WHY WE GO FOR KOEL?-FOR EXPANSION OUR BUSSINESS RELATION WITH MULTINATIONAL COMPANY & THIS IS GOOD OPPORTUNITY SO WE GO FOR KOEL.
PROJECT TITLE‘2R/3R’ CRANKCASE MACHINING AT M/S. ALKA ENGG. WORKS. (A MACHINING DIVISION OF M/S. SHRIRAM FOUNDRY LTD.)
REQUIREMENT’S FOR 2R/3R CRANKCASE LINE INSTALLATION AT ALKA ENGG.WORKS • Floor Space • Connected load in KW • Air in CFM • Man power • Machining quotation
RA CRANKCASE LINE INSTALLATION ACTIVITY • Renewed & extended machine shop shed for suitable layout • Finalized machine shop layout. • Intensive training of operators & supervisor completed at KOEL(40days) • Layout marking of each machine & its foundation bolts(phase wise). • Layout marking of conveyors system ,hoists & tower crane. • Maintain lux level at shop floor as per KOEL recommendation (650 lux for final Inspection, on m/c 450 lux, open space 350 lux) • Identify sequences of machine for installation (phase wise). • Training of inspection method in process & CMM. • Suppliers list for special cutting tools , gauges & spares. • Provided separate compressor.
AS PER OUR CHAIRMEN’S INSTRUCTION DURING PLANT VISIT, WE HAVE RENEWED & EXTENDED EXISTING SHED WITHIN THREE WEEKS. FOR THIS RENEWED & EXTENDED SHED WE HAD SPENT Rs.25 LAC
MACHINE SHOP LAYOUT (ALKA) R CRANKCASE LINE
2R/3R Crankcase Line MM MM
MACHINE DISMANTALING FROM KOEL & INSTALLATION AT M/S ALKA ENGG.WORKSIN FOUR PHASES • First Phase -03 machine. • Duration -26 Feb 2010 – 06 March 2010(Dispatched Qty 614 nos.) • Second Phase - 10 machines • Duration - 8 Mar 2010 – 20 Mar 2010 (Dispatched Qty 943nos.) • Third Phase – 14 Machines • Duration - 25 Mar 2010- 10 April 2010(Dispatched Qty 996nos.) • Fourth Phase – 1 Machines • Duration - 15 June 2010- 23 June 2010(Dispatched Qty 200nos.)
PROJECT TAKEN BY M/S.ALKA ENGG.WORKS
PROJECT-1 OPERATION MISTAKE PROOFING Machine No:-RDM 578/548/552 Scope:- Detection for oil hole crossed through Operation : Bearing cap drilling
Previous method of detection • Coolant was passed through the oil hole. • Passed coolant was flowing through all Crossed oil holes as shown in the picture. Oil hole Ø4 mm is opened in cam bore Ø52mm & crosses to the coolant input hole Ø11mm. This hole was shifted & could not detected by this method.
Present method of detection • New gauge is produced to check the Ø4 mm oil hole crossed in correct position. • Gauge is having hole & hole distance is controlled from face as per drg. If oil hole is through crossed in Ø52 bore coolant is passes through the gauge hole & flows at gauge end portion as shown in the picture. Coolant is Passing after Matching gauge Hole to job hole
PROJECT-2 Operation :- Dip stick hole drilling. • Drilling & Reaming of Hole Ø11 +0.018 is carried out on RDM. • Coolant is passed through oil hole by nozzle pin having Ø11 -0.05. • If reaming opn. Is missed nozzle pin will not enter in the bore. SCOPE:-POKAYOKE FOR DIPSTICK HOLE
PROJECT-3 Operation :Bearing cap notching • Previous : • Job was located on two location pins. So there was • possibility of wrong fitment • Of bearing cap on pins. SCOPE:-MISTAKE PROOFING
Rest pad added MISTAKE PROOFING After : • Added one rest pad on fixture. So that wrong position bearing cap could not fit on location pins.
PROJECT-4 SCOPE:-Time reduction in Loading/Unloading Operation : Bearing cap drilling
Previous : Bearing cap was mounted on jig with the help of two individual stud. Time for clamping two stud is1mins per job.
After : C clamp is introduced to hold the brg. Cap as shown in the picture no.1. So only one center clamp is require to lock only instead of two individual stud. Time for clamping ‘C’ clamp is 0.5 mins per job.
PROJECT- 5 Operation : Tappet Boring Machine No. ; 2830 III rd operation • Previous operation is bearing cap assembly. • Proxy is fitted near roller below job resting face at gear end face . • If bearing is fitted at wrong side i.e. Fw End side instead of gear end side gap between proxy & cap face will increase & machine will not start.
PROJECTED PLAN WILL BE INTRODUCE 3WAY TAPPING SPM IN MACHINING SET UP
SCOPE • GAINED QUANTITY PER SHIFT THROGH THREE RDM IS 50Nos PER SHIFT. REQUIRED 80 NOS FOR NEXT OPERATION. • BOTTLE NECK OPERATION. • POTENTIAL QUALITY ISSUE LIKE MISSING OPERATION & TAP DEPTH O/S OR U/S.
DATA COLLECTION • Operations Lop cap dowel drilling , reaming & all side Tapping M8, M14, M18x1.5 are carried out on three RDM. Production per shift is 50Nos. Next Operation is finish top milling & production per shift is 80 Nos per shift. 30 jobs less quantity getting for finish milling operation.
PROJECT DEFINED AS –USE OF SINGLE SPM INSTEAD OF THREE RDM INCEASE IN PRODUCTION QTY QUALITY IMPROVEMENT
Present operation details After implement operation details will be
PRESENT SET UP PROJECTED SET UP
BENEFITS OF THE PROJECTS • POTENTIAL QUALITY ISSUE LIKE MISSING OPERATION & TAP DEPTH O/S OR U/S. • FLOOR SPACE REDUCES . • TWO OPERATORS REDUCESS • IMPROVE PRODUCTIVITY
PENDING POINTS FROM KOEL SIDE:- • PAINTING OF ALL MACHINES • CYCLE TIME EASTABLISHED AS PER KOEL CYCLE TIME WHICH IS ALREADY SUBMMITED TO US. • THREE TOWER CRANES
WE ARE PLANNING TO STRUCTURAL MEETING ALONG WITH KOEL REGARDING FUTURE PLAN.