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it includes my Project work on process capability in grinding machines which was undertaken by me during the tenure of jan 2017 to june 2017. This work is an authentic work and all rights are reserved. This presentation can be used for further research purpose.
An example of how LEAN MANUFACTURING was used in a Production Capacity Plan report to illustrate how eliminating Non-Value Add steps can increase production capacity and productivity with minimal costs.
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addition, when the engine is very small, as it is the case of this engine, all dimensions are miniaturized therefore
making it extremely difficult to design, cast and finish. The cooling chamber, in particular, has a critical inner core
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following redesign and new casting simulations. This paper illustrates the various tasks involved in the design and
development stages leading to the production of a running prototype of the cylinder head for this small engine.
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it includes my Project work on process capability in grinding machines which was undertaken by me during the tenure of jan 2017 to june 2017. This work is an authentic work and all rights are reserved. This presentation can be used for further research purpose.
An example of how LEAN MANUFACTURING was used in a Production Capacity Plan report to illustrate how eliminating Non-Value Add steps can increase production capacity and productivity with minimal costs.
The report was prepared within 3 days of visiting the plant without any prior knowledge of the product or production processes.
Deployed Lean Manufacturing in fabrication of Exhaust After Treatment System Rack made for VOLVO / Mack Trucks used Lean to increase productivity by 50% and Six Sigma
methodology to resolve complex design issues, improve quality controls for sustained improvement
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Abstract. This work shows the development of the design and manufacturing of a very small engine, namely its head.
The engine works under the 4-stroke cycle, therefore having a very complex cylinder head, housing the camshaft,
valves and its auxiliaries (seats, guides, springs), spark plug, inlet and exhaust passages and a coolant chamber. The
geometries, both inner and outer are highly intricate which makes the production of such a part a very difficult job. In
addition, when the engine is very small, as it is the case of this engine, all dimensions are miniaturized therefore
making it extremely difficult to design, cast and finish. The cooling chamber, in particular, has a critical inner core
removal problem due to reduced accessibility, imposing casting limitations. The cores place also a problem of air and
gas removal during metal filling and solidification. Rapid prototyping may be the only solution to build the cores, and
may help in the design and manufacturing phases of the casting tools. 3D printing with a plaster based material as a
rapid prototyping technique presents itself as a tool to drastically reduce the design-development-casting process effort
and time cycle. This technique enables the designer to obtain new moulds for castings on the shortest time possible,
following redesign and new casting simulations. This paper illustrates the various tasks involved in the design and
development stages leading to the production of a running prototype of the cylinder head for this small engine.
Assembly of the components (Crank shaft, Connecting rod, Gudgeon pin and Piston) by
using different manufacturing processes from the material generated as a scrap during
manufacturing of different products through various processes.
Removing snow from driveways during Chicago winters can be one of the most frustrating jobs given the long winters the city experiences. There are readily available hydraulic shovels and engine operated blowers in the market but given the cost of these devices, it is not affordable to the common man. As a team, I worked on a simple and affordable system which can be mounted onto the Jeep ANYTIME and doesn’t require any external source to run the shovel. The final design of the shovel is a retro-fitment and can be DE-attached from the car when not in use.
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Lean green belt project improvement
1. Project Theme : To Improve Through Put Yield of the Plant.
Sponsor / Champion : Mr. SHAKTI SINGH
Black Belt : Mr. SHAKTI SINGH
Team Leader : ANKUR SHARMA
LEAN SIX SIGMA – PROJECT REPORT
2. INTRODUCTION
Brief description of unit: AMTEK AUTO LIMITED SHED-3
We carry out the machining (Milling, Boring, Drilling, Tapping and
Grooving Operations) on the Grey Cast Iron Castings.
All of our customers are OEM’s and we are tier 1 supplier to JCB INDIA
LIMITED, Case New Holland Private Limited, John deere INDIA Pvt.
Limited, Swaraj Mazda ISUZU Limited, Ashok Leyland Limited, Eaton
INDIA Pvt. Limited.
6. JCB - Drive Head JCB - FLYWHEEL HOUSING CNH - FAS PTO CONVERTOR
OUR PRODUCTS
JCB - KING POST JCB - GEAR CASE SML -CYLINDER BLOCK EATON - Transmission case
7. Introduction
Definition of Project
– Project title, Target, Business Case, Team, SIPOC, Process Map.
