Rajat Saxena completed a summer internship where he was assigned various tasks. He completed standard operating procedure documentation for mast assembly, designed a new layout for the fabrication shop to improve workflow, conducted a time study for the EOS mast assembly process, designed a table for bench vise installation and a new hose support system, calculated the center of gravity for a tilt table, and performed a time and motion study for oil filling processes on the Kibo truck. He also analyzed the costs of making versus buying pre-cut hoses and provided suggestions to improve scheduling and safety for sensitive machines.

2. Summer Internship
By
Rajat Saxena
2

3. 3
OVERVIEW
Make
Vs Buy
ASSIGNMENTS MANAGER STATUS
Sop Design - Mast Assembly Ricky G. Completed
Plant Layout -fabrication shop Saul Completed
Time Study- EOS fabrication Afework Completed
Time- Kibo EM Kutty Completed
Design & Prototype for bench vise
installation
Dinesh Completed
Design & prototype of Hose Support Yonas Completed
C.G.- Tilt Table Dinesh Completed
Make vs. Buy Yonas Completed

4. Approach
4
Assignment-1 (Standard Operating Procedure-
Mast Assembly)
Take pictures Use drawing
Spec. from the
drawing
Match the
drawing part
nos. with B.O.M.
Check the parts
no. with ASO
400
Updates the SOP
with correct
drawing no.

5. 5
Sample SOP
No.
5
4
8 3
8 2
8 1
Qty No.
4
3
2
1
0 RS
CHG Init.
Legend: Visual Check Torque Requirement Critical Dimension
Quality Control Special Requirement Jig/Fixture Indicator
Safety Environment Procedure Setup/Repeat
9421010912
9421010911
Part Number
9421111800
Mast Assembly- 5M25C37 1/6
6/11/2015
Date
Review for initial release
Description of Change
Document Name Page
N/A
EO - MO
Note
Shim T-0.5
For all three
channels
Shim T-1.0
Roller Main
Part Name
Any shim can be used
as per requirement
Bearing should have proper
fit with item 2
Mitsubishi Caterpillar Production System
Standard Operating Procedure
Procedure Quality Point
1
Placing shim(item 1) onto inner shaft
2 of middle and outer channel.
Lubricate no.2 before
installations
2
Installing roller main (item 3) with the
help of pnematic bering press(item4)
onto inner shaft of outer and middle
channel.
Step # 1 Step # 1
Step # 2 Step # 2
1
3
2
4

6. 6
Suggestion
1. Flow Diagram

7. 7
2. Control Plan
Prototype Prelaunch Model Documentno
Partname Personincharge Preparedby
Partno. Customername Checkedby
Drg.Name Suppliername Approvedby
Drgno. Coreteam
Size Freq. Y/N SIZE
94111-07500 Shim-0.5 0.1mm Fillerguage 4
94111-07400 Shim-1.0 0.1mm Fillerguage 4
Line
operatorInstallingtheshim
ontotheshaft
1
CONTROLPLAN
Through
hands
Sample Reccording
Part/
Processno.
Processname/
Operation
description
M/CJigs,
Toolsfor
MFG
PartNo. ProductName Process
Class
Product/Process
specification
tolerance
Characteristic
Evaluation
measurement
technique
Method
Photo
InspectedBy
Control
Method
ReactionPlan
Revisionno.
Dateorg.
Daterev.
Production
MastAssembly
Pageno

8. 1. Layout of fabrication shop
8
Assignment-2 Fabrication Layout

9. Old Layout
9
Progress

10. New Layout
10
Progress

11. Approach
 Dimension of fabrication layout
 Studied the flow
 Studied the Constraints
 Layout Design
Constraints
11
Robots are fixed
Space
Conveyors are fixed
Space for fork lift
movement
Magellan and
Victoria should be
closed to Robot
One directional
Flow
Electrical
Connections
Budget

12. Total Flow Dimension Required for each shop
12
Studies Required
Model
No. of units
produced
Total
Flow
Magellan/Victoria 739 739
Atlas/Kibo 124 124
Centaur/EOS 80 80
Mercury 79 79
Apollo 23 23
PlannedArea
Vertical Horizontal Area Vertical Horizontal Area
EOSWeld 29 26 754
EOSFabrication 29 20 580
Polaris 29 23 667 31 23 713
Centaur 29 27 783 35 23 805
Mercury/Mars 29 79 2291 66 35 2310
Apollo 29 82 2378 29 83 2407
Atlas 29 98 2842 30 100 3000
Helios 29 28 812 29 30 870
30 23 690
54 15 810
TotalArea 12298 12991
CurrentDimension
ShopName
66 21 1386
Dashboard 29 41.06 1191

13. Material
Handling
Punch
Press,
Laserand
plasma
Frame
Fabricatio
n
Robot Stamping
Shot
Blasting
Paint Storage
Scheduling
Material
Handling
PunchPress,
Laserand
plasma
Frame
Fabrication
Robot
Stamping
ShotBlasting
Paint
From
Atlas/Madgella/Victoria
To
Material
Handling
Punch
Press,
Laserand
plasma
Frame
Fabricatio
n
Stamping
Shot
Blasting
Paint Storage
Scheduling
Material
Handling
Punch
Press,Laser
andplasma
Frame
Fabrication
`
Stamping
Shot
Blasting
Paint
From
EOS/POLARIS/CENTAUR/MARS&MERCURY/APOLLO/
HELIOS
To
13
From- To Chart Analysis

