1. 1
PROJECT
ON
“INCREASING PRODUCTIVITY OF L/H & R/H CRANKCASE
COVER”
Under the guidance of:
Mr.J. Sathya,
Manager, Machine cell,
Royal Enfield,Thiruvottiyor, Chennai
From 26/11/2015 to 26/12/2015
By:
Arun Kumar
Sripal Kumar B,
SRM University
Chennai
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ACKNOWLEDGEMENT
It gives me tremendous pleasure in bringing out this project entitled “ Increasing
Productivity of L/H and R/H crankcase covers” taken up during my final year
B.Tech degree course.
First of all, we would like to thank Mr.J.Sathya, Manager, Machine cell, Royal
Enfield, for guiding us in each and every step of our project right from day 1.
His guidance and supervision were useful to us in many aspects, which led us
successfully complete our project.
Next we would like to thank Mr. Ramalingam, Manager, HR, Royal Enfield for
giving us permission to carry out this project without any interruptions. His kind
gesture and very acceptable nature is to be well appreciated as well.
I am thankful to Mr. Duraivelu, dean and Mr. Karthikeyan Head of Dept of
Mechanical Engineering , SRM University for granting me permission for this
work and the help extended to me during the course of this project.
We would also like to thank the Almighty and our parents without whose
support, successful completion of this project would have been a difficult task.
Last but not the least, we would like to thank each and every staff of Royal
Enfield, Thiruvottiyur for their kind cooperation and helping nature.
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INTRODUCTION
Royal Enfield was the brand name under which the Enfield Cycle
Company manufactured motorcycles, bicycles,lawnmowers and stationary
engines. The first Royal Enfield motorcycle was built in 1901; the original
British concern was defunct by 1970. The Enfield Cycle Company is
responsible for the design and original production of the Royal Enfield Bullet,
the longest-lived motorcycle design in history.
Like other motorcycle manufacturers such as BSA and IZhMASh, the Enfield
Cycle Company began business as a weapons manufacturer, most famous for
the Enfield rifle. This legacy is reflected in the company logo, a cannon, and
their motto, "Made Like A Gun".
In 1955, Enfield Cycle Company partnered with Madras Motors in India in
forming Enfield of India, based in Chennai, and started assembling the 350cc
Royal Enfield Bullet motorcycle in Madras. The first machines were assembled
from components imported from England. Starting in 1957, Enfield of India
acquired the machines necessary to build components in India, and by 1962 all
components were made in India.
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AIM & OBJECTIVES
The main aim of our project is to increase the productivity of the manufacturing
cell which manufactures L/H and R/H Crankcase covers. Increase of
productivity requires analysation of various process carried out from raw
material to final product. There are various machining processes which are been
carried out on crank case covers like drilling, boring, counter boring, taping,
reaming, milling, etc. Thus if we require the process to be effective, it is
necessary to monitor each and every aspect of the machining process.
Various objectives which can be carried to accomplish the desired:
1. Reduce cycle time.
2. By line balancing.
3. Reducing interruptions
4. Change the sequence of activities
5. Perform activities in parallel
Here in our project we have studied in detail about the production process of
Crankcase covers and in doing so we have carefully studied about the
implementation of the process of line balancing in order to increase productivity
and eliminates wastage .
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MATERIALS AND METHODS
In order to increase the productivity of crankcase covers, we have studied the
manufacturing of L/H and R/H crankcase i.e, the no. of cnc machines required
in both the cases, tools required, operations undergone by each cnc machine.
We have also studied the programs fed into each cnc machine using G-codes
and M-codes which does the required operation.
No. of machines required in each case:
1. For L/H crankcase covers, there are 5 cnc machines used, whose
operations in detail would be described later.
2. For R/H crankcase covers, the company uses 2 phases of
manufacturing independently. In phase 1, there are 9 machines used
and the operation time for manufacturing each crankcase is also less.
In phase 2, there are 4 machines used and thus operation time is also
more compared to the previous method.
3. Manufacturing of L/H is less compared to that of R/H because of very
less machining, drill holes, taps and counter bores required. Thus
productivity of L/H is more compared to that of R/H. In order to
equalise the production of both the cases, R/H utilizes 2 phase of
manufacturing.