Measure
– Trends, CTQ, Check sheet, data collection
– Cause & Effect Diagrams, Potential causes
Analyse
– Physical Mechanism (PM) Analysis, Potential Xs, Verification of Xs,
– Identify root cause & validate, % contribution of each cause, Design of Experiments
– Quick hit action points
Improve
– Implement identified actions, Improvements in X, Verification of Results
Control
– Control Plan, SPL, SOP, Training
Financial Benefits
REPORT STRUCTURE
8. DMAIC
D E F I N E
Definition of Project
– Project title
– Target
– Business Case
– Team
– SIPOC
– Process Map
DEFINITION
9. DMAIC
Project Title
Title of the Project is to improve Through Put Yield by using basic tools
of Lean(Waste Elimination) Six Sigma(Control Over Variations).
10. DMAIC
Target and Business Case
Direct & Tangible Target of Savings – INR Three-Four Lacs PER ANNUM
Indirect & Intangible Target – Lead Time of Conversion of RM into FG
will be Reduced.
Business Case – Business will be in direct impact as if FTY is improved
time bound feeding to Customer’s line will be achieved.
11. DMAIC
Name Function Key responsibilities
Mr. SHAKTI SINGH OPERATIONS Member in G shift
Mr. VINOD KR. VERMA PRODUCTION Member in G shift
Mr. MANOJ KR. SHARMA QA Member in G shift
Mr. SHRIPAL TOOLING Member in G shift
Mr. HANSRAJ QA Member in G shift
Mr. Kalamuddin/Mr. SUNIL DUTT QA G shift (FROM FOUNDRY)
Team Members
12. General Process Flow Diagram (SIPOC)
Supplier
CASTEX/JCB/SML
Oiling
&
Packing
Castings
Input Process Output Customer
Machining
(Finish
Milling,
Drilling,
Tapping,
and Boring)
Finished
Goods
JCB/SML/CNH
EATON
DMAIC
13. Process Mapping/Road Map
1. Identification of type of Losses in our facility & Components.
2. Discrimination of losses into Lean and Six Sigma.
3. Selection of Tool.
4. Application of Tool.
5. Results after application.
6. Monitoring of Results and Savings Calculation.
DMAIC
14. DMAIC
MEASURE
Measurement
– Strategy of work
– Listing Issues and Impact.
– Targets.
– Cause & Effect Diagrams.
– Listing of Probable Causes.
Measurement
15. Measurement
8 Losses of Lean: Six Sigma:
T – Transport – Constraint. Control Over Variations
I – Inventory – As per Customer & Norms.
M – Motion – Constraint.
W – Waiting – As per Machine availability
& Volumes.
O – Over Production – As per Customer & Norms.
O – Over Processing
D - Defect
S - Skill
Strategy how Team will work upon
Stage - 1 Stage - 2
DMAIC
16. Listing of Issues and Impact
Customer Component Issue w.r.t. Through Put Yield Impact
JCB Flywheel
Housing
1. Finn in Window area after machining
OP 10. Grinding being done.
2. Wall Shifting after OP 10, grinding
required on wall adjacent to tapping
Hole M50X2. Grinding being done.
1. Over Processing Loss : As
Components after machining gets
hold for grinding.
2. As grinding is done manually, so lead
time at this process is variable and
skill bound.
JCB Gear Case
VAVE
Machining mold hole Ø83 mm.
1. Over Processing loss : As this machining
is not required in Drawing, additional
machining is being done. Cycle time of
machining is raised because of this.
JCB Drive Head
3DX/3CX
Chamfer less over Ø88
Grinding being done.
1. Over Processing Loss : As
Components after machining gets
hold for grinding.
2. As grinding is done manually, so lead
time at this process is variable and
skill bound.
DMAIC
17. Listing of Issues and Impact
Customer Component Issue w.r.t. Through Put Yield Impact
JCB King Post 1. Grinding requires after machining.
1. Over Processing Loss : As
Components after machining gets
hold for grinding.
2. As grinding is done manually, so lead
time at this process is variable and
skill bound.
3. Electric Grinder and Wheels as
consumables.
4. Additional Manpower requires.
5. Grinding dust spoils HMC’s.
DMAIC
18. Listing of Issues and Impact
Customer Component Issue w.r.t. Through Put Yield Impact
JCB Axle Arm Punching of Traceability on components
after machining.
1. Manual punching is being done and
components got on hold after
machining
2. As Punching is done manually, so
lead time at this process is variable
and skill bound.
3. Additional manpower requires.
SML Block Cylinder
1. Additional machining being done at
specific sections to assist assembly line at
SML.
