project report on layout change in filter company

8/18/2019 project report on layout change in filter company

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LAYOUT CHANGE & SKILL CENTER

SUBMITTED BY:- RAJKUMARME(Auto) 7 th Sem.ROLL NO. – 13MEBLAO18

SHOOLINI UNIVERSITY


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Contents

1.Decleration ……………………………………………………………………………………3

2.Acknowledgement …………………………………………………………………………….4

3. Abrastract …………………………………………………………………………………….5

4.Company overview …………………………………………………………………………6 -145.Project Detail

6. Project-01 ................................................................................................................................................

7. Project-02 ................................................................................................................................................

8. Project-03 ................................................................................................................................................

9. Project-04 ................................................................................................................................................

10. References ……………………………………………………………………………..


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DECLARATION

I hereby declare that the project work entitled SHOP FLOOR

TRANSFORMATION & MADE DEXTERITY CENTER (SKILL

CENTER) it is record of my own work carried out at MAHLE FILTERS

SYSTEMS INDIA LIMITED as requirements of two months project semester

for the award of degree of B-tech. (ME, Automobile), Shoolini University, Solan,

under the guidance of Mr. KAMAL PANDA during 8 th June 2015 To 8 th Aug

2015.

RAJKUMARDATE:- ______________ 13MEBLA018

Certified that the above statement made by the student is correct to the best of ourknowledge and belief.

Mr. Munish Sethi Mr. KAMAL PANDA

(Mechanical department) (PRODUCTION DEPTT.)


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Company Overview

Mahle filter system is the largest manufacturer and exporter of Automotive and filtration solution for

the automotive filtration, railways and aviation of India a joint venture between MAHLE Filter

System Gmbh Germany Globe leader in Engine Systems and Filtration Solutions and Anand, India.


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Mahle Filter System GMBH:-

The Mahle unit with its two business unit Engine System and component as well

as and Filtration and Engine peripherals , rank amongst the top three system

suppliers worldwide system for piston systems,cylender components, valve train

systems ,air management system, and liquid management systems.

MAHLE has local presence in all major world market. Approximately 48,000

employees work at over 100 production plants and 7 research and developmentcenters in Stuttgart, Northampton,

Detroit ,Tokyo and Shanghai.

Around the world, approximately 2,400 development engineers’ technicians

are working forward-looking concepts, product and system for the ongoing

development of vehicle power trains.The industry business unit bundles the MAHLE Group’s industrial activities.These include the area of large engines, industrial filtration as well as cooling andair conditioning systems for Railway and special vehicles, buses, ships,construction and agriculture machinery, the aerospace industry, and stationarylarge engine for power generation. The aftermarket business unit serves theindependent spare part market with MAHLE products in OE quality


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Anand Group:

Anand group has been operating in India since 1961. Anand is a group

of 19 companies that have been set up over a period spanning five

decades. It is no mean achievement that ever Anand Company is either a

market leader or rank among the top three in the country in its field of

operation. Integrating this multifarious units an operation with a drive

world force spread across 50 locations into a power full unified entity,has made Anand the large conglomerate that it is today.

The Anand group is present almost in every part of the world .


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The khandsa plants manufacture air filters, fuel filters and oil filters. The product rangeis highlighted below .


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Leading Automotive Filter Supplier:

MAHLE Filter Systems India, as the leading Automotive Filter supplierin the country has consistently invested in research & development todevelop filtration media, new filter geometries, constructions andsystems.

Market Leading Brands in the After Market: ‘Purolator’ &‘MAHLE’:

The company is the largest in its segment in the Aftermarket as well andits products are marketed under the brands – ‘MAHLE’ and ‘Purolator’ .

India’s Leading Exporter, OEM and After Market Supplier:

With the widest range of automotive and industrial filters in the country,MAHLE is the principal supplier to both the OEM segment and theAftermarket with a sizeable presence in overseas markets as well .

The company has four state-of-art filter plants, located at Parwanoo(Himachal Pradesh), Pune (Maharashtra), Khandsa (Haryana) andChennai (Tamil Nadu). The Khandsa facility is equipped with an ultra-modern filter paper impregnation plant, the largest of its kind in thecountry .

Originally known as ‘Purolator India Limited:

The company was originally known as Purolator India Limited, set up asJoint Venture in 1964 between Purolator, USA and Anand. MAHLEFilter Systems India was established in 2005 .


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Major R&D Achievements at MAHLE Filter Systems India:

Involved in several research projects like the development of a highefficiency multi-layered filter media using nano fibers for use in fuelfilters of commercial diesel vehicles.

Involved in the development of all-plastic Air Intake systems for HCVapplications for improved aesthetics and noise control.