L/H CRANKCASE MANUFACTURING:
There are 5 operations in manufacturing of a L/H cover which are described as
follows:
1. OPERATION 10
2. OPERATION 20
3. OPERATION 30
4. OPERATION 40
5. OPERATION 50
Here we have studied about the tools required, cycle time, and surface
counters and machining undergone during each operation.
OPERATION 10:
Here, the un machined raw material is machined for 2 purposes.
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The operations undergone here are:
1.Rough milling
2.7 mm drill hole
3.Chamfering
Cycle time: 1minute 50 seconds
OPERATION 20:
Here the operations are followed in contiguous to that of operation 10.
The operations undergone here are:
1. 5.5mm drill hole
2. 6mm reamer
3. 10 mm end mill
Cycle time: 1 minute 56 seconds
OPERATION 30:
The operations undergone here are:
1. 7 mm mounting drill
2. Combination tool drill
3. 20mm reamer
Cycle time: 30 seconds
OPERATION 40:
The operations undergone here are:
1. Milling for rod insertion
2. Lubrication for smoothening of operations
Cycle time: 40 seconds
OPERATION 50:
The operations undergone here are:
1. Hole for clutch insertion
2. Combination tool drill
Cycle time: 50 seeconds
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PROBLEMS:
1. Imperfection of gauges
2. Improper finish
3. Inaccurate dimensions
4. Breakage of material
RECTIFICATIONS:
1) Regular checking of gauges
2) Use of propertool for machining
3) Replace wearer tool with new one
4) Perform additional machining if required
5) Check the material
R/H CRANKCASE MANUFACTURING:
The operations undergone for machining R/H crankcase are:
1. OPERATION10
2. OPERATON20
3. OPERATION30
4. OPERATION40
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5. PLUG FIXTURE AND LEAK TEST
OPERATION10:
Operations are performed on un machined R/H cover.
The operations undergone here are:
1 .16 mm end mill
2 .6.75 drill combination with 13.75 mm drill
3 .4.62 mm drill
4 .M5 tap
5 .5.7 double hole drill
6 .23.5 oil seal bore
7 .27 rough bore
8. 35 OD turning
9. milling cutter(joint face)
10. 6mm reamer
11. 14 x 7.2 reamer
12. 24 oil seal reamer
Cycle time: 3 minutes 10 seconds
OPERATION20:
The operations performed here are:
1. 40 mm bore facemill
2. 24.5 bore rough
3. Groove insert
4. 25 mm finish reamer
5. 40mm bore
6. Combination tool of 26.5mm and 19.5mm
7. Combination tool of 27mm and 20mm reamer
8. 5.5 mm drill
9. M6 tap
10.27 Backboard
Cycle time: 3minutes 18 seconds
OPERATION30:
The operations performed here are:
1. 17.5mm drill
2. M20 tap
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3. 37mm stoppage
4. 10.5mm drill
5. M12 tap
6. 22 stopbore
7. 12.75 mm drill
8. M14 tap
9. 24 stopbore
10.6.5 mm drill
11.6.5 mm whole mill
12.4.5 mm step drill
13.4.5 mm long drill
14.7 mm reamer
15.5.5 mm reamer
Cycle time: 1 minute 54 seconds
OPERATION40:
The operations performed here are:
1. 6.5 mm drill
2. 5 mm oil hole
3. End mill
Cycle time: 55 seconds
PLUG FIXTURE AND LEAK TEST:
The operations performed here are:
1. Insertion of plug and its fixing through proper seal
2. Leak test is performed on R/H crankcase to find out the reason of
leakage and rectification of the same.
INITIAL PRODUCT:
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1. Regular checking of tool and replacing the tool
2. Propercodeto be fed in ATC system
3. Replacement of old pallet with new one
IMPLEMENTATION OF LINE BALANCING TO INCREASE THE
PRODUCTIVITY:
Line balancing is an effective tool to improve the throughput of assembly line
while reducing non-value-added activities, cycle time. Line balancing is the
problem of assigning operation to workstation along an assembly line, in such a
way that assignment is optimal in some sense. This project mainly focuses on
improving overall efficiency of single model assembly line by reducing the non-
value added activities, cycle time and distribution of work load at each work
station by line balancing. The methodology adopted includes calculation of
cycle time of process, identifying the non –value-added activities, calculating
total work load on station and distribution of work load on each workstation by
line balancing, in order to improve the efficiency of line and increase overall
productivity.
