Project Title- Manufacturing Process stabilization of a new product 'Ultra XL+ Navtal' Performed at Godrej & Boyce Mfg Co Ltd, Madkai Plant Goa

1. KONKAN GYANPEETH COLLEGE OF ENGINEERING
DEPARTMENT OF PRODUCTION ENGINEERING
KARJAT, RAIGAD, INDIA 410201
UNIVERSITY OF MUMBAI
2017-18
Bachelor of Engineering
In
Production Engineering

2. Manufacturing Process Stabilization Of A
New Product ‘Ultra XL+ Navtal
Executed in Gogrej & Boyce mfg. co. ltd
Presented By
Mr. Bhalchandra Pradip Parkar
Under the Guidance of
Prof. M.T. Bhagawati
Associate Professor & W/S Supdt.
A Project presentation
on

3. Contents
1. Introduction
2. Literature Survey
3. Problem Definition
4. Methodology
5. Result and Discussion
6. Conclusions
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4. 1. Introduction
Objective of the project - i. Stabilization
ii. Make manufacturing process
suitable for mass/flow production
Project involve – i. Manufacturing process stabilization for
Shackles
ii. Improvement in strip
iii. Manufacturing process stabilization for
Housing
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Fig. Ultra XL+ Navtal padlock

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Costly
High Security Level
10 C combinations
3 Ton
Difficult to handle
More rigid
Good aesthetic look
Low Price
Low Level security
3 Lac combinations
1 Ton
Easy to handle
Less rigid
Poor aesthetic look
Navtal Padlock Ultra Technology Padlocks
Images
Price
Security Level
Key combinations
Break Load Capacity
Handling
Rigidity
Aesthetic

6. 2. Literature Survey
PART A: MANUFACTURING PROCESS STABILIZATION FOR SHACKLE:
1. For blanking operation
• Shackle - Material is Boron steel
-Chemical composition 0.5-11.5 % of
boron + 2.5-35 % of silicon + additives
like aluminum, magnesium, titanium,etc
& remaining % of steel
-Advantages of using boron steel
• Automats – Multiple tool contact
• Traub – For mall dimensional workpieces
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Fig. Tooling on traub

7. 2. For bending operation
• Compression bending is used
• Similar to edge bending of sheet metal
• The rod is held by force applied by rest and locking profile, bracket with roller bends
the rod.
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Fig. Bending machine

8.  PART B: IMPROVEMENT IN STRIP USED FOR BLANKING OPERATION FOR TOP
SUPPORT PLATE AND BOTTOM SUPPORT PLATE :
• Press working –Chip less manufacturing process to get finished component from sheet metal
• Advantages of press working – production rate high, efficient, economic, good surface finish,
suitable for mass production.
• Blanking – Cutting of sheet metal along a close outline to separate the piece from the
surrounding stock.
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Fig. Products of blanking oprn and blanking opern

9. PART C: MANUFACTURING PROCESS STABILIZATION FOR
CYLINDER HOUSING:
Jigs & fixtures
Advantages of jigs & fixtures :
• Productivity
• Interchangeability
• Quality
• Skill reduction
• Cost reduction
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Fig. Cylinder Housing

10. 3. Problem Definition
PART A: MANUFACTURING PROCESS STABILIZATION FOR SHACKLE:
1. For blanking operation -
• Initially prototypes of shackle blanks were made on lathe machine.
• Many problems were there.
• Process was not suitable for mass/batch production.
2. For bending operation -
• Prototyping on other machines is not possible.
• Many problems were there.
• There was a need to change that process
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11. PART B: IMPROVEMENT IN STRIP USED FOR BLANKING
OPERATION FOR TOP SUPPORT PLATE AND BOTTOM
SUPPORT PLATE :
• Problems were there regarding scrap production
• Strip used for blanking was of size 84*0.8 mm which was more.
PART C: MANUFACTURING PROCESS STABILIZATION FOR
CYLINDER HOUSING:
• Initially prototypes were made on CNC machine.
• Many problems
• Process was not suitable for mass/batch production.
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12. 4. Methodology
PART A: MANUFACTURING PROCESS STABILIZATION FOR SHACKLE:
1. For blanking operation -
Step1.) selection of tooling
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Step2.) Calculation of cam degrees
Spindle speed, N =
1000∗𝑉
𝛱∗𝐷
=
1000∗60
𝛱∗11.1
=1720.59 R.P.M
Fig. Tooling required Table. Selection of cam degrees

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Fig. Design of cams
Fig. Cams for parting, chamfering & grooving
Fig. Mounting of toolings on automat

14. • 1st modification:-
1. Booster Attachment
2. Support to the Former
• Problems solved
1. Movement of Former is less
2. Now, Single pass is enough for bending
• Problems which are still there
1. All problems are still there except double
bending
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2. For bending operation -
Fig. First stroke Fig. Second stroke
Fig. Dent mark on shackle Fig. C-D gauge Fig. Profile gauge

