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IMPLEMENTATION OF FLEXIBLE MANUFACTURING SYSTEM FOR
BEARING MANUFACTURING PLANT
Prepared by:
Dhruv Shah (104849040)
Parth Patel (104849039)
Nishanth Srinivasan (104851605)
Submitted to:
Dr. Hoda Elmaraghy
Presentation Outline
 Product family and its variant
 Comparison between the products
 Sequence of operations for the product variants
 Grouping
 Macro process plan
 Process Layout
 Flexsim simulation
 Output
 What if scenarios
 Conclusions
Contribution of the Members:.
Dhruv Shah:
Master Macro process planning, Flexsim modelling, Production and plant layout.
Nishanth Srinivasan:
Material Handling System, Presentation, Flexsim Pros and Cons, and conclusion.
Parth Patel:
Identified various scenarios for plant layouts, Cycle time calculation, presentation completion, and
report compilation.
PRODUCT FAMILY & VARIANTS
COMPARISON BETWEEN THE PRODUCT VARIANT
COMPONENTS OF
BEARING
BALL BEARING CYLINDRICAL ROLLER
BEARING
TAPPER ROLLER
BEARING
OUTER RING Spherical Grooved Flat Ring Cone Shaped
INNER RING Spherical Grooved Rectangular Groove Cup Shaped
ROLLERS Ball Cylinder Cylinder
RETAINER Separator Separator Cage
SEQUENCE OF OPERATIONS
PART 1- OUTER RING
OPERATIONS & PROCESS BALL BEARING CYLINDRICAL ROLLER
BEARING
TAPER ROLLER BEARING
Turning 1 1 1
Heat treatment 2 2 2
Face Grinding 3 3 3
OD Grinding 4 4 4
Raceway Superfinishing 5 - -
ID Superfinishing - 6 6
SEQUENCE OF OPERATIONS
PART 2- INNER RING
OPERATIONS &
PROCESS
BALL BEARING CYLINDRICAL ROLLER
BEARING
TAPER ROLLER BEARING
Turning 1 1 1
Heat treatment 2 2 2
Face Grinding 3 3 3
Lip Grinding 4 4 4
ID Grinding 5 5 5
Raceway Superfinishing 6 6 6
SEQUENCE OF OPERATIONS
PART 3- ROLLING ELEMENT
OPERATIONS &
PROCESS
BALL BEARING CYLINDRICAL ROLLER
BEARING
TAPER ROLLER BEARING
Header 1 - -
Heat Treatment 2 2 2
Rough Grinding 3 3 3
Lapping 4 - -
Finishing Grinding - 5 5
Super Finishing Grinding - 6 6
SEQUENCE OF OPERATIONS
PART 4- RETAINER
OPERATIONS &
PROCESS
BALL BEARING CYLINDRICAL ROLLER
BEARING
TAPER ROLLER
BEARING
Blanking 1 1 1
Press Forming - 2 2
Punching 3 3 3
Polishing 4 4 4
GROUP OF PARTS – RANK ORDER CLUSTERING
Operations
Machines
OR2 OR3 OR1 IR1 IR2 IR3 SP2 SP3 SP1 RL2 RL3 RL1
CNC Lathe 1 1 1
Heat Furnace 1 1 1 1 1 1 1 1 1
Centerless Grinder 1 1 1
Duplex Grinder 1 1 1
Precision Grinder 1 1
Single Spindle ID Grinding 1
Centerless Grinder 1 1 1
Duplex Grinder 1 1 1
Lip Grinder 1 1 1
Single Spindle ID Grinding 1 1 1
Raceway Superfinishing 1 1 1
Press Machine 1 1 1
Punching Machine 1 1 1
Sand Blasting fur 1 1 1
Centerless through feeder 1 1
Finishing Grinder 1 1
Super Finishing Machine 1 1
Header 1
Precision Grinder 1
Lapping Machine 1
1- Ball Bearing
2- Cylindrical Roller
Bearing
3- Taper Roller Bearing
OR- Outer Ring
IR - Inner Ring
SP- Separator
RL- Roller
MACRO PROCESS PLAN
PLANT LAYOUT
- - Outer Ring
- Rollers
- Inner Ring
- Separator
FLEXSIM SIMULATION
OUTPUT
OUTPUT
RESULTS
Assumed market demand: 1600000 units
Market share : 12.03%
Takt Time: 0.15 min.
Cycle time: 1.24 min.
WHAT-IF SCENARIOS
• Market share
decreases by 4%
• Takt Time: 0.3-0.4 min.
• Cycle Time: 1.24 min.
• Market share
increases by 9%
• Takt Time: 1.05 min.
• Cycle Time: 1.36 min.
Demand
Capacity
CONCLUSIONS
 By implementing FMS, all the 3 bearings can be
manufactured in a single system.
 Although the total output in implemented system is
increased due to flexibility, the output per variant does not
necessarily increase.
