.
Duration of
Study
(Month)
Total
Productivity
(%)
Loss of
Productivity
(%)
Contribution by each Parameters
(%)
Washing
Station
Vacuum
Station
Cooling
Station
1 December
‘13
88.20 11.80 07.30 4.13 0.37
2 January ‘14 90.92 09.08 06.60 2.15 0.39
3 February
‘14
91.67 08.33 05.80 2.01 0.52
4 March ‘14 92.10 07.90 05.39 2.06 0.45

11. Productivity Improvement in Bottleneck Machine 5207
Fig. 9 Trend Analysis of issues related with washing, vacuum and cooling station
(Before Improvement)
V Conclusion
The study presented here utilizes systematic improvement methodology to identify the
problems. Productivity of the bottleneck machine was largely affecting the cylinder
block line. The detailed analysis revealed the issues with washing, vacuum and
cooling stations of the bottleneck machine. Other problems like issues with sensors,
abnormal sounds from the system, fault with the transducer to detect the water levels
(both low and high water levels), because of their less magnitude were not focused in
the present study. Only the major issue related to washing station was focused upon.
The design modification of the fixture of the washing station had showed great sign of
improvement in improving the productivity of the bottleneck machines.
References
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Enhancing the Bottleneck Station in an Alternator Production Plant with
Layout Improvement and its Cost Analysis, International Journal of Scientific
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Manufacturing (MASM), 2002.
[3] A.Gunasekaran, P.Cecille, Implementation of Productivity Improvement
Strategies in a Small Company, 1998, Volume 18(5).

12. 5208 Ajinkya P. Patil and Yash B. Parikh
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Controlled Using Lab View, International Journal of Scientific and Research
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