15. • 2nd modification:-
1. Extra support is given to the Former by
bolting .
• Problems solved:-
1. Movement of Former is less compared to
the last operation
2. Now shackles enters in center distance
Gauge
• Problems which are still there
1. Dent mark
2. Movement of Former is still there
• 3rd modification:-
1. Replace Metric Thread Lead Screw with
Square thread lead screw
2. Give Rigid Support from lower side of the
Former
• Then all the problems were solved
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16. PART B: IMPROVEMENT IN STRIP USED FOR BLANKING OPERATION
FOR TOP SUPPORT PLATE AND BOTTOM SUPPORT PLATE :
• Old strip layout of top support plate
Gross weight for this
component=pitch*sheet thickness*coil
size*density of material
= 64*0.8*84*0.00785
= 33.76 grams
Net weight = 18.6 grams
% utilization of material =
𝑛𝑒𝑡 𝑤𝑒𝑖𝑔ℎ𝑡
𝑔𝑟𝑜𝑠𝑠 𝑤𝑒𝑖𝑔ℎ𝑡
*100
=
18.6
33.76
*100
=55.09 %
• % of wastage = 44.9 %
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17. • Old strip layout of
bottom support plate
• Gross weight for this
component= 33.76 grams
• Net weight = 17.02
grams
• % utilization of material =
50.41 %
• % of wastage = 49.58 %
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• New strip layout of top
support plate
• Gross weight for this
component= 28.93 grams
• Net weight = 18.6 grams
• % utilization of material =
64.29 %
• % of wastage = 35.7 %
• New strip layout of bottom
support plate
• Gross weight for this
component= 28.93 grams
• Net weight = 17.02 grams
• % utilization of material =
58.88 %
• % of wastage = 41.16 %

18. PART C: MANUFACTURING PROCESS STABILIZATION FOR CYLINDER
HOUSING:
Before Procedure :
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Fig. Steps to clamp housing in CNC fixture
Fig. Back hole drilling operation
Fig. Drilling-tapping operation

19. Sr. No Steps Photographs
1 Designing of fixture
2 Making SPM
3 Installation of fixture
4 Installation of other
things for safety and
simplicity
5 Trials
Sr. No Step Photographs
1 Designing of fixture
2 Making SPM &
installation of
Indexing page
3 Installation of fixture
4 Installation of other
things for safety and
simplicity
5 Trials
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• SPM was made for back hole drilling operation • SPM was made for drilling-tapping operation

20. 5. Result and Discussion
 PART A: MANUFACTURING PROCESS
STABILIZATION FOR SHACKLE:
1. For blanking operation -
• Output per hour =
𝑠𝑝𝑖𝑛𝑑𝑙𝑒 𝑟𝑝𝑚∗𝑐𝑎𝑚 𝑓𝑎𝑐𝑡𝑜𝑟
6
=
𝟏𝟕𝟐𝟎.𝟓𝟗∗𝟎.𝟓𝟏𝟐
6
= 146 piece /hour
• Actual output/hour is 95-100 piece/hour because
we are not considering rod loading time , personal
time ,etc .
• Cycle time for old process was 120-160 sec.
• Cycle time for new process is 35 sec.
20
Fig. Variations in dimensions

21. 1. For blanking operation –
1. In the above graph in the y axis is no of components and in x axis there are before and
after modification situations. Here we have taken the lot size of 100 components. In before
stage no of ok components were 0. In after stage no of ok components were 96
2. Red arrow in the graph shows this transformation.
0
20
40
60
80
100
120
Before
modifications
After
modifications
Total no of components
OK Components
Column1
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22. PART B: IMPROVEMENT IN STRIP USED FOR BLANKING OPERATION
FOR TOP SUPPORT PLATE AND BOTTOM SUPPORT PLATE :
• For top support plate. % of waste by old method was 44.9 % which is reduces to 35.7%. Difference
of 9.2 % is more.
• For top support plate. % of waste by old method was 49.58 % which is reduces to 41.16%.
Difference of 8.42 % is more.
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23. PART C: MANUFACTURING PROCESS STABILIZATION FOR
CYLINDER HOUSING:
• Cycle time for back hole drilling was 20 sec which is reduced to 8 sec. and that of
drilling-tapping was 30 sec which is reduced to 10 sec. Black arrows in both the graphs
shows this transformation.
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0
5
10
15
20
25
30
35
40
45
On CNC
machine
(old )
On SPM
(New)
Series 1
Column2
Column1
0
10
20
30
40
50
60
70
On CNC
machine
(old )
On SPM
(New)
Series 1
Column2
Column1

24. 6. Conclusions
 The manufacturing processes to manufacture components of ‘Ultra XL+
Navtal’ are stabilized and suitable for batch or mass production basis.
 Quality of the machining , cycle time, productivity, operator safety, moral of
an operator is improved. Scarp formation is reduced.
 Now the department can achieve the desirable target for Ultra XL + Navtal
with less efforts and in efficient way .
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25. Thank you
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