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Introduction

Introduction

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Introduction

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  1. Introduction WEL COME TO SHRIRAM FOUNDRY MACHINE SHOP

  2. COMPANY PROFILE Machine Shop Area- 0.35 Acers Machine shop man power- 120 Nos. Machine Shop turnover- 2.4 Cr / Year

  3. Our Customers Continued…

  4. OUR PRODUCTS CLAAS PULLEYS CONMET ROTOR DISC CONMET HUB FRONT & REAR HUB

  5. Our Team SHRIRAM MACHINE ESTABLISHED ON -29TH APRIL 2011 MR .SANJAY JADHAV SIR( CO-ORDINATOR) MR.P. S. ACHARI SIR ( FACILATOR) PATIL SUNIL B.( LEADER) 1)PATIL P.K. 2)PATIL PRATAP P. 3)NERLEKAR R. R. 4) MANE S. G. 5)NAIKWADI R. M. 6) SHAIKH G.M. 7) HIREMANI S.R. 8) SUTAR N.S.

  6. Project title TO IMPROVE PRODUCTIVITY BY REDUCING REJECTION Time period – MAY 2011 to Project Selection Date-29 APRIL 2011

  7. Data collection Shriram Foundry machine shop quality circle 2010-2011 ( conmet hub hole 24.86 rejection from JAN2011 to APRIL 2011)

  8. Contribution of defects in REJECTION

  9. Cause & effect diagram for defect of hole 24.86 rejection Machine Man Is the specified M/C used ? Is operator trained ? Is it due to improper correction M/C Setting parameters Is operator temporary ? Is M/C in good condition ( SIZE VARIATION PROBLEM)? Is it due to improper Rework ? Hole 24.86 oversize rejection Is material hard ? Are Control Plan followed ? Is Size setting of tool easy for ( SPM Machine) ? Is praper tips used ? Method Material Tooling

  10. Root Cause analysis for defect hole 24.86 rejection Machine Man M/c size variation Problem Hole 24.86 Rejection Is Size setting of tool easy for ( SPM Machine)? Method Material Tooling

  11. Why-why analysis Why-why analysis for caused 1 – Machine size variation Problem

  12. Identified cause & action Cause no. 1 DTC Machine spindle run- out is not with-in specification ( i.e. required is 5 microns and observed is 25 microns ). Action Machine given for maintenance and it is decided that not to take production of hole 24.86 on DTC machine.

  13. Why-why analysis Why-why analysis for cause 2 – hole Dia. Oversize for SPM machine

  14. Identified cause & action Cause no. 2 Size variation problem for SPM-03 Machine. Action Machine was Hand over to maintenance from 09th June 2011 to 10th June 2011

  15. Results- After maintenance data collection FROM JUN 2011 TO JULLY 2011

  16. Why-why analysis Why-why analysis for cause 2 – – out cut problem

  17. Next action done

  18. Results- Data collection after action implementation FROM 1st August 2011 TO 30th August 2011

  19. Results- Rejection cost before implementation Rejection cost after implementation

  20. Rejection Percentage Graph 1.54 1.28 0.65

  21. Rejection Percentage Graph

  22. tangible benefits--- Rejection percentage from 1.54% to 0.65%.

  23. Project title 2)TO IMPROVE PRODUCTIVITY & REDUCE WASH OUT OF ROTOR Time period – August 2011 to Project Selection Date-1 August 2011

  24. Semifinish to finish process flow Semifinish to finish Process Casting HMT M/c.1 HMT M/c.2 Semifinish Ist Operation Bore rough Semifinish IInd Operation Back face rough Finish job Maxmullar M/c. No 2 Maxmullar M/c. No 1 Finish IInd Operation back face finish Finish Ist Operation Bore & front face finish

  25. Semifinish to finish Semifinish Ist Operation Resting & holding Semifinish Ist Operation carried out Resting done at two points Job holded here in jaws Bore semifinish Facing of face OD rough

  26. Semifinish to finish Semifinish IInd Operations carried out Semifinish IInd Operation holding & resting ID 256 rough Face rough OD rough Bore location Job resting

  27. Semifinish to finish Finish Ist Operation Operations carried out Resting & holdings Job holded At Od in jaws Job rested at this face Bore finosh Face finish

  28. Semifinish to finish Finish IInd Operation Operations carried out Resting & holdings ID 256 finish OD finish Resting face Bore location & Clamping Face finish

  29. Problem faced in semifinish to finish process( old process) Reason Problem • Wash-out problem due to resting problem Resting comes on these no. Wash out at spot face

  30. Casting to finish process flow Casting to finish Process: Finish job HMT M/c.2 Casting Casting front face rough to finish Ist Operation Bore & front face finish back face rough IInd set-up back face finish

  31. Cating to finish process- Ist operation bore finish Front face finish & back face rough ,OD finish IInd operation back face finish Front & back Face finish Bore finish OD finish ID256 finish Face rough

  32. Cating to finish process- Ist operation holding & resting Hold at ID 256 Resting points

  33. Development in holding devices: Rotor holding jaws New Process Rotor holding jaws Old Process Job resting Jaw holding face on OD Restpad for resting Holding Jaw on ID 256

  34. Development of tooling Old tool holder New tool holder

  35. DATA COLLECTION • Total time per job in semi-finish to finish operation (Old Process) -

  36. DATA COLLECTION • Total time per job in in casting rough to finish operation

  37. Machining time Graph Saving of 15.85 Min./job

  38. DATA COLLECTION • Total Manpower per job in semi finish to finish operation

  39. DATA COLLECTION • Total Manpower per job in casting rough to finish operation

  40. Machining Manpower Graph SAVIMG OF 5 Mans.

  41. DATA COLLECTION • Total labor cost per job in semi finish to finish operation

  42. DATA COLLECTION • Total labor cost per job in in casting rough to finish operation

  43. Labor cost Graph Saving of Rs.18.67./job

  44. DATA COLLECTION • Total tool cost per job in semi finish to finish operation

  45. DATA COLLECTION • Total tool cost per job in casting rough to finish operation

  46. Tool cost Graph

  47. Machining cost Graph Saving of Rs. 12.14 /job

  48. Rejection percentage

  49. Tool cost Graph

  50. Machining cost Graph