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PRODUCTIVITY IMPROVEMENT IN MANUFACTURING DIVISION OF SHEET METAL INDUSTRY
Guided by : Dr. Gukan Rajaram
KANNAN P
Roll No : 13MM09
E-mail : [email protected]
Mobile No : 9500254280
PROJECT WORK REVIEW : Phase 2 TITLE
Department of mechanical EngineeringDr.DRK- Prof.NGK- Prof.VVA ME : LM-4SEM13ML72 1 P S G T E CH
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LITERATURE REVIEW
IMPROVING PRODUCTIVITY OF MANUFACTURING DIVISION USING LEAN CONCEPTS AND DEVELOPMENT OF MATERIAL GRAVITY FEEDER
• Productivity improvement is achieved by optimizing the layout.
• Distance travelled by the material in the Proposed layout is compared with current
layout.
• Simulation of current and proposed layout is done by using Witness software to
identify the efficiency of each layout
PROJECT WORK REVIEW : Phase 2 LITERATURE REVIEW
Department of mechanical EngineeringDr.DRK- Prof.NGK- Prof.VVA ME : LM-4SEM13ML72 2 P S G T E CH
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OBJECTIVES
• To achieve reduction in material movement distance for Gilbargo’s CE Carrier
assembly by 20%.
• To identify new spaces for Drilling station and Paint touch up station in powder
coating area instead of the packing area.
• To increase the utilization of resource by availing the suitable scrap sheets for
Punching operation.
• To introduce Multi hoist-Electrically operated overhead crane to load/unload
the part into pre-treatment process to reduce the waiting time
PROJECT WORK REVIEW : Phase 2 OBJECTIVE
Department of mechanical EngineeringDr.DRK- Prof.NGK- Prof.VVA ME : LM-4SEM13ML72 3 P S G T E CH
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METHODOLOGYPROJECT WORK REVIEW : Phase 2 METHODOLOGY
Department of mechanical EngineeringDr.DRK- Prof.NGK- Prof.VVA ME : LM-4SEM13ML72 4 P S G T E CH
Implementation and Follow-up phase
Proposed Layout
Analysis of results
Comparison of Layouts
Estimation of Performance
Simulation study
Redesigning of Layout
Problem identification
Collection of Data and Time study
Plant study
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CATIA DIAGRAM OF PRODUCT
PROJECT WORK REVIEW : Phase 2 CATIA DIAGRAM OF PRODUCT
Department of mechanical EngineeringDr.DRK- Prof.NGK- Prof.VVA ME : LM-4SEM13ML72 5 P S G T E CH
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PRODUCT DETAIL
• Product name - CE Carrier Assembly• Customer - Gilbargo• Demand
• Average demand - 450 products• Lead time to delivery - 15 days• Application - Fuel dispensing pump
PROJECT WORK REVIEW : Phase 2 PRODUCT DETAIL
Department of mechanical EngineeringDr.DRK- Prof.NGK- Prof.VVA ME : LM-4SEM13ML72 6 P S G T E CH
S.No Product name Demand
1 Aug2014 480
1 Oct2014 400
2 Dec2014 400
3 Jan2015 520
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PROCESS MAP
PROJECT WORK REVIEW : Phase 2 DETAILED PROCESS MAP
Department of mechanical EngineeringDr.DRK- Prof.NGK- Prof.VVA ME : LM-4SEM13ML72 7 P S G T E CH
Punching Part removal Filing
DeburringWelding/ fabrication
Pre-treatment
Powder coating Drilling Assembly/packing
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TIME STUDY
PROJECT WORK REVIEW : Phase 2 TIME STUDY
Department of mechanical EngineeringDr.DRK- Prof.NGK- Prof.VVA ME : LM-4SEM13ML72 8 P S G T E CH
DETAILS OF TIME STUDY
operation
numberMachine type
Number of
operators