IMPLEMENTATION OF FLEXIBLE MANUFACTURING SYSTEM FOR BEARING MANUFACTURING PLANT

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IMPLEMENTATION OF FLEXIBLE MANUFACTURING SYSTEM FOR BEARING MANUFACTURING PLANT

  • 1. IMPLEMENTATION OF FLEXIBLE MANUFACTURING SYSTEM FOR BEARING MANUFACTURING PLANT Prepared by: Dhruv Shah (104849040) Parth Patel (104849039) Nishanth Srinivasan (104851605) Submitted to: Dr. Hoda Elmaraghy
  • 2. Presentation Outline  Product family and its variant  Comparison between the products  Sequence of operations for the product variants  Grouping  Macro process plan  Process Layout  Flexsim simulation  Output  What if scenarios  Conclusions
  • 3. Contribution of the Members:. Dhruv Shah: Master Macro process planning, Flexsim modelling, Production and plant layout. Nishanth Srinivasan: Material Handling System, Presentation, Flexsim Pros and Cons, and conclusion. Parth Patel: Identified various scenarios for plant layouts, Cycle time calculation, presentation completion, and report compilation.
  • 4. PRODUCT FAMILY & VARIANTS
  • 5. COMPARISON BETWEEN THE PRODUCT VARIANT COMPONENTS OF BEARING BALL BEARING CYLINDRICAL ROLLER BEARING TAPPER ROLLER BEARING OUTER RING Spherical Grooved Flat Ring Cone Shaped INNER RING Spherical Grooved Rectangular Groove Cup Shaped ROLLERS Ball Cylinder Cylinder RETAINER Separator Separator Cage
  • 6. SEQUENCE OF OPERATIONS PART 1- OUTER RING OPERATIONS & PROCESS BALL BEARING CYLINDRICAL ROLLER BEARING TAPER ROLLER BEARING Turning 1 1 1 Heat treatment 2 2 2 Face Grinding 3 3 3 OD Grinding 4 4 4 Raceway Superfinishing 5 - - ID Superfinishing - 6 6
  • 7. SEQUENCE OF OPERATIONS PART 2- INNER RING OPERATIONS & PROCESS BALL BEARING CYLINDRICAL ROLLER BEARING TAPER ROLLER BEARING Turning 1 1 1 Heat treatment 2 2 2 Face Grinding 3 3 3 Lip Grinding 4 4 4 ID Grinding 5 5 5 Raceway Superfinishing 6 6 6
  • 8. SEQUENCE OF OPERATIONS PART 3- ROLLING ELEMENT OPERATIONS & PROCESS BALL BEARING CYLINDRICAL ROLLER BEARING TAPER ROLLER BEARING Header 1 - - Heat Treatment 2 2 2 Rough Grinding 3 3 3 Lapping 4 - - Finishing Grinding - 5 5 Super Finishing Grinding - 6 6
  • 9. SEQUENCE OF OPERATIONS PART 4- RETAINER OPERATIONS & PROCESS BALL BEARING CYLINDRICAL ROLLER BEARING TAPER ROLLER BEARING Blanking 1 1 1 Press Forming - 2 2 Punching 3 3 3 Polishing 4 4 4
  • 10. GROUP OF PARTS – RANK ORDER CLUSTERING Operations Machines OR2 OR3 OR1 IR1 IR2 IR3 SP2 SP3 SP1 RL2 RL3 RL1 CNC Lathe 1 1 1 Heat Furnace 1 1 1 1 1 1 1 1 1 Centerless Grinder 1 1 1 Duplex Grinder 1 1 1 Precision Grinder 1 1 Single Spindle ID Grinding 1 Centerless Grinder 1 1 1 Duplex Grinder 1 1 1 Lip Grinder 1 1 1 Single Spindle ID Grinding 1 1 1 Raceway Superfinishing 1 1 1 Press Machine 1 1 1 Punching Machine 1 1 1 Sand Blasting fur 1 1 1 Centerless through feeder 1 1 Finishing Grinder 1 1 Super Finishing Machine 1 1 Header 1 Precision Grinder 1 Lapping Machine 1 1- Ball Bearing 2- Cylindrical Roller Bearing 3- Taper Roller Bearing OR- Outer Ring IR - Inner Ring SP- Separator RL- Roller
  • 12. PLANT LAYOUT - - Outer Ring - Rollers - Inner Ring - Separator
  • 16. RESULTS Assumed market demand: 1600000 units Market share : 12.03% Takt Time: 0.15 min. Cycle time: 1.24 min.
  • 17. WHAT-IF SCENARIOS • Market share decreases by 4% • Takt Time: 0.3-0.4 min. • Cycle Time: 1.24 min. • Market share increases by 9% • Takt Time: 1.05 min. • Cycle Time: 1.36 min. Demand Capacity
  • 18. CONCLUSIONS  By implementing FMS, all the 3 bearings can be manufactured in a single system.  Although the total output in implemented system is increased due to flexibility, the output per variant does not necessarily increase.