Innovative design of a heavy duty air filter element with minimum metal parts

New non-woven air filter media for passenger cars with increasedservice life

Design, Development and Installation of Fuel rig, Collapse rig, and Flyash test rig for Mahle, China.

Development of air filter rig (Life & Efficiency) for Guard filter,Pakistan.

Pressure sensors for air filtration. Diesel water separation media. Software development for the prediction of permeability in filter media

and efficiency / DHC in a oil filter test rig. Oil Filter Systems for turbo-charged engines Eco-friendly Metal-Free Fuel Filters Oil Filters Turbo-fan Dry type Air Filters New Pleating technology to reduce spin-on filter sizes New dual-layered filtration medias for fuel and oil application


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R&D C APABILITIES :

Designing of new generation portfolios validated by CAE:

The designing of new generation portfolios validated by CAE,comprising of Plastic Air Intake Manifolds, Integrated Head Covers withOil Mist Separators & complete Plastic Air Intake Systems withsnorkels, pre-cleaners and plastic air cleaners with polyurethaneelements, using special filter media with respect to change over lifetime

and efficiency as required by the new generation engines.

Design & Simulation capabilities with a range of advancedsoftware Design & Simulation capabilities with a range of advanced software to

produce 3d acoustic calculation; optimize Air Intake Systems andResonator performance; generate accurate results of air borne noise infront of orifices; obtain an accurate result of structure borne noise in a

defined point above the surface of interest; all-round solution formeasurement, analysis, and evaluation of sound and vibration signals.

Advanced Testing Infrastructure & FacilitiesMAHLE’S advanced testing Infrastructure includes test facilities foradvanced product lines with the latest environmental control equipmentlike Salt spray testing and a Thermal chamber; dust feeder in the air testrig which helps controlled feeding of test dust; street test bench to aid

correlation of field performance of the air filter; validation of thesimulated acoustic results with a NVH facility; OMS testing apparatusfor testing separation efficiency of the Oil Mist Separator.


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KAIZEN

‘Kai’ means continuous and ‘Zen’ means improvement so Kaizen is Continuous improvementover current processes. This continuous improvement can occurs for machinery, materials, laborutilization, and production methods through applications and ideas of company teams.


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OBSERVATIONS

MPFI Line

1. COILING MACHINECoiling machine make element coil for the filter. The main parts are :- centre tubeand filter paper.

Number of Coil = 12+/-1 Coil Height = 40+/-0.8 Hot melt Weight = 3.5 to 5.5 gm. Fold Height = 8 mm+/-1 Paper gap = 3 mm max Hot melt Distance = 6 mm+/-1 Hot melt width = 4 mm+/-1

Temperature of hot melt = 250 to 260C

Total time required per piece = 20 secTime required by the machine = 7 sec

Time per Piece Table:- S.no Loading Time Machine Time Unloading Time Total cycle Time

1. 7:50 7 4:49 18:99

2. 8:00 7 5:05 20:05

3. 7:43 7 5:25 19:68

4. 8:00 7 5:20 20:205. 8:00 7 5:35 20:35

6. 7:56 7 4:20 18:78

7. 8:05 7 5:10 20:15

Average time required by 1 piece = 20sec (approx)


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2. EPOXY MACHINEEpoxy machine is used up to fill the gap between the coil and the bowl by using anAdhesive like structure “Ana bond ’’.

1. Vaccum gauge pressure = 2-3 bar2. Pressing gauge = 2-3 bar3. Machine inlet pressure = 6-7 bar4. Dispensing time = 1000-2000 ms5. Shot weight = 3-3.4 grams

Coil insertion in the bowl till the dead centre is also done in the epoxymachine.

HEAT OVEN

Heat oven is used for the hardness of ‘Ana bond’ by providing a high temperature.It has three heating coils to provide heat.

1. Temperature = 150 +/-10 degree C

2. Time = 10-15 min

Inspection of adhesive hardness is manual. Pin holes are also checked.

Pin holes or improper hardness of the adhesive is considered under rejection.


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3. SEEMING MACHINE(AUTO-3)

LOCTITE DISPENSINGThe process of this machine is to dispense a sticky substance which we call as loctite.

Loctite is used to cover up the gaps and prevent the leakage after the bowl and covering isseemed.

1. Pressure = 0.3 – 0.69 bar2. Time = 2 – 3 sec

SEEMINGSeeming machine is used to join the bowl and the upper covering. It has four rollers, 2 to

roll up and 2 to seem.

1. Seeming O.D = 67.0 +/-12. Sean Width = 4.5 +/-0.53. Total ht = 60 +/-0.84. Seam hook overlap = 1 mm Min5. Pipe height = 28 +/-0.86. Pressure = 3-5 kg/sq.cm

Poka yoka in it is hand body detecting sensors. If any part of body is inside theworking area than the machine stop working and save that person from any harm.


