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ALKA ENGINEERING PRESENTS PROJECT ON PRODUCTIVITY IMPROVEMENT & SAVING IN LABOUR CHARGES

ALKA ENGINEERING PRESENTS PROJECT ON PRODUCTIVITY IMPROVEMENT & SAVING IN LABOUR CHARGES . TO INCREASE PRODUCTIVITY FOR DRILLING / TAPPING OPERATION OF KOEL CRANK CASE . SAVING IN LABOUR CHARGES . TEAM MEMBERS . Mr. Neeraj Zanvar Mr. S. C. Jadhav Mr. Niwas Patil Mr. K. S. Patil

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ALKA ENGINEERING PRESENTS PROJECT ON PRODUCTIVITY IMPROVEMENT & SAVING IN LABOUR CHARGES

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  1. ALKA ENGINEERING PRESENTS PROJECT ON PRODUCTIVITY IMPROVEMENT & SAVING IN LABOUR CHARGES

  2. TO INCREASE PRODUCTIVITY FOR DRILLING / TAPPING OPERATION OF KOEL CRANK CASE SAVING IN LABOUR CHARGES

  3. TEAM MEMBERS • Mr. NeerajZanvar • Mr. S. C. Jadhav • Mr. NiwasPatil • Mr. K. S. Patil • Mrs. VarshaPatil

  4. PROOF OF THE NEED • GAINED QUANTITY PER SHIFT THROGH THREE RDM IS 50Nos PER SHIFT. REQUIRED 80 NOS FOR NEXT OPERATION. • BOTTLE NECK OPERATION. • SAVINGS IN LABOUR CHARGES. • POTENTIAL QUALITY ISSUE LIKE MISSING OPERATION.

  5. ORGNISATION FOR IMPROVEMENT

  6. 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. Labour charges for six operators ( two shit working) is Rs. 30000/- per month

  7. PROJECT DEFINED AS –USE OF SINGLE SPM INSTEAD OF THREE RDM INCEASE IN PRODUCTION QTY SAVING IN LABOUR CHARGES

  8. Present operation details

  9. PROJECT SCOPE

  10. PROJECT DETAILS • Add new machinery i.e. SPM for all above Three operations. Approx. cost of machine is Rs. 20 00000/- Less RDM cost Rs. 7 50000/- Total Project cost to be bare i.e. 12 50000/- Approx. Production per shift is 70 Nos. Only one operator is required for loading & unloading job. • Three RDM can utilize for another products.

  11. BENEFITS OF THE PROJECTS Net savings in labour charges is Rs. 120000/- per year

  12. Increased production capacity with new SPMIncrease in production qty.per shift by 20 Nos.Per day by 60 Nos. Per month by 1500 Nos. BENEFITS OF THE PROJECTS

  13. BENEFITS OF THE PROJECTS - SAVING IN LABOUR CHARGES • Crank case requirement per month are maximum 3000Nos. 3 RDMs are required 60 shifts for production of 3000 Nos. • SPM will require 43 shifts for production of 3000 Nos. • SPM will ideal for Total 18 shifts. • SAVINGS IN LABOUR CHARGES FOR 18 Shifts for one operator is Rs. 3460/- month. • SAVINGS IN LABOUR CHARGES per Year Rs. 41520/-

  14. BENEFITS OF THE PROJECTS • One operator is required to handle this SPM & also will be comfortable to operate previous operation machine i.e. finish milling. • Total space is covered by three RDM is 24 x 10.5 sq. feet. • Approx. space will require by SPM 15 x 8 sq. feet. • Saving in floor space about 9 X 2.5 sq. feet • Presently previous operation completed excess jobs are kept on gangway. We can use this saved space for this material stock & gangway will for easy movement.

  15. Elimination of Quality Concern like Operation missing & enhance in customer satisfaction.

  16. Detection for oil hole crossed throughly Crank Case Oil hole gallery drilling operation

  17. 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. Previous method of detection

  18. 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 throughly crossed in Ø52 bore coolant is passes through the gauge hole & flows at gauge end portion as shown in the picture. Present method of detection Coolant is Passing after Matching gauge Hole to job hole

  19. Part Name ; Crank Case Operation ; Bearing cap notchingMachine No. ; • Previous : • Job was located on two location pins. So there was • possibility of wrong fitment • Of bearing cap on pins.

  20. Part Name ; Crank Case Operation ; Bearing cap notchingMachine No. ; Rest pad added MISTAKE PROOFING • After : • Added one rest pad on fixture. So that wrong position • Bearing cap could not fit on location pins.

  21. Operation : Oil gallery & dip stick hole drilling. Machine No. ; 552 , 548 • 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.

  22. LOADING / UNLOADING TIME REDUCTION Operation : Bearing cap drilling

  23. Previous : Bearing cap was mounted on jig with the help of two individual stud. Time for clamping two stud is mins per job.

  24. 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 mins per job.

  25. III rd operation Operation : Tappet Boring Machine No. ; 2830 • 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.

  26. T H A N K Y O U

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