Number of
component
Loading &
unloading time
(s)
Value added
time per compone
nt
Total cycle time per compone
nt (s)
setup time cycle time allowance inventory
Material movement distance
1 Punching 1 1 70 850 920 54000 22
2 Part removal 2 6 40 200 240 0 2550 382.5 2932.5 10
3 Filling 2 6 50 27 77 0 600 90 690 11.1
4 Deburring 2 6 80 62 142 180 480 72 732 10
5 Pressing 2 6 50 150 200 300 1110 166.5 1576.5 14.3
6 Welding 6 6 100 600 700 1200 2700 405 4305 84.1
7 Pre-Treatment 3 12 720 3000 3720 4200 5400 810 10410 54.5
8 Powder coating 5 6 100 2000 2100 1600 6480 972 9052 81.3
9 Drilling 1 6 120 40 160 120 10500 1575 12195 35.4
10 Inspection 2 6 40 100 140 60 720 108 888 16
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CURRENT LAYOUTPROJECT WORK REVIEW : Phase 2 CURRENT LAYOUT
Department of mechanical EngineeringDr.DRK- Prof.NGK- Prof.VVA ME : LM-4SEM13ML72 9 P S G T E CH
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PROJECT WORK REVIEW : Phase 2 MATERIAL MOVEMENT
Department of mechanical EngineeringDr.DRK- Prof.NGK- Prof.VVA ME : LM-4SEM13ML72 10 P S G T E CH
MATERIAL MOVEMENT
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PROJECT WORK REVIEW : Phase 2 CSVSM
Department of mechanical EngineeringDr.DRK- Prof.NGK- Prof.VVA ME : LM-4SEM13ML72 11 P S G T E CH
CURRENT STATE VALUE STREAM MAPPING
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PROJECT WORK REVIEW : Phase 2 PROPOSED LAYOUT
Department of mechanical EngineeringDr.DRK- Prof.NGK- Prof.VVA ME : LM-4SEM13ML72 12 P S G T E CH
PROPOSED LAYOUT
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DISTANCE TRAVELED BY OPERATOR WITH MHS
S.NO StationDistance traveled
with MHS (m)
Distance traveled without MHS
(m)
Distance traveled
in conveyor
(m)
1 Punching 0.73
2 Part removal 0.6
3 Filing
4 Deburring 2.45
5 Pressing 3.75
6 Welding 23.5
7 Pre-treatment 0.23 7.32
8 Powder coating 4.54 34.88
9 Drilling 7.55
10 Inspection 0.6
11 Assembly /packaging 0.83
DISTANCE CALCULATION FOR CURRENT LAYOUT
PROJECT WORK REVIEW : Phase 2 DISTANCE CALCULATION
Department of mechanical EngineeringDr.DRK- Prof.NGK- Prof.VVA ME : LM-4SEM13ML72 13 P S G T E CH
DISTANCE TRAVELED BY MATERIAL
S.NO Station Distance traveled with MHS (ft)
Distance traveled without MHS (ft)
1 Punching 14 8
2 Part removal 10
3 Filing 11.1
4 Deburring 3 7
5 Pressing 14.4 0
6 Welding 62.8 21.3
7 Pre-treatment 33.6 20.9
8 Powder coating 17.4 64
9 Drilling 31.9 3.5
10 Inspection 16
11 packing 3
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DISTANCE CALCULATION FOR PROPOSED LAYOUTPROJECT WORK REVIEW : Phase 2 DISTANCE CALCULATION
Department of mechanical EngineeringDr.DRK- Prof.NGK- Prof.VVA ME : LM-4SEM13ML72 14 P S G T E CH
DISTANCE TRAVELED BY MATERIAL
S.NO Station Distance traveled with MHS (m)
Distance traveled without MHS (m)
1 Punching 14 8
2 Part removal 10
3 Filing 11.1
4 Deburring 3 7
5 Pressing 14.4
6 Welding 62.8 21.3
7 Pre-treatment 7.1 20.9
8 Powder coating 21 64
9 Drilling
10 Inspection
11 packing 31.9
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COMPARISON OF CURRENT WITH EXISTING LAYOUTSPROJECT WORK REVIEW : Phase 2 COMPARISON WITH EXISTING LAYOUT
Department of mechanical EngineeringDr.DRK- Prof.NGK- Prof.VVA ME : LM-4SEM13ML72 15 P S G T E CH
Welding Pre-treatment Powder coating Drilling paint touch up packing0
10
20
30
40
50
60
70
COMPARISON OF CURRENT LAYOUT & PROPOSED LAYOUT
