CYCLE TIME REDUCTION IN MANUFACTURING OF KNUCKLE

Presentation on-

By-Sudhanshu SengaonkarDigvijay Phadke

Guided by-Mr. D. S. Patil

Rough Turning

Facing and centering

Finish TurningInspection

Knuckle Storage

Module 1 : Layout

Number Punching

Module 2: Layout

Fillet Rolling Taper Bore

Crack Detection Complete

Inspection Area

Bush Pressing and

Broaching

Keyway Broach

(Vertical Broaching)

Wash/Anti- Rust

Application

PackagingNumber Punching

Problems Faced on Knuckle Line

• Number Punching operation being done manually• Doors of CNC machines need to be closed manually• One person doing multiple jobs on module 1• Center drill remains idle• Checking for tooling problems• Insert wear • Turret shifts downwards when idle for long times on FMS

Process Time(T1)(Seconds) T2 T3 T4 T5 T6 T(avg) in sec

1. Pick up job and place on center drill

41.6 37.4 43.7 31.3 48.2 46.1 41.38

2. Center drill operation 66 64 62 63 63 64 63.66

3. Pick up job from central drill and place for rough turning

25.9 32.9 30 37 33.8 31.2 31.8

4. Rough turning 248 240.078 240.076 240.078 240.08 240.07 241.4

5. Remove and Punch 22.6 21.2 18.1 42.8 20.9 21 24.43

6. Pick and place for finishing and complete operation time

212 235 206.3 210.5 205 207.6 212.73

7. Inspection after finishing(Includes picking job from FMS)

137 57 29.8 44 43 62.16 62.15

Total Average time 677.56

Process Time Evaluation (Module 1)

 

Process Time T1 T2 T3 T4 T5

T(avg) in sec

1. Pickup job and place on Centering machine 53.6 54.2 68.9 92 72

68.14

2. centering machine operation time 60.1 59.6 55.8 62 60.2

59.54

3. Pickup from centering machine and place on Proteck 45 32 33.1 36 44

38.02

4. Proteck operation time 248 248 248 248 248 248

5. Pickup job from Proteck and place for number punching 25 19.1 18.6 20 23

21.14

6. Pickup job from punch and place on FMS 30 54 32.9 52 29.3 39.64

7. FMS operation time 216 209 210 212 205 210.4

8. Pickup from FMS place for inspection/complete inspection 70.2 70.8 78 65 72

71.2

Total average time 756.08

Process Time Evaluation(Module 1)

Error Proofing – MCD II

Source of Defect Knuckle Line

Problem Statement Number punching operation missing & Number punching location shift

Analysis Number punching missing & location shift due to number punching activity is manual.

Occurred at Knuckle Line

Lift the job from input pallet.

Keep the job on stand manually with proper

orientation for number punching –

(Unsafe working condition )

Manual number punching operation done

by holding number punching machine in

hand

Process Flow at job loading stage - Before

Facing & centering

Rough turning

Finish turning

Lift the job from input pallet.

Facing & centering operation Rough turning

Process Flow at job loading stage - After

Automatic number punching operation with button start.

Finish turning operation

Error Proofing – Checklist

Principles Questions to be asked to the process Solution Effectiv-ness Cost

Implimentation

SPN

Elimination Can we eliminate the error-prone process in totally? NoCan we eliminate the error from process partially? No

Replace-ment

Can we automate the process? Yes , automation can be done for number punching operation 3 3 3 27

Can we provide supporting tools like checklists/gages/samples?

Yes 1 3 3 9

Facilitata-tionCan we simplify the operation or introduce changes in the operation? (standardization, color coding, unique shape, etc)

No

Detection

Can we record the outcome / product parameters of the earlier operation and verify it before starting next operation

No

Can we restrict the motion in such way that the operator will see the abnormality?

No

Can we verify the outcome / product parameters of the said operation before passing the part to next operation ?

No

MitigationCan we make detection at multiple levels? No

Can we make ergonomic condition better so as not to produce / miss the defects?

Yes 1 2 3 6 Solution Priority Number (SPN) CriteriaEffecive-ness 1 : Less Effective 2 : Effective 3 : Very Effective Solution Cost 1 : High 2 : Medium 3 : Low

Automation is required at number punching stationImplemen-tation 1 : Difficult 2 : Easy 3 : Very Easy

Error Proofing – Before

Before Counter measure :. Job is kept on table as per required orientation & number punching is done manually by hand.

Error Proofing – After

After Counter measure :

Automatic number punching operation

Automation setup with pneumatic cylinder & solenoid valve mounted on stand .

Error Proofing – Design Review

Sr. No.

Design Review Parameter Description

1 Fail-Safe performance

Unsafe working condition eliminated at manual number punching

2 Cost effectiveness Proposed solution is cost effective.

3 Ease of operation Easy to operate as button start.

4 Protection from external damage

Automation setup is mounted on stand hence no chance of damage.

5 Simplicity in design Proposed solution is simple to implement.

Grinding Operation

Time

T1 T2 T3 T4 T5 Average

Loading 22.5 64 53 61 47 49.50

Commands 6.3 4 14.01 10.58 8.4 8.66

Operation time 180 181 180 180 181 180.40

Inspection 73 63 68 71 62 67.40

Unloading 32 29 31 26 27 29.00

Rotate Job 12.26 12.15 12.33 12.01 11.48 12.05

Input Job Number on record 12.17 12.35 12.48 12 13.2 12.44

Total time 359.44

Time in min 5.99

Hardening Operation

Time(sec)

T1 T2 T3 T4 T5 Average

Loading 47.37 25.28 65 50 54 48.33

Operation Time 170 172 170 171 170 170.60

Unloading 97 54 34 45 68 59.60

Total time 278.53

Time in min 4.64

16

Action plan

Sr. no Machine ActivitiesTime saved by (sec) Remark

Grinding and Hardening

1Make provision for parking crane near operator for ease of operation 6

2 Job should be ready prior to operation 8

3Fixture for resting job and air nozzle for removal of central burr 5

4Provide stand near grinding operation for inspecting the job 40

5Provide conveyor along with coolant after hardening 15

6 Stand for log book for better ergonomics 4

7 Combine two snap gauges 12

Thank You!