Presentation describing the changes that could be made in Aurangabad Electricals to improve production and reduce expenses

1. Plant-IX Aurangabad Electricals Ltd.
Fasteners Division

2. Methods for improving processes and
increasing efficiency
The three main ideas I have stressed upon are:
 Increasing energy efficiency of plant
 Method for sorting nuts and bolts of unequal dimensions
 Increasing safety of centre less grinding machines

3. Increasing energy efficiency of the plant

4. Increasing energy efficiency of the plant
 The TPM policy of the various plants of all the plants stress on
energy conservation.
 It was observed that the lights in the finished goods area of
plant 9 are kept on throughout the day, whether or not
someone is present there.
 Mostly, workers carry lots of products and find it difficult to turn
the lights on and off.
 Designed a layout for motion sensing switches to reduce
wastage of power.

5. Increasing energy efficiency of the plant
As soon as someone steps into any red area, the lights in the area
around the person turn on and turn off again once the person has left.

6. Increasing energy efficiency of the plant
Current Usage
96 tube lights x 24 hours x 28 watt
64.512 kWh or Rs. 451.854
Monthly, this amounts to 1935.36
kWh or Rs. 13547.52
After installation of sensors
96 tube lights x 6 hours x 28 watt +
44 sensors x 1 watt *24 hours
16.656 kWh or Rs.116.592
Monthly, this amount to 499.68 kWh
or Rs. 3497.76
Cost of installation = 800 * 22
= Rs. 17600
Cost recovered from savings in less
than 2 months

7. Increasing energy efficiency of the plant
By using these motion
sensing switches for lights,
the power used in the
finished goods section
drops by 74% and the
power can be used for
more productive purposes.
1935.36
kWh
499.68
kWh
0
500
1000
1500
2000
2500
Before sensors After sensors
Power usage per month in
finished goods area

8. Increasing energy efficiency of the plant
To compare the power wasted
everyday, we can compare it
against other day to day in plant
processes.
64.512 Kwh per day
 Running an M8 forging machine
for three hours (enough time to
forge three rolls ~ 30000 pieces).
 Running a rolling machine for six
and a half hours (enough time to
roll ~ 80000 pieces).
 Running entire array of plating
machinery for 20 minutes

9. Method for sorting nuts and bolts of unequal
dimensions

10. Method for sorting nuts and bolts of unequal
dimensions
 Many times, nuts and bolts of similar sizes and
specification, differing in one or two things get mixed up due to
their apparent similarity.
 Test case: two nuts of same external diameter, internal
diameter, material, grade and exterior finish had different
pitches of thread. One was 1.5mm and the other was 1.25mm.

11. Method for sorting nuts and bolts of unequal
dimensions
 This error was reported to the plant by the customers and the
lot was sent back to the plant.
 Sadly, currently such issues are resolved by employing manual
labour.
 They have to tighten each bolt on a nut of specified pitch and
decide whether the bolt fits or not.

12. Method for sorting nuts and bolts of unequal
dimensions
A possible way to easily sort the different products is to use
computers. Using MATLAB and its image processing
capabilities, we can take images of the bolts, decide whether
they have all the correct dimensions or not, and pass or reject the
product.

13. Method for sorting nuts and bolts of unequal
dimensions
MATLAB processes black and white picture, to determine where
the edges are by observing changes in color

14. Method for sorting nuts and bolts of unequal
dimensions
Now, by using the
histogram function of
MATLAB, we can count the
number of times that an
edge is encountered in a
specified length
interval, thus indicating
pitch of the object.

15. Method for sorting nuts and bolts of unequal
dimensions
For separating bolts, the loading
machine can be used to guide the
bolts towards a cog that will hold
the bolt for the camera array to
examine. Depending on whether
the bolt is as per the correct
requirements, the computer can
make the cog spin clockwise or
counter clockwise, sending the bolt
into the correct bin.

16. Method for sorting nuts and bolts of unequal
dimensions
For separating nuts, the nuts can
be loaded into the tapping machine.
As they come down the guides, the
camera take pictures. The
computer then decides whether the
bolt is correct, and accordingly
open or closes the chutes so that
the nuts are collected or stopped

17. Method for sorting nuts and bolts of unequal
dimensions
As an added advantage, the machines can also be used to help
the final inspection. This will reduce the load on the workers and
the inspection can be done quickly and more effectively as
compared to manual checking. This is because currently, only
one in every 100 bolts from the smaller sizes is done. Using
this, every bolt can be checked in the same or lesser time.

18. Increasing safety of centre less grinding
machines

19. Increasing safety of centre less grinding
machines
 The centre less grinding machines are a major source of
worker injuries.
 The injuries mostly occur when the workers are pulling out the
bolts from between the wheels.
 This is a place, where wearing safety gloves, actually
increases the risk of losing a limb, as if the glove is even
slightly loose, it may get caught in the wheels and pull off the
workers arm.

20. Increasing safety of centre less grinding
machines
 Thankfully, no major incidents have ever occurred here.
 But minor injuries are very common in this section because of
how close a workers hand comes to the wheels while removing
the bolts.
 The injuries not only hamper the factory productivity, but also
leave the worker temporarily unemployed, since he cannot
work till he recovers completely

21. Increasing safety of centre less grinding
machines
 To reduce this hazard, a system can be put in place which
automatically pushes the bolt out a little bit, say by 4 inches, so
that the worker can easily pull it out without putting himself at
risk of getting injured.
 The machine will only allow grinding once the bolt is properly in
place

22. Increasing safety of centre less grinding
machines
 The modification involves
adding a motor to the stopper
rod.
 The bolt will push the rod
against a switch, which will
allow the machine to start
 Once the grinding is
done, the motor will push out
the rod, moving out the
bolt, making it safe to
remove.

23. Increasing safety of centre less grinding
machines
 This system will make the bolt easier and safer to remove from
the machine.
 A second advantage is that unless the bolt is of the correct
size, within tolerances, the machine will not allow the part to be
ground, reduces waste of effort on wrong bolts.