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EXPECTED RESULTS• Total distance travelled by a material in current layout
= 207.2 ft
• Total distance travelled by a material in the proposed layout = 165.3 ft
PROJECT WORK REVIEW : Phase 2 EXPECTED RESULTS
Department of mechanical EngineeringDr.DRK- Prof.NGK- Prof.VVA ME : LM-4SEM13ML72 16 P S G T E CH
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FUTURE STATE VALUE STREAM MAP
PROJECT WORK REVIEW : Phase 2 FSVSM
Department of mechanical EngineeringDr.DRK- Prof.NGK- Prof.VVA ME : LM-4SEM13ML72 17 P S G T E CH
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ARENA SIMULATION MODEL
PROJECT WORK REVIEW : Phase 2 Arena Model
Department of mechanical EngineeringDr.DRK- Prof.NGK- Prof.VVA ME : LM-4SEM13ML72 18 P S G T E CH
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PROJECT WORK REVIEW : Phase 2 KAIZEN
Department of mechanical EngineeringDr.DRK- Prof.NGK- Prof.VVA ME : LM-4SEM13ML72 19 P S G T E CH
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REAL TIME DATA TRACKING SYSTEM-FRONT END
PROJECT WORK REVIEW : Phase 2 Real time Data tracking system
Department of mechanical EngineeringDr.DRK- Prof.NGK- Prof.VVA ME : LM-4SEM13ML72 20 P S G T E CH
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REAL TIME DATA TRACKING SYSTEM-BACKEND
PROJECT WORK REVIEW : Phase 2 Database
Department of mechanical EngineeringDr.DRK- Prof.NGK- Prof.VVA ME : LM-4SEM13ML72 21 P S G T E CH
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PROJECT WORK REVIEW : Phase 2 KAIZEN
Department of mechanical EngineeringDr.DRK- Prof.NGK- Prof.VVA ME : LM-4SEM13ML72 22 P S G T E CH
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PROJECT WORK REVIEW : Phase 2 KAIZEN
Department of mechanical EngineeringDr.DRK- Prof.NGK- Prof.VVA ME : LM-4SEM13ML72 23 P S G T E CH
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PROJECT WORK REVIEW : Phase 2 KAIZEN
Department of mechanical EngineeringDr.DRK- Prof.NGK- Prof.VVA ME : LM-4SEM13ML72 24 P S G T E CH
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PROJECT WORK REVIEW : Phase 2 Multi Hoist-Electrically operated overhead crane
Department of mechanical EngineeringDr.DRK- Prof.NGK- Prof.VVA ME : LM-4SEM13ML72 25 P S G T E CH
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IMPLEMENTATION
PROPOSED LAYOUT:
Investment cost = Rs. 5000
Monthly cost saving = Rs. 500
Return Of Investment = 10 months
ROI calculation
PROJECT WORK REVIEW : Phase 2 Implementation
Department of mechanical EngineeringDr.DRK- Prof.NGK- Prof.VVA ME : LM-4SEM13ML72 26 P S G T E CH
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FUTURE WORK• Comparison of results for current and proposed layouts.
• Implementation of Visual studio application to store the necessary detail about
Scrap sheets.
• Implementation of Material Handling device to hold the material that is removed
from the conveyor.
• Design and development of Multi-Hoist Electrically operated overhead crane in
the pre-Treatment area.
PROJECT WORK REVIEW : Phase 2 FUTURE WORK
Department of mechanical EngineeringDr.DRK- Prof.NGK- Prof.VVA ME : LM-4SEM13ML72 27 P S G T E CH
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THANK YOU
PROJECT WORK REVIEW : Phase 2
Department of mechanical EngineeringDr.DRK- Prof.NGK- Prof.VVA ME : LM-4SEM13ML72 28 P S G T E CH