This document provides a semester review for a student's internship project at Munjal Showa, Manesar. The student worked on three projects: 1) improvements in the rear assembly process, 2) air pollution control in the machine shop, and 3) value stream mapping. For the rear assembly project, the student identified issues like excess cycle times and implemented solutions like fixing equipment faults to improve productivity. For the air pollution control project, the student updated data on exhaust fans and introduced pollution control measures in welding and buffing shops. Through value stream mapping, the student identified ways to eliminate non-value-added activities and reduce man-material movement in processes.

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PROJECT SEMESTER REVIEW
Name: Zorawar Singh Nandwal
Roll No: 401257013
Organization: Munjal Showa, Manesar
Department: Rear Assy, I.E
Project Guide: Mr. Narinder Madan

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Munjal Showa in very few years of its existence has become a national leader
in manufacturing of Suspensions for 2 & 4-Wheelers. Since its formation in
1987 with Showa group of Japan it has grown substantially and has achieved
success in both national and international markets. Today Munjal Showa
Limited is one of the largest suppliers of shock absorbers to major auto giants.

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PROJECT TITLES
1. Improvements in Rear Assembly
2. Air Pollution Control in machine shop
3. Value Stream Mapping

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ACTIVITY PLAN
S.N
O ACTIVITY JAN FEB MAR APR MAY JUN
1 IMPROVEMENTS IN REAR ASSEMBLY
2 AIR POLLUTION CONTROL IN MACHINE SHOP
3 VALUE STREAM MAPPING

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Objectives
1. Productivity Improvement
2. Reduce man-material movement
3. Manpower Management
4. Observing Standard Operating Procedure (SOP)
5. Maintenance of newly installed features
6. Improving cleanliness in the new air tight enclosure
IMPROVEMENT IN REAR
ASSEMBLY

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PRODCUTIVITY IMPROVEMENTS
 Calculated cycle time of all 6 lines.
 Compared cycle times of each line to set a standardized way of operating
the same equipment on different lines.
 Found out rod guide pressing of line-5 was taking longer time than others
 Located a fault in ECU of the equipment.
 Excess cycle time of piece bottom pressing in Line-3 i.e. 4.4 secs as
compared to 1.5-1.75 in other lines.
 Maintenance dept informed about the fault. ..MunjalShowa
AssemblyRear
AssyLayoutRe
ar
AssyLayoutLine
5.xlsx..MunjalShowaAss
emblyRearAssyCycl
eTimeRear
AssyLine5KSPGCy
cleTimeline5.xlsx

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OBSERVING SOP
 In rod guide pressing the worker had to keep on pressing the buttons till
the time the process was not completed.
 Whereas in other machines the operator just presses the button once and
during the processing time he/she unloads the next piece from the bin.
 Maintenance dept was informed and necessary action was taken.
4.4
1.75
Cycle Time
OLD NEW

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Reduce man-material movement
 Often wrong raw material is brought to the work station due to which time is
wasted.
 Naming done on raw material.
 Newly installed chute should have particular rack for the same type of raw material.
 This will lead to worker’s proper understanding.

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In oil filling trolley movement was reduced by making the RM available
at a shorter distance. Also by creating side racks the need for a trolley at all
times was eliminated.
0
20
40
60
Initial Final
Initial
Final
54
14
S
T
E
P
S

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MANPOWER MANAGEMENT
 Between Rod guide pressing and rolling the manpower is 3. 1st workers
operates the RGP m/c, 2nd worker places the end plate & checks the
moment and the 3rd worker operates the rolling m/c.
 The rod guide pressing operator can insert the end plate and can place in
the loading bin of rolling worker.
0
0.5
1
1.5
2
2.5
3
3.5
Existing New
M
A
N
P
O
W
E
R

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Maintenance & Improvement of Newly
installed features
 The new chute installed which is used to slide down the final assembled
part outside the air-tight enclosure had started bending after 2-3 days of
use.
 A support was provided in between the chute so that it doesn’t bend and the
smooth flow continues.
 The rack installed in the air tight system which allows the trolley operator
to load the raw material without entering the air tight enclosure. Thus
saving man and material movement.
 Here there no particular rack for a particular raw material. Therefore a
proper description was provided on each rack.