Assembly line balancing is the problem of assigning various tasks to
workstations, while optimizing one or more objectives without violating any
restrictions imposed on the line. ALBP has been an active field of research over
the past decades due to its relevancy to diversified industries such as garment,
footwear and electronics. The assembly line balancing problem has received
considerable attention in the literature, and many studies have been made on
this subject since 1954. The assembly line balancing problem was first
introduced by Bryton in his graduate thesis. In his study, he accepted the
amount of workstations as constant, the workstation times as equal for all
stations and work tasks as moving among the workstations. The first article was
published in 1955 by Salveson. He developed a 0-1 integer programming model
to solve the problem. COMSOAL (Computer
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Method of Sequencing Operations for Assembly Lines) was first used by Arcus
in 1966 as a solution approach to the assembly line balancing problem.
Helgeson ve Birnie [11] developed the “Ranked Positional Weight Technique”.
In this method, the “Ranked Positional Weight Value” is determined. It is the
sum of a specified operation time and the working times of the other operations
that can’t be assembled without considering the operation finished. While
taking into consideration the cycle time and technological precedence matrix,
the operation having the largest ranged weight is assigned to the first
workstation, and other operations are assigned to workstations in accordance
with their ranked positional weight value. Con figurations of assembly lines for
single and multiple products could be divided by three line types, single-model,
mixed-model and multi-model. Single -model assembles only one product, and
mixed-model assembles multiple products, whereas a multi-model produces a
sequence of batches with intermediate setup operations. A single-model line
balancing problem with real application was solved in this project. ALBP with
various objectives are classified into three types
-I: Minimizes the number of workstations, for a given cycle time.
-II: Minimizes the cycle time, for a given number of workstations.
-III: Maximizes the workload smoothness, for a given number of
workstations.
In type I problems, the ALBP of assigning tasks to workstations is formulated
with the objective of minimizing the number of workstations used to meet a
target cycle time. It can result in low labor costs and reduced space
requirements. Type II problems maximize the production rate of an assembly
line. Since this objective requires a predetermined number of workstations, it
can be seen as the counterpart of the previous one. In general, shop managers
are concerned with the workload equity among all workers. The issue of
workload smoothing in assembly lines allocates tasks among a given number of
workstations, so that the workload is distributed as evenly as possible. This
problem is known as Type III problem. Our project was focused on type-1 line
balancing problem. Relevant data obtained from an apparel industry was used to
formulate the solution. The objective of the project was to balance the cycle
time for various operations and minimization of workstations.
PROBLEM STATEMENTS:
1. Reducing line efficiency.
In flow line production the product moves to one workstation due to time
restriction. Once its get stuck due to accumulation in certain workstation, it
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exceeds the cycle time in that station. Faster station is limited by slowest
station. Thus, decreasing the rate of productivity.
2. Unbalance workloads
Due to starving, the workers need to wait the products to come.
PROBLEM OBECTIVES
Two objectives are expected in the end of the project:
1. To improve productivity and efficiency of existing layout and new layout
2. To meet unpredictable demand
PROJECT SCOPES
The research will be conducted at manufacturing based company in Kuantan
specifically in electronics company.
1. Software application, WITNESS is used to simulate data.
2. Comparison between existing and new layout.
3. Proposing new layout (3 layout and the best is chosen).
4. Stopwatch is used to take the time
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FLOW CHART:
Small and Medium Industry
Manually Machining Line
Types of Machining Line
Workstation
Material Handling System
Line Balancing
Simulation
Work Measurement
Efficiency
Productivity
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CONCLUSION
Thus in this project we have studied about the process of machining of L/H and
R/H crankcase covers. After careful study about the machining process, tools
required and cycle time for each machining process was noted down. The
problems which occurred during the operations were also discussed along with
their rectification methods. Finally, implementation of line balancing was also
proposed which was useful in increasing the productivity by the usage of same
labours and reducing wastage and time required for its completion.
Further improvements in the productivity can be achieved by considering large
amount of order minimum. Proposed layout model has been followed the logic
of modular system (one worker works more than two processeswho is skilled on
all processes and these combination of skilled workers finish their work in piece
flow production) and traditional system (one worker works in one process and
all the workers who may be skilled or not finish their work in bundle flow
production) both together where only modular production system can be
applicable with a series of skilled workers to achieve more productivity. On this
occasion, skilled workers are eligible for the production processes and proper
training and supervision is essential to achieve the optimum improvements on
productivity and efficiency.
