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Cycle time reduction
- 1. CYCLE TIME REDUCTIONIN MANUFACTURING OF KNUCKLE Presentation on- By- Sudhanshu Sengaonkar Digvijay Phadke Guided by- Mr. D. S. Patil
- 2. Rough Turning Facing and centering Finish Turning Inspection Knuckle Storage Module1 : Layout Number Punching
- 3. Module 2: Layout FilletRolling Taper Bore Crack Detection Complete Inspection Area Bush Pressing and Broaching Keyway Broach (Vertical Broaching) Wash/Anti- Rust Application Packaging Number Punching
- 4. Problems Faced onKnuckle Line • Number Punching operation being done manually • Doors of CNC machines need to be closed manually • One person doing multiple jobs on module 1 • Center drill remains idle • Checking for tooling problems • Insert wear • Turret shifts downwards when idle for long times on FMS
- 5. Process Time(T1)(Seconds) T2T3 T4 T5 T6 T(avg) in sec 1. Pick up job and place on center drill 41.6 37.4 43.7 31.3 48.2 46.1 41.38 2. Center drill operation 66 64 62 63 63 64 63.66 3. Pick up job from central drill and place for rough turning 25.9 32.9 30 37 33.8 31.2 31.8 4. Rough turning 248 240.078 240.076 240.078 240.08 240.07 241.4 5. Remove and Punch 22.6 21.2 18.1 42.8 20.9 21 24.43 6. Pick and place for finishing and complete operation time 212 235 206.3 210.5 205 207.6 212.73 7. Inspection after finishing(Includes picking job from FMS) 137 57 29.8 44 43 62.16 62.15 Total Average time 677.56 Process Time Evaluation (Module 1)
- 6. Process Time T1T2 T3 T4 T5 T(avg) in sec 1. Pickup job and place on Centering machine 53.6 54.2 68.9 92 72 68.14 2. centering machine operation time 60.1 59.6 55.8 62 60.2 59.54 3. Pickup from centering machine and place on Proteck 45 32 33.1 36 44 38.02 4. Proteck operation time 248 248 248 248 248 248 5. Pickup job from Proteck and place for number punching 25 19.1 18.6 20 23 21.14 6. Pickup job from punch and place on FMS 30 54 32.9 52 29.3 39.64 7. FMS operation time 216 209 210 212 205 210.4 8. Pickup from FMS place for inspection/complete inspection 70.2 70.8 78 65 72 71.2 Total average time 756.08 Process Time Evaluation(Module 1)
- 7. Error Proofing –MCD II Source of Defect Knuckle Line Problem Statement Number punching operation missing & Number punching location shift Analysis Number punching missing & location shift due to number punching activity is manual. Occurred at Knuckle Line
- 8. Lift the jobfrom input pallet. Keep the job on stand manually with proper orientation for number punching – (Unsafe working condition ) Manual number punching operation done by holding number punching machine in hand ProcessFlowat jobloadingstage-Before Facing & centeringRough turningFinish turning
- 9. Lift the jobfrom input pallet. Facing & centering operation Rough turning ProcessFlowat jobloadingstage-After Automatic number punching operation with button start. Finish turning operation
- 10. ErrorProofing–Checklist Principles Questions tobe asked to the process Solution Effectiv- ness Cost Implim entatio n SPN Elimination Can we eliminate the error-prone process in totally? No Can we eliminate the error from process partially? No Replace-ment Can we automate the process? Yes , automation can be done for number punching operation 3 3 3 27 Can we provide supporting tools like checklists/gages/samples? Yes 1 3 3 9 Facilitata-tion Can we simplify the operation or introduce changes in the operation? (standardization, color coding, unique shape, etc) No Detection Can we record the outcome / product parameters of the earlier operation and verify it before starting next operation No Can we restrict the motion in such way that the operator will see the abnormality? No Can we verify the outcome / product parameters of the said operation before passing the part to next operation ? No Mitigation Can we make detection at multiple levels? No Can we make ergonomic condition better so as not to produce / miss the defects? Yes 1 2 3 6 Solution Priority Number (SPN) Criteria Effecive-ness 1 : Less Effective 2 : Effective 3 : Very Effective Solution Cost 1 : High 2 : Medium 3 : Low Automation is required at number punching station Implemen-tation 1 : Difficult 2 : Easy 3 : Very Easy
- 11. ErrorProofing–Before Before Counter measure:. Job is kept on table as per required orientation & number punching is done manually by hand.
- 12. ErrorProofing–After After Counter measure: Automatic number punching operation Automation setup with pneumatic cylinder & solenoid valve mounted on stand .
- 13. ErrorProofing–DesignReview Sr. No. Design Review Parameter Description 1 Fail-Safe performance Unsafeworking condition eliminated at manual number punching 2 Cost effectiveness Proposed solution is cost effective. 3 Ease of operation Easy to operate as button start. 4 Protection from external damage Automation setup is mounted on stand hence no chance of damage. 5 Simplicity in design Proposed solution is simple to implement.
- 14. Grinding Operation Time T1 T2 T3T4 T5 Average Loading 22.5 64 53 61 47 49.50 Commands 6.3 4 14.01 10.58 8.4 8.66 Operation time 180 181 180 180 181 180.40 Inspection 73 63 68 71 62 67.40 Unloading 32 29 31 26 27 29.00 Rotate Job 12.26 12.15 12.33 12.01 11.48 12.05 Input Job Number on record 12.17 12.35 12.48 12 13.2 12.44 Total time 359.44 Time in min 5.99
- 15. Hardening Operation Time(sec) T1 T2 T3T4 T5 Average Loading 47.37 25.28 65 50 54 48.33 Operation Time 170 172 170 171 170 170.60 Unloading 97 54 34 45 68 59.60 Total time 278.53 Time in min 4.64
- 16. 16 Action plan Sr. noMachine Activities Time saved by (sec) Remark Grinding and Hardening 1 Make provision for parking crane near operator for ease of operation 6 2 Job should be ready prior to operation 8 3 Fixture for resting job and air nozzle for removal of central burr 5 4 Provide stand near grinding operation for inspecting the job 40 5 Provide conveyor along with coolant after hardening 15 6 Stand for log book for better ergonomics 4 7 Combine two snap gauges 12
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