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4. MAGNIFYNG, SCREENING

Magnifying is done check the cracks, sharper edges etc. If cracks or something that mayhave damaged the filters are found than that piece is sent to rejection.

Screening is done to provide names, dates or as per the company requirement. Thereshould be no smudges, if there than the part is reworked and then sent to next station fornext process.

5. WATER LEAK TESTING - 1

Water leak testing is done to check out leakages in seemed part. This is a must requiredprocess because it is possible that we can see outer cracks through magnification but theleaks can’t be seen through magnifying glass that’s why we perform water leak testingoperation.Water leak testing is performed by putting the filter inside the water and passing a highpressure gas inside the filter. If bubble formation is there then we get the rejection piece.

Time = 30 secPressure = 5-6 kg/sq.cmOperator coding properly visiblePoka yoka = Hutter for blocked piece

= bubbles for leaked piece


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PAINT SHOP

The loading to unloading process of one bowl take approximate 1.5hours.

Solid powder paint is used instead of liquid paint because liquid paint

starts flowing down and form an uneven layer of paint on the bowl andwe can’t get the desired result.

Degreasing is done to remove the oily surface that is there on the filterbowl so that the paint can be easily got on it.

LOADING OF BOWLSON CONVEYER BELT

DEGREASING OFBOWL BY CHEMICAL

MIXTURE

WASHING OFBOWLS TO REMOVECHEMICALS FROM

IT

PAINT SPRAY

BOOTH(SOLID PAINTSPRAYED ON BOWL)

BOWLS NEXTPASSES FROM

WATER DRY OVEN

BOWLS PASSESBLOW OF MACHINE

TO BLOW OFFWATER

IR(PAINT STARTSMELTING IN THIS

AREA)

PCO(PAINT CUREOVEN) PROVIDE A

SHINING FINISH TOBOWL

UNLOADING(INSPECTION)


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1ST

PROJECT SHOP FLOOR LAYOUT CHANGE:- The project is provided to me by Mr. Kamal Panda sir and I thankhim for giving me this opportunity.

In the shop floor layout change, the main purpose is to get the extraspace out from the shop floor area so as to increase WIP and 5’S.

For changing the layout we measure the shop floor area andAUTO1 is taken as the reference for the layout arrangement. Aftertaking the area of the shop floor, all the machine area is alsonoticed so as to arrange the machines in the desired area .

DRAW LAYOUT CLICK


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After taking all the dimensions a layout is made on the paper sheet.After making the layout it is checked by Kamal Panda sir and then afterthe approval it is applied. Machines are shifted as per the reference lineis provide.

The toughest job was of shifting of packing line, but is an interesting andlearning project.

LAYOUT CHANGING WORK:-


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After the change of layout WIP and 5’S is improved. Not only this but it also helpin increasing my knowledge and made me to learn some new thing. Its teaches methat nothing is perfect so once we should also try ourselves to make things perfectso as to get a benefit from them.The extra space we have for keeping our bins and trolley without disturbing our5’S. Now the uneven lying of material is no more there and we also have space tokeep the desired material at desired machine so the movement is also decreased.

K EY L EARNINGS:-

Safety measures How to behave with your team mates Working procedure in a company About kaizen Time wastage study Quick solution of some common occurring problem How to improve 5’S in a company and what’s the importance of 5’S

How to increase productivity

Benefits :- 5’S of plant improve very well. Space for WIP increase. Conjunction of line decrease. Plant looks neat & clean. Manpower movement decrease.


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AFTER LAYOUT CHANGED:-

SHOP FLOOR APPEARING VERY WELL


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PROJECT NO.-2

DEXTERITY CENTER:-

Dexterity center means skill center, wherewe give same working condition as at work floor to the new employees.Here employees learn about company’s goals, mission, vision, product,

process, machine, equipments, safety & maintenance etc.

PICTURES OF SKILL CENTER

DOCUMENTS BOARD


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ACKNOWLEDGEMENT

Training as teaching is an essential part of an individual’s future career.The “learn while you work” attitude is a very practical touch in the

complete tenure of a personal life. Training bridges the gap between the

learnt and the happening. During this phase the trainer or guide or the

supervisor is the one who can help make the most of this golden

opportunity.