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Improving cleanliness level in the new
air tight enclosure
 In gas shock absorbers an air gun is used to clean the remains of oil on the
part. This led to accumulation of oil droplets on the wall and the floor.
 This also led to accumulation of oil on the conveyor which further would
effect the work piece.
 Therefore a bin was created. Now the operator will use the air gun while
pointing towards the bin

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Improving cleanliness level in the new air
tight enclosure
Date 26/12 29/12 2/1 6/1 10/1 17/1 23/1 23/2 23/3 23/4 23/5
DFT Dirty Dirty Clean Clean Clean Clean Clean Clean Clean Clean Clean
Oil
Filling
Dirty Dirty Clean Clean Dirty Dirty Clean Clean Clean Clean Clean
Air Gun Very
Dirty
Very
Dirty
Very
Dirty
Dirty Dirty Clean Clean Dirty Clean Clean Clean
 In oil filling machine where the chances of contamination are the highest it
was ensured that the workplace will be cleaned at regular intervals by the
operator.
 Also in the Dampening Force Testing Machine due to the presence of heat
exchanger the water used to get collected on the equipment. Though it
happened very rarely but when it did it was ignored

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Reducing Rust in DAMPER CASE pipe
 Rust inside the D/C pipe is a major problem which leads to contamination
of oil and thus effects the performance of the shocker.
 To reduce this damper case washing is done on a in-house manufactured
machine. This process is the first step of any line in Rear Assembly.
 A brush is used to clean the inside of the pipe.
 The brush used to clean is only suitable for 30,000 cycles.
Therefore it has to be changed every 3 days.

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Air Pollution Control in machine shop
Objectives
1. To update data regarding number of exhaust fans working.
2. To control pollution in Welding Shop & Buffing shop.

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ELECTRICAL EXHAUST FANS

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NATURAL EXHAUST FANS

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Air Pollution Control in machine shop
 Data regarding Electric exhaust and natural exhaust fans was updated and
reported to the industrial coordinator.
 Ducts were introduced at every work station.
 As the raw material consisted of oil and grease
It caused excess release of fumes during welding.
Therefore it was made mandatory for all operators to
First dip the RM in thinner(SOKLIN)
 Also ducts were introduced above WIP
collecting trolleys

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The D/C parts that are sent by the vendors are full of oil and grease particles. When the
operator starts to weld these parts the pollution caused is high because the electrode now
has to penetrate through the oil layer as well.
Therefore the workers were instructed to dip the RM first inside thinner for 10-15
seconds and then take the lot to the work station.

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Air Pollution Control in machine shop
 In buffing shop where bottom case is buffed, lot of dust is produced.
 The ducts installed are not effective.
 Some repairs were made to reduce dust inside
the shop.

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Value Stream Mapping(AAHA)
Objective
 To eliminate the avoidable NVA and to minimize unavoidable NVA
 To understand Process Flow.

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CAUSE & EFFECT

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PROCESS FLOW
Damper Case
Welding Line
Loading/Unloading
Loading/Unloading
Store
Piston
Rod Line
Piston Rod
Cutting Piston Rod
Plating
U/S Washing
Assembly
Begins
Assembly
Ends
Despatch
Area

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ELIMINIATING AVOIDABLE NVA &
MINIMIZING UNAVOIDABLE NVA
1.The standard stoppage time is 50 mins for 1 shift. Though the average break time
comes out to be more than 76 mins. There is a difference of 26 mins.
 Keeping this in mind targets were given to each line each hour. If the line in
consideration fails to achieve the target on regular basis, the HOD provides them
with training.
2. Paint shop is located at the farther end of the plant. Due to this any major/minor
breakdown takes time to be checked and corrected.
 Many times the hose air pipe gets damaged and it takes more than 15 minutes to
inform the maintenance dept and bring a new pipe for replacement. For this the
supervisors and the operators were trained by the TPM dept. to take quick action if
any such situation arises and the replacement pipes were present at the paint shop..
This would prevent line stoppage.

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ELIMINIATING AVOIDABLE NVA &
MINIMIZING UNAVOIDABLE NVA
3. Due to the unavailability of trolley at the unloading station of the excise store the
worker first had to place the goods on the floor and then wait for the trolley to be
free. Then he loaded the goods on to the trolley.
 Therefore two trolleys were made available to the workers. This would reduce the
fatigue and increase productivity.
4.To reduce man material movement a new path was allocated for taking the piston
rods to the plating line.
 This lead to a decrease of 61% in man material movement.

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REDUCING MAN MOVEMENT &
FATIGUE

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PREVIOUS PATH FOLLOWED (PISTON ROD LINE-->>PISTON
ROD PLATING)

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NEW PATH FOLLOWED (PISTON ROD LINE-->>PISTON ROD
PLATING)

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REDUCTION IN MAN MATERIAL MOVEMENT

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Thank You!