1. Over Processing losses on HMC.
DMAIC
19. DMAIC
Trends of the Issues
Flywheel Housing
Issue 1 – Finn in window area after OP 10
100%100%100%100%100%100%100%100%100%
35%
0 0 0 0 0 0 0 0 0 0
0%
50%
100%
150%
Percentage of Loss
Percentage of Loss
Issue 2 – Casting Shifting against locator
30 27
38 36 38 34 34 37 38 38 42 39 41 43 44
37
0
39
49
14
0
20
40
60
Percentage of Loss
Percentage of Loss
20. DMAIC
Trends of the Issues
Gear Case Issue – Machining mold hole Ø83 mm.
100%100%100%100%100%100%100%100%100%100%100%100%100%100%100%100%100%100%
57%
0
0%
50%
100%
150%
Percentage of Loss
Percentage of Loss
Issue – Ø88 Chamfer less due to casting issue
16% 16% 15% 15% 15%
9% 9% 8%
6% 6% 5% 4%
6% 5% 5% 4% 5%
19%
15%
0%
5%
10%
15%
20%
Percentage of Loss
Percentage of Loss
Drive Head 3DX/3CX
21. DMAIC
Trends of the Issues
King Post Issue – Grinding after machining
100%100%100%100%100%100%100%100%
50% 50% 50% 50% 50% 50% 50% 50% 50% 50% 50% 50%
0%
50%
100%
150%
Percentage of Loss
Percentage of Loss
Issue – Excess machining to assist assembly at SMLI
100%100%100%100%100%100%100%100%100%100%100%100%100%100%100%100%100%100%100%100%
0%
50%
100%
150%
Percentage of Loss
Percentage of Loss
SML – Block Cylinder
23. PROBABLE CAUSES
Customer Component Non Conformance Probable Causes Validation Result
JCB Flywheel
Housing
1. Finn in Window
area after
machining OP 10.
Grinding being
done.
2. Wall Shifting after
OP 10, grinding
required on wall
adjacent to
tapping Hole
M50X2. Grinding
being done.
Loose Core Not Valid
Pattern Broken Not Valid
Low Sand mold Hardness Not Valid
NO Relief in tooling Valid
Extra Casting Valid
Locator NG Valid
Air Went not OK Not Valid
DMAIC
24. PROBABLE CAUSES
Customer Component Non Conformance Probable Causes Validation Result
JCB Gear Case
Machining mold hole
Ø83 mm.
Loose Core Not Valid
Pattern Broken Not Valid
Low Sand mold Hardness Not Valid
NO Relief in tooling Valid
Extra Casting Valid
Locator NG Valid
Air Went not OK Not Valid
DMAIC
25. PROBABLE CAUSES
Customer Component Non Conformance Probable Causes Validation Result
JCB Drive Head
Chamfer less over Ø88
Grinding being done.
Loose Core Not Valid
Pattern Broken Not Valid
Low Sand mold Hardness Not Valid
NO Relief in tooling Valid
Extra Casting Valid
Locator NG Valid
Air Went not OK Not Valid
DMAIC
26. PROBABLE CAUSES
Customer Component Non Conformance Probable causes
JCB King Post 1. Grinding requires
after machining.
1. Legacy issue.
2. Burr is BI-Product of machining.
JCB Axle Arm
Punching of
Traceability on
components after
machining.
N/A
SML Block Cylinder
1. Additional
machining being done
at specific sections to
assist assembly line at
SML.
N/A
DMAIC
28. DMAIC
WHY-1
Finn
Observed
after
machining
WHY-2
Mold box
is being
unboxed
and fin is
broken
with chisel
and
Hammer
Custo
mer
Compon
ent
Non
Conformance
Probable
Causes
Validation Result Constraint
JCB Flywheel
Housing
1. Finn in
Window
area after
machining
OP 10.
Grinding
being done.
Finn of Mold Box Valid Section is being unlocked after
mold setting, and being broken
with chisel and hammer, zero finn
is not feasible and grinding finn
before machining will lead to
crack issues in transit.
WHY-3
No relief is
there in
core
WHY-4
Castings on
lower limit
of tolerance
and no
permissible
degree of
draft
ANALYZE
29. DMAIC
WHY-1
Locator
tolerance
with mold
cavity is in
range of 1.6
mm.
WHY-2
Shifting
observes
on
opposite
side of the
locator.
Custo
mer
Compon
ent
Non Conformance Probable
Causes
Validation
Result
Constraint
JCB Flywheel
Housing
1. Wall Shifting after OP 10,
grinding required on wall
adjacent to tapping Hole
M50X2. Grinding being
done.
Locator
Tolerance
Valid Locator range of 1.6 mm and
mismatch allowed of 1 mm in
drag and cope as per
standard ISO 8032 C09 JCB.
WHY-3
No relief
has been
extended
as against
the locator
variation.
WHY-4
Castings on
lower limit
of tolerance
and no
permissible
degree of
draft
WHY-5
ANALYZE
30. DMAIC
WHY-1
Finn has to
be removed
at
machining
WHY-2
Finn
relaxes as
is in Drag
Side of
pattern
WHY-3
No Sand in
Casting
process
WHY-4
Tooling
constraint
Customer Component Non Conformance Probable Causes Validation Result
JCB Gear Case Machining mold hole
Ø83 mm.
NO Relief in tooling Valid
Section with finn in mold hole
is in Drag pattern of the
casting.
ANALYZE
31. DMAIC
WHY-1
Secondary
Core
shifting
issue in
castings
WHY-2
Core tilted
due to more
interference
and manual
application
WHY-3
Sand mold
making
tool die
worn out
WHY-4
Life of
Tooling has
been
achieved
Custo
mer
Compon
ent
Non
Conformance
Probable Causes Validation Result Constraint
JCB Drive
Head
Chamfer less over
Ø88
Grinding being
done.
Excess Relief in tooling Valid
Tooling life has been
achieved.
ANALYZE
32. DMAIC
Customer Component Non Conformance Probable causes
JCB King Post 1. Grinding requires
after machining.
1. Legacy issue.
2. Burr is BI-Product of machining.
JCB Axle Arm
Punching of
Traceability on
components after
machining.
N/A
SML Block Cylinder
1. Additional
machining being done
at specific sections to
assist assembly line at
SML.
N/A
ANALYZE
34. DMAIC
IMPROVE
Customer Component Non Conformance Root Causes Action Plan/Executed
JCB Flywheel
Housing
1. Finn in Window
area after
machining OP 10.
Grinding being
done.
Castings on lower
limit of tolerance
and no
permissible
degree of draft.
Casting of 1.5 mm at a permissible draft
of 3 degree as per ISO 8032 C09 Standard,
that will ensure, after machining from
Drag to cope side during machining finn
will chipped off.
Only Filing is enough to remove these
sharp edges
Improved Castings
35. DMAIC
IMPROVE
Customer Component Non Conformance Root Causes Action Plan/Executed
JCB Flywheel
Housing
1. Wall Shifting after
OP 10, grinding
required on wall
adjacent to
tapping Hole
M50X2. Grinding
being done.
Castings on lower
limit of tolerance
and no permissible
degree of draft
A linear relief of 0.7 mm has been given
in castings by grinding pattern at tooling
to compensate the variation due to
Locator pad.
Castings will be received un batches of
14.7-15.5 mm.
15.6-16.3 mm.
36. DMAIC
IMPROVE
Customer Component Non Conformance Root Causes Action Plan/Executed
JCB
Gear Case
1. Machining mold
hole Ø83 mm.
Tolling Constraint
to avoid finn from
this hole.
Upon mutual discussion with JCB, it has
been finalized that his finn won’t be an
trouble at JCB assembly as far as there is
no sharp edge in ID.
37. DMAIC
IMPROVE
Customer Component Non Conformance Root Causes Action Plan/Executed
JCB Drive Head Chamfer less over Ø88
Grinding being done.
Excess Relief in tooling, Life of
Tooling has been achieved
Two slips has been added at
secondary core placement so
that no relief is left for core
tilting.
New Tooling From JCB has
reached CASTEX and is under
verification
38. DMAIC
IMPROVE
Customer Component Non Conformance Root Causes Action Plan/Executed
JCB King Post Grinding requires after
machining.
Legacy Issues and Burr being
the BI-product of the process
From Section one, Y travel of
cutter has been made -1 mm,
and grinding has been
stopped.
Instead of Electric grinder,
Pneumatic grinder with steel
tool has been introduced.
Section-1 Section-2
39. DMAIC
IMPROVE
Customer Component Non Conformance Root Causes Action Plan/Executed
JCB Axle Arm Punching of Traceability
on components after
machining.
N/A
Instead of Punching, itching has been
proposed on component at different
locations and is under approval phase
from JCB.
40. At these specific locations, 100% machining is being done to assist assembly at SML.
1.
2.
IMPROVE
DMAIC
41. At this specific location, 100% machining is being done to assist assembly at SML.
3.
IMPROVE
DMAIC
42. At this specific location, 100% machining is being done to remove unwanted finn from the
cross section to assist assembly at SML.
4.
IMPROVE
DMAIC