I would like to put forth my regardful thanks to all those who have and

are making it a remarkable attempt in guiding me and making me learn

the most during my training at MAHLE FILTERS SYSTEM INDIA

LTD. KHANDSA GURGAON

I also pay my special thanks to Mr. KAMAL PANDA (PRODUCTION

HEAD) who cared to give out an ample amount of time to me,

regardless of being extremely busy at their work. Ahead I put my special

regards to the management, workers and my co-trainees at MAHLE

FILTERS SYSTEM INDIA LTD. KHANDSA GURGAON who have

always been so supporting, loving and always ready to help. I have been

in close touch with them since the beginning of my training at MAHLE

FILTERS SYSTEM INDIA LTD. KHANDSA GURGAON. And I

appreciate the relationship they all have developed with me


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DOCUMENTS BOARD


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OUR PRODUCT (OIL FILTER)

INLET HOLES OUTLET HOLE

15 FACETS TO TIGHTEN THE FILTER WITH TOOL


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CHILD PART OF OIL FILTER WITH FUNCTION

Gasket retainer

Functio n: Hold the gasket and join

Cover plate

Functio n: Provide threads toassemble with mating part andable to sustain under vibration andpressure

End plates

Functio n: Act as support the filterand provide sealing from both

ends with the help of bondingadhesive

Adhesive

Functio n: Bonding of paper fromboth ends

Relief valve

Function : Act as safety valve when filter ischocked and allow oil to pass through to avoid

any Engine seizer or damage.

Sealing gasket

Function : Provide sealing between filter andengine block

CV gasket

Function : Act as sealingbetween clean and

dirty oil.

Center tube

Function : Act assupport to filter media

and allow

Housing (Bowl )

Functio n: Act ascanister and join withcover ass .

Bottom spring

Function : Act as support to filter elementand ensure no mixing of clean and dirty oil


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FUNCTION FLOW DIAGRAM OF OIL FILTER

OIL INLET THROUGH HOLE OIL OUTLET THROUGH CENTER HOLE

OILFLOW


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PICTURES OF SKILL CENTER

SAMPLES OF PRODUC


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WATER LEAK TESTING M/C

SAFETY MAN WITH PROPER PPE’S


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OBJECTIVE OF SKILL CENTER:-

Objective of skill center is to provide working environment to the new employees of the company.

As show in above pictures, in the skill center we used machines,measuring instruments, process flow charts, safety man with properequipments, assembly tables and moulding fixture etc.

To provide working environment on skill center as at shop floor. To provide practical during induction training. To provide knowledge about our product, company process,machines & measuring equipments.

To be friendly with machines & equipments. To provide knowledge about safety equipments, how to use & benefits of safety equipments. Practical knowledge about how to make the filter at seamingmachine, how to perform water leak testing & then what is the

procedure of packing & how it will?


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BENEFITS OF SKILL CENTER:-

During seven days induction training new employees know moreeffectively about the company. They get practical knowledge about product & machines beforecome to the shop floor. Surprise about machine mechanism & operation almost hide. New employees try to learn very effectively.

They perform & learn about the machine.

They can differentiate the good & reject piece. They know very well about the quality concern. They awake about safety & safety equipments. During induction new employees learn through the practical whichthey will perform.


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Quality at Mahle:-

Our professional project management system identifies possible sourceof defects already during the initial phases of development. In this way,

we prevent problem that could be expensive later on.

Consistent control procedures during the development process monitor

timing and achievement of the project targets.

All Mahle plants are certified according to the international qualitystandard of the automotive industry.


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Quality at Mahle:-

Our professional project management system identifies possible sourceof defects already during the initial phases of development. In this way,

we prevent problem that could be expensive later on.

Consistent control procedures during the development process monitor

timing and achievement of the project targets.

All Mahle plants are certified according to the international qualitystandard of the automotive industry.


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Training as teaching is an essential part of an individual’s future career. The “learn while y ou

wthe gap between the learnt and the happening. During this phase the trainer or guide or the

supervisor is the one who can help make the most of this golden opportunity.

I would like to put forth my regardful thanks to all those who have and are making it a

remarkable attempt in guiding me and making me learn the most during my training at MAHLE

FILTERS SYSTEM INDIA LTD. KHANDSA GURGAON

I also pay my special thanks to Mr. KAMAL PANDA (PRODUCTION HEAD) who cared to

give out an ample amount of time to me, regardless of being extremely busy at their work. I

would also like to appreciate that they gave me experience of almost every cell of the company.

so, that I could utilize every single minute in the company.

Ahead I put my special regards to the management, workers and my co-trainees at MAHLEFILTERS SYSTEM INDIA LTD. KHANDSA GURGAON who have always been sosupporting, loving and always ready to help. I have been in close touch with them since the

beginning of my training at MAHLE FILTERS SYSTEM INDIA LTD. KHANDSAGURGAON. And I appreciate the relationship they all have developed with me.

Finally, I express my indebtedness to all who have directly or indirectly contributed to thesuccessful completion of my industrial training.

project report on layout change in filter company

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