14. 14
Suggestion 3

15. Creo Drawing Model
15
Assignment-3 Design Table for Bench-vise
Installation

16. 16
Assignment-4 Time Study for EOS Mast
(Sample)

17. Time Measurement
 Used stop Watch to measure the time.
 Machine Time
 Loading & Unloading Time
 Average time
Challenges faced
 Shift Changes
 No specific schedule followed by the
supervisor
 Machining time is different for similar cut
 Operator has to wait for the forklift to flip the
part.
17
Approach

18. Advantages
• Reduce waste of time
• Forklift Operator can see the flag from
any part of the plant.
• It is also helpful for the maintenance
department
18
Suggestion-4 Flag interpretation to call forklift operator to avoid
time waste

19. Formula Used
Momentum
M1R1 + M2R2 = (M1 + M2)R
R = M1R1 + M2R2/ (M1 + M2
Moment of body A
Area of square / 2 * Area of triangle
10 *38.05/8 *38.08 = 5/4
Mass of rectangle = 5/9*500 =277
Mass of two triangles = 500- 277 =223
Center of gravity with reference to plane A
C.G. of the body A
= (277 * 19.04 + 223 * 12.69)/ 500 =14.3
C.G. of the whole body (A and B)
= (268 * 40.08 + 500 * 14.3)/768= 23.29
Center of gravity with reference to plane B
C.G. of the whole system (A+B+C)
= ((12+5)*4500 + (272+23.29)*(500+268))/
(500+268+4500) = 57.75
Drawing
19
Assignment-5 Center of Gravity of Tilt Table

20. Challenges Faced
 Hanging hoses create disruption
during the processes.
 Hose- Stand in not utilized well
 Existing are not perfectly aligned
 Hoses are entangle with each other
20
Assignment-6 Design for new Hose Support-
Kaizen

21. Creo Drawing Prototype
21
Design in Creo & Prototype

22. 22
TOTAL
STUDY
TIME:
Date:
Serial No. Process Start Time End Time Cycle Time
1 Gear oil (Differential) filling to the front axle 0:00:00 0:05:40 0:05:40
2 Engine Oil (Motor oil) filling 0:00:45 0:02:30 0:01:45
3 Coolant(ATF) filling to the radiator 0:02:10 0:04:30 0:02:20
4 Coolant(ATF) filling to the reserviour tank 0:04:50 0:05:08 0:00:18
5 Hydraullic oil filling 0:00:40 0:06:02 0:05:22
6 Bolting the front axle 0:06:40 0:07:50 0:01:10
7 Bolting the hydrallic tank 0:08:01 0:08:18 0:00:17
8 Instal floor plate L.H. with insulator 0:09:26 0:11:52 0:02:26
0:11:52
0:01:00
Total cycle time ( filled simultaneously)
Total motion time
MCFA Time & Motion Study
PRODUCT DESCRIPTION: KIBO EMERGINGMARKET PERFORMED BY: RAJAT
OPERATION DESCRIPTION: OIL FILLING STUDYBY:
START TIME:
Assignment 7 Time Study for the Kibo Truck

23. Approach
 Recorded the video for each station.
 Calculated the start time and end time for
each process.
 Calculated the material Handling time for
motion study.
Challenges faced
 Part Shortage
 Mismatch in scheduling plan vs action plan
 Waiting for the frame or other parts
23

24. Table
Process TotalCycleTime TotalMotionTime TotalTime
Sub-Assembly 4:12:34 1:24:50 5:37:24
PowerStation1&2 0:47:56 0:09:34 0:57:30
PowerStation3&4 1:00:11 0:35:22 1:35:33
MainlineStation1&2 1:09:17 0:53:09 2:02:26
MainlineStation3&4 1:23:09 0:48:52 2:12:01
MainlineStation5 0:46:23 0:07:24 0:53:47
MainlineStation6 0:11:52 0:01:00 0:12:52
Total 9:31:22 4:00:11 13:31:33
Graph
24
Results
0:00:00
1:12:00
2:24:00
3:36:00
4:48:00
6:00:00
Total Cycle Time
Total Motion Time
Total Time

25. 25
Suggestion 5 - For Scheduling

26. Total Cost
Make Buy
OrderingCost 3,250.00$ 101,000.00$
TotalcutCost 91,617.03$
HoldingCost 6,673.03$ 2,200.61$
TotalUncutCost 58,672.54$
LabourCost 6,100.38$
TotalCost 74,695.95$ 194,817.64$
Graphical Representation
26
Assignment 8 Make Vs Buy for the Hose Cut
$- $50,000.00 $100,000.00$150,000.00$200,000.00$250,000.00
Ordering Cost
Total cut Cost
Holding Cost
Total Uncut Cost
Labour Cost
Total Cost
Chart Title
Buy Make

27. 27
Suggestions

28. 28
Suggestion 6- for sensitive machines

29